Final Report Production PVC

7/26/2019 Final Report Production PVC

http://slidepdf.com/reader/full/final-report-production-pvc 1/32

2. Table of Contents

Number Title Page

1 Cover Page 0

2 Table of Content 1

3. Abstracts 2

4. Introduction 35. Main contents

5.1 Raw aterials fro crude oil

5.2 Proses !escri"tion

5.3 !efinition of end "roduct to consuer

5.# $uture issues regarding bot% interediate

and end "roducts

5.5 &nvironental ' %ealt% and safet(

considerations

#

12

2#

2)

2*

6. References 317. A""endices 32

1



3. Abstract

Petroleu or +nown as crude oil is a natural flaable li,uid t%at is found on t%e roc+

forations in t%e eart%. Crude oils are co"le- i-tures of %(drocarbons and organic

co"ounds. T%e crude oil will undergo fractionation "rocess. It is t%e first ste" of converting t%e

crude oil into various "roducts. &t%(lene or et%ane is a colorless gas at roo te"erature and

"ressure. It %as slig%tl( sweet sell and %as flaable "ro"erties. &t%(lene can be "roduced

eit%er b( e-traction fro natural gas using fractional distillation follow b( stea crac+ing at

te"erature 50 to *00oC and followed b( li,uefaction of t%e gas and t%en furt%er fractional

distillation or e-traction of crude oil using fractional distillation followed b( stea crac+ing at

te"erature 50 / *00oC of t%e na"%t%a or gas oil fractions followed b( li,uefaction of t%e gas

and t%en furt%er fractional distillation. Crac+ing is a t%eral deco"osition "rocess b( w%ic%

large al+ane %(drocarbon olecules are bro+en down b( "assing t%e over a %eated catal(st at

%ig% "ressure. It is done b( %eating soe of t%e less used fractions to a %ig% te"erature va"or

and "assing over a suitable %ot catal(st at %ig% "ressure. &t%(lene can be used to "roduce

"ol(ers suc% as "ol(et%ane' et%(lbenene and ot%er c%eicals. T%e "rocesses to "roduce

et%(lene are t%e stea crac+ of et%ane and "ro"ane fro natural gas and fro crude oil' t%e

stea crac+ing of na"%t%a fro crude oil and t%e catal(tic crac+ing of gas oil fro crude oil. T%e

future issues relatable to PC are in its dis"osal "rocess because PC contains %eav( etal

additives suc% as lead' organotin and cadiu usuall( found in t%e slag and fl( as% after

incineration. 4o it needs to overcoe t%is "roble b( i"leenting t%e strategies t%at %ave

been "roved. T%e as"ects of t%e environental awareness and safet( and %uan %ealt% also

s%ould considerate because it a( affects t%e "rocess of PC "roductions and soe as"ects

t%at affects t%e counit( around t%e "lants.

2



4. Introduction

Pol(vin(l c%loride PC was first anufactured in eran( in 1*31 as a robust and

lig%tweig%t new "lastic. T%is brea+t%roug% aterial was broug%t about to substitute for etals'

glass' wood' natural fibers' "a"ers and fabrics. 6ver 30 illion tons of PC is used around t%e

globe toda(' bot% in industrialied and develo"ing countries' due to its cost efficienc(' durabilit('

self/e-tinguis%ing "ro"erties' "rocessabilit(' and resources saving features. 6wing to its safe'

%ealt%(' convenient and aest%etical advantages' PC "roducts su""ort dail( life in a wide

variet( of fields including urban infrastructures' electronic "roducts' and consuer goods. $or

e-a"le' PC can be found in "ublic lifelines suc% as water su""l(' sewage "i"es' or "ower

lines. It is also used in building aterials suc% as sidings' furniture' s"outs' window "rofiles'

flooring' dec+ing boards' and roofing s%eets. Agricultural and industrial a""lications include

green%ouse s%eets' seiconductor cleansing facilities' e-%aust ducts' and "arts for autoobile

and %oe electrical a""liances. Consuer "roducts include food wra"s' s(nt%etic leat%er and

stationer(. PC' or "ol(vin(l c%loride7vin(l c%loride resin' is a raw aterial used in a vast range

of a""lications.Tetsuo 8is%ide' 2009

3



5.1 A! "AT#IA$

5.1.1 %esired s&ecification including &'(sical and c'emical &ro&erties

Petroleu or +nown as crude oil is a natural flaable li,uid t%at is found on t%e roc+

forations in t%e eart%. Crude oils are co"le- i-tures of %(drocarbons and organic

co"ounds. T%e crude oil co"onents can range fro ver( lig%t olecules t%at %as low boiling

"oint suc% as et%ane to a ver( %eav( olecules and %aving %ig% boiling "oints. Crude oil ain

c%aracteristics are generall( classified according to its s"ecific gravit( and densit( w%ic% is

easure b( "etroleu industr( as Aerican Petroleu Institute API gravit(. :ig%t crude oil

%aving low densit( wit% API gravit( above t%an 30 w%ile %eav( crude oil %aving %ig% densit( wit%

API gravit( is between 10 until 20.

T%e "%(sical and c%eical "ro"erties of %(drocarbon s"ecies for t%e crude oil is not onl(

de"end on t%e nuber of carbon atos in t%e olecule but include t%e nature "ro"ert( of t%e

c%eical bond between t%e. Carbon atos freel( can bond wit% anot%er atos in an( wa(s

suc% as single bonds' double bonds' and tri"le bonds to for different classes of %(drocarbon

Mat%Pro' 2011. T%ere are 3 general classes of co"ounds in crude oil t%at are "araffins'

aroatic and na"t%enes. T%e aroatic co"ounds %ave %ig%er carbon/to/%(drogen C7; ratios

t%an na"%t%enes' w%ic% in turn %ave %ig%er C7; ratios t%an "araffins. T%e %ig%er t%e C7; ratio'

t%e crude oil will be %eavier w%ic% also eans denser.

Paraffin is saturated non/ring %(drocarbon co"ound in w%ic% all carbon atos are

connected b( single bonds <aes ;. ar(' nd. Paraffin %(drocarbon co"onent of crude oil

%as t%e generic forula Cn;2n=2. T%is "araffins %(drocarbon can be co"rise as gases' li,uids

or solids w%ere it is de"ends on t%eir olecular weig%t or t%e value of n in t%eir generic forula.

T%is "araffin can %ave eit%er straig%t c%ains or branc%ed of carbon atos. &-a"les of straig%t

c%ain olecules are et%ane' et%ane' "ro"ane and butane w%ere is in gases for' w%ere

"entane and %e-ane in li,uids for. T%e branc%ed/c%ain isoer "araffins are found in %eavier

fractions of crude oil and %ave %ig%er octane nubers t%an noral "araffins. T%ese co"ounds

are saturated %(drocarbons' wit% all carbon bonds filled. T%e e-a"le of straig%t c%ain and

branc%ed of "araffin %(drocarbon is s%own below>

4



$igure 1> e-a"le of straig%t c%ain and branc%ed "araffin %(drocarbon in crude oil.

8a"%tenes is a t("e of %(drocarbon co"ound t%at is +nown as c(clo"araffin' "arafins

wit% a ring structure <aes ;. ar(' nd. It is a saturated ring/t("e c(clic' arranged in t%e for

of closed rings. T%is na"%tenes %(drocarbon %aving generic olecular forula of t%e for

Cn;2n. T%e e-a"les of na"t%enes %(drocarbon is s%ow in figure below>

$igure 1> e-a"le of na"t%enes %(drocarbon in crude oil

Aroatic is t("e of %(drocarbon co"ound containing at least one benene ring.

Aroatic %(drocarbons occur to a var(ing e-tent and %ave a %ig%er ratio of carbon to %(drogen

t%an an( of t%e coonl( occurring "araffins or na"%t%enes. Aroatic olecular forula is

Cn;2n/) if t%e( are single ring onl(. T%e coon e-a"le for t%is aroatic series for

ononuclear are ?enene' toluene' and cuene. T%e figure below s%ow t%e e-a"les of

aroatic series>

$igure 2> e-a"le of aroatic %(drocarbon in crude oil.

5



T%e crude oil will undergo fractionation "rocess. $ractionation also +nown as crude oil

distillation. T%e first ste" in t%e refining "rocess is se"aration of crude oil into various fraction b(

distillation in atos"%eric distillation. $igure below s%ow t%e fractionation of crude oil into t%eir

"roduct>

$igure 3> fractionation of crude oil into "roduct.

&t%(lene or et%ane is a colorless gas at roo te"erature and "ressure. It %as slig%tl(

sweet sell and %ave flaable "ro"erties. It %as low elting and boiling "oint w%ere t%e

elting "oint et%(lene is /1)*oC and boiling "oint of et%(lene is /10#oC. &t%(lene can be

"roduced eit%er b(>

I. &-traction fro natural gas using fractional distillation follow b( stea crac+ing at

te"erature 50 to *00o

C and followed b( li,uefaction of t%e gas and t%enfurt%er fractional distillation or

II. &-traction of crude oil using fractional distillation followed b( stea crac+ing at

te"erature 50 / *00oC of t%e na"t%a or gas oil fractions followed b(

li,uefaction of t%e gas and t%en furt%er fractional distillation.

6



8a"%t%a is "roduct strea t%at boils in t%e gasoline boiling range. T%e "ro"erties of na"%t%a is

s%own in table below>

?oiling "oint #0 to 190oC

densit( 0.0

viscosit( :ow

Range of n/"araffin C) to C10

Table 1> "%(sical "ro"erties of na"%t%a

8a"%t%a' or gas oil' a( also be efficientl( crac+ed to et%(lene and "ro"(lene' alt%oug%

t%e "ro"ortion of et%(lene in t%e "roduct strea is generall( lower for t%ese feedstoc+ t%an fro

et%ane or "ro"ane. ;owever' t%is fle-ibilit( of "ossible feedstoc+ to et%(lene enables a refiner(

to "rocess t%ose streas in current e-cess in order to "roduce t%e olefins t%at it a( currentl(

need.

Crac+ing is a t%eral deco"osition "rocess b( w%ic% large al+ane %(drocarbon

olecules are bro+en down b( "assing t%e over a %eated catal(st at %ig% "ressure. It is done

b( %eating soe of t%e less used fractions to a %ig% te"erature va"or and "assing over a

suitable %ot catal(st at %ig% "ressure. 4oeties t%e fraction is %eated wit% stea to a %ig%

te"erature. @sing different conditions in e-a"le b( var(ing wit% or wit%out stea'

te"erature' "ressure or catal(st' we can control t%e co"osition of t%e i-ture and a+e a

variet( of different %(drocarbon "roducts.

To "roduce t%e et%(lene fro na"%t%a' lig%t co"onent is ost needed fro t%e

fractionation "rocess. It is because et%(lene is in range lig%t crude oil.

7



5.1.2 Potential su&&lier of crude oil

$igure below s%ow general su""lier of crude oil>

$igure #> oil "roduction base on countr( 2015

T%e oil "roduction b( countr( is doinate b( 4audi Arabia wit% 11'30'000 barrel "er

da(. T%en follow b( @nited 4tates 11'110'000 barrel "er da(' Russia 10'##0'000 barrel "er

da(' C%ina #'1*'000 barrel "er da( and Canada 3'95)'000 barrel "er da(. T%e cost of

crude oil is s%own in figure below>

8



$igure 5> "rice of crude oil until 6ctober 2015

9



5.1.3 "aterial trans&ortation

Crude oil is trans"orted b( oil "i"elines' tan+er s%i"s' and railroads or road tan+er fro

oil fields to refineries. Crude oil "i"eline is t%e c%ea"est ean of trans"ortation' and it is used

for crude oil trans"ort fro oil fields to sea "ort fro w%ic% crude oil is trans"orted b( tan+er

s%i"s to refineries or terinal fro w%ere crude oil is again trans"orted b( "i"elines to refineries

in land. Crude oil trans"ort b( railroad or road tan+er is ore e-"ensive and it is used ostl( on

s%orter distances w%ere t%ere are no "i"elines &ir Ceric' nd.

1. 6il Tan+ers

Toda(s cutting/edge tan+ers are t%e "roduct of a coitent to safet( cobined wit%

t%e "ower of co"uter/assisted design. As a result' t%e new s%i"s traveling t%e seas are

stronger' ore aneuverable' and ore durable t%an t%eir "redecessors.

2. Pi"elines

T%e nations ore t%an 1*0'000 iles of li,uid "i"elines and over 300'000 iles of

natural gas "i"elines' w%ic% are t%e "riar( eans of oving "etroleu "roducts to consuer

ar+ets. Pi"elines are safe' efficient and' because ost are buried' largel( unseen.

3. Pi"eline Perforance Trac+ing 4(ste

T%e Pi"eline Perforance Trac+ing 4(ste' PPT4' is a +e( co"onent of t%e oil

"i"eline industr(s &nvironental and 4afet( Initiative' a ulti/disci"line a""roac% tounderstanding and i"roving industr( "erforance.

#. Rail Trans"ortation

Railroad infrastructure su""orts t%e trans"ortation needs of industries as diverse as oil

and gas' anufacturing' and agriculture. 8ort% Aerica benefits fro an integrated railwa(

s(ste t%at is vital to reac%ing ot%erwise underserved ar+ets. Railroads are a safe and

efficient eans of trans"orting crude oil and ot%er "etroleu "roducts.

10

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Oil-Tankers

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Pipeline

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Pipeline-Performance-PPTS

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Rail-Transportation

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Oil-Tankers

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Pipeline

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Pipeline-Performance-PPTS

http://www.api.org/Oil-and-Natural-Gas-Overview/Transporting-Oil-and-Natural-Gas/Rail-Transportation



$igure below is s%ow %ow t%e crude oil is being trans"ort>

$igure )> crude oil trans"ortation

11



C r u d e O i l • C r a c k i n g

• D i s t i l l a t i o n

E t h a n e

• C r a c k i n g

E t h l e n e

• ! t e a " C r a c k i n g

# C $ • D i r e c t C h l o r i n a t i o n $ e t h o d • O % c h l o r i n a t i o n $ e t h o d

& # C

• & o l " e r i s a t i o n

5.2 Process descri&tion )from ra* material intermediate &roductfinis'ed &roduct+

5.2.1 ,ac-ground and &rocess flo*

&t%(lene are t%e largest scale "etroc%eical aong industr( and can be ade fro natural gasor na"%t%a. &t%(lene can be used to "roduce "ol(ers suc% as "ol(et%ane' et%(lbenene and

ot%er c%eicals. &t%(lene can be "roduce fro t%e fraction obtained fro distillation of natural

gas and crude oil. T%e "rocesses involve are>/

1. T%e stea crac+ of et%ane and "ro"ane fro natural gas and fro crude oil2. T%e stea crac+ing of na"%t%a fro crude oil.3. T%e catal(tic crac+ing of gas oil fro crude oil.

$igure >/ T%e "rocess flow of "roduction of PC

5.2.2 eaction conditions and mec'anism for #t'(lene /C" and P/C.a+ Production of et'(lene

T%e initial et%od used to "roduce et%(lene b( catal(tic de%(dration of et%anol.

$igure 9> T%e reaction of "roduction et%(lene

12



T%is laborator( e-"erient et%od is ca"able to (ield around *0 B of et%(lene based on

et%ane under te"erature between 330 to #00 ℃ . Refiner( et%(lene is usuall( ade b( t%e

catal(tic crac+ing of et%ane' "ro"ane or i-ed %(drocarbon stea' suc% as recovered natural

gas' li,uids' na"%t%a or gas oil. 8a"%t%a or gas oil a( be efficientl( crac+ed to et%(lene and"ro"(lene alt%oug% t%e "ro"ortion of et%(lene in t%e "roduct strea is generall( lower for t%ese

feedstoc+s t%an fro et%ane or "ro"ane. ;owever' t%is fle-ibilit( of "ossible feedstoc+s to

et%(lene enables a refiner( to "rocess t%ose streas in current e-cess in order to "roduce t%e

olefins t%at it a( currentl( need.

Crac+ing condition for refining et%(lene>/

• Te"erature >/ 50 *00 ℃

• Pressure >/ low "artial "ressure

• Catal(st >/ etal o-ide catal(st

• Crac+ing Reaction>/

• T%e initial ste">/ ;ool(sis of t%e carbon carbon bond.• C;3C;3 2 ;3C

.

T%e second ste"> / Pro"agation reactions.

• ;3C. = C;3C;3 C;# =

. C;2C;3

•. C;2C;3 C;2

¿ C;2 = ;.

• ;. = C;3 C;3C;3 ;C = .C;2C;3t

T%e t%ird ste" >/ Terination reactions of %(drocarbon

• C;3/C;3C2/C;3 C;2¿

C;2 = C;#

• C;3 C;2 C;3 C;2¿

C; C;3 = ;2

b+ eaction and "ec'anism of /C"

C%loroet%ene vin(l c%loride is also used to "roduce co/"ol(ers' for e-a"le wit% et%en(l

et%anoate vin(l acetate. T%e co/"ol(er can be "rocessed at uc% lower te"eratures t%an"ol(c%loroet%ene %oo"ol(ers of t%e sae relative olecular ass. It is used for coating

etals and wood. T%e fil is fle-ible' %ard wearing' resistant to c%eical attac+ and can be

"igented so t%at it is "articularl( suitable' for e-a"le' for s%i"s. T%e co/"ol(er is also used

in ad%esives and in in+s.

Manufacture of CM involes into 2 stages>/

13

http://www.essentialchemicalindustry.org/polymers/polymers-an-overview.html#SBS_ABS


http://www.essentialchemicalindustry.org/materials-and-applications/paints.html#ethenyl_ethanoate








I. %irect C'lorination

&t%ene is reacted wit% c%lorine in t%e li,uid "%ase' using e-cess c%loret%ene as solvent. T%e

reaction is e-ot%eric and no e-ternal %eat is needed.

Reaction condition>/

Te"erature >/ 320 D 350 D

Pressure > # at

Catal(st used > / iron III c%loride

Reaction > / &-ot%eric reaction E; F /19 +< ol/1 CI&C' 201#

$igure *> T%e reaction of "roduction 1'2/ dic%loroet%ane CI&C' 201#

C%lorine = &t%ene G 1' 2 dic%loroet%ane

1' 2 dic%loroet%ane = water Gc%loroet%ene = ;Cl

II. 0(c'lorination

T%e crac+ing of 1'2/dic%loroet%ane during stage b of t%e overall "rocess fors

%(drogen c%loride as a b(/"roduct. It is unwanted as %(drogen c%loride and is ver(

detriental to t%e environent. ;owever' it can be used in t%is second et%od of

a+ing 1'2/dic%loroet%ane.&t%ene is i-ed wit% %(drogen c%loride and air enric%ed

wit% o-(gen. T%e gases are "assed over a %eated solid catal(st in etal tubes' in

a fluid bed reactor .

14

http://www.essentialchemicalindustry.org/processes/chemical-reactors.html#fluid_bed





$igure 10 > A diagra to illustrate t%e use of a fluid bed reactor for t%e

o-(c%lorination of et%ane to c%loroet%e. 6n t%e left %and side' t%e catal(st "articles

are at rest. 6n t%e rig%t %and side' t%e t%e "articles are now acting as a fluid' as t%e

gaseous reactants "ass t%roug% t%e solid. CI&C' 201#.

&t%ene = 6-(gen = ;Cl G 1'2/dic%loroet%ane = water G c%loroet%ene = ;Cl

• Reaction condition>/

• Te"erature >/ 225H / 325 C

• Pressure > 1/ 15 atos"%eres.

• Catal(st used > / iron III c%loride• Reaction > / &-ot%eric reaction E; F /23* +< ol/1 CI&C' 201#

&-"lanation >/ 6"erating at %ig%er te"erature allow for %eat recover( w%ic% result in"lant energ( savings. &t%(lene will react wit% o-(gen and a rec(cled ;C: to

"roduce 1'2/dic%loroet%ane and water and will undergo furt%er reaction of

t%eral crac+ing to "roduce vin(l c%loride.

c+ eaction and "ec'anism of P/C

Pol(vin(l c%oride is abbreviated to PC. ?ut "ol( c%oro et%(lene and

"ol( c%loroet%ane are ot%er naes for "ol(vin(l c%loride .Pol(vin(l c%loride is a t%ero"lastic '

it softens w%en %eat and "ressure is a""lied so it can be oldeded into different s%a"es.

Pol(vin(l c%loride "reci"itates out as a w%ite solid as it fors because it is insoluble in water

and insoluble in c%loroet%ene. Pol(vin(l c%loride is "roduced in an addition "ol(eriation

reaction fro c%loroet%ene vin(l c%loride onoers>/

T%e e,uation is suall( written>/

15



$igure 11 > T%e reaction e,uation of onoer to "ol(er b( "ol(erisation

C%loroet%ene Pol(c%oroet%ene

CM in(l C%loride PC "ol(vin(l c%loride

• Reaction >/ Pol(erisation Reaction

• Te"erature condition > 325 D 350 D

• Pressure >/ 13 at• Reaction >/ &-ot%eric reaction E; F /*) +< ol/1

• Catal(st @sed >/ 8one

T%e addition "ol(erisation of c%loroet%ene to "roduce "ol(c%loroet%ene "roceeds b(

a free/radical ec%anis. A free radical is a olecule t%at %as no c%arge' but' is %ig%l( reactive

because it %as an un"aired valence electron. In t%e industrial "re"aration of "ol(vin(l c%loride'

a free radical is used to initiate t%e c%ain reaction. T%is source of free radicals is called t%e

initiator. 6rganic "ero-ides wit% t%e general forula R/6/6/R are often used as initiators

because t%e( can s"lit into free radicals at elevated te"eratures>

organic &eroide al-o( free radical

00 20

T%e al+o-( free radical cobines wit% a olecule of c%loroet%ene to for a new free radical>

$igure 12> T%e reaction foring new radical Aus' 2009

16



T%is new free radical can t%en cobine wit% anot%er olecule of c%loroet%ene>

$igure 13 > T%e reaction foring new radical cobine wit% c%loroet%ne Aus' 2009

T%is new free radical can react wit% anot%er c%loroet%ene olecule to for a new free

radical' etc' until a ver( large "ol(vin(l c%loride olecule %as been built.

T%e "ol(erisation sto"s w%en two free radicals react wit% eac% ot%er.

d+ tructure of P/C

T%ere are a nuber of different wa(s in w%ic% c%loroet%ene olecules can cobine toget%er to

for long "ol(er c%ains. $or instance ' t%e t("e of structure of PC is isotactic PC'

s(ndiotactic PC and atactic PC. Aus' 2009

Name Isotactic (nriotactic Atactic

T(&e P/C

tructure

#&lainatio

n

All t%e c%loroet%ene

olecules cobine so

t%at t%e c%lorine

atos are all on t%e

sae side of t%e carbon

bac+bone of t%e "ol(er

c%ains

T%e c%loroet%ene

olecules cobine so

t%at t%e c%lorine

atos alternate

between being above

t%e "lane of

t%e carbon bac+bone

T%e c%loroet%ene

olecules cobine so

t%at c%lorine atos are

randol( oriented along

t%e c%ains' wit% soe

above and soe below

t%e "lane of t%e carbon

bac+bone

5.2.3 Process ariables &arameters to be controlled to ac'iee 'ig'

ualit( Intermediate &roduct.

a Production of ra* material for P/C )/C"+

CM is a %ig% "ressure gas wit% a olecular weig%t of )2.5 and boiling "oint of / 13.*

℃ ' t%erefore it is anufactured under strict ,ualit( and safet( control. T%ere are two wa(s to

anufacture CM' t%e direct c'lorination met'od and o(c'lorination met'od. @nder t%e

direct c%lorination et%od' et%(lene obtained fro t%eral crac+ing of na"%t%a and c%lorine

17



obtained fro electrol(sis of salt reacts wit%in a catal(st/containing reactor to for t%e

interediate aterial &!C. &!C is t%en t%erall( crac+ed to (ield CM at few %undred ℃ .

$igure 1# > T%e overall "rocess of conversion et%(lene to CM t%en finall( to PC. Tetsuo

8is%ide' 2009

J%en t%e %(drogen c%loride obtained as b("roduct fro t%e above et%od reacts wit%

et%(lene in t%e "resence of catal(st and air or o-(gen' &!C is obtained again. T%is is called

t%e o-(c%lorination "rocess in t%e figure above J%en &!C fro t%e o-(c%lorination "rocess is

de%(drated and t%en t%erall( crac+ed li+ewise wit% t%e &!C fro t%e direct c%lorination

"rocess' CM is obtained. T%ese two et%ods are cobined t%us at t%e aKor CM "lants in

<a"an. $ig.1# is a flow c%art of CM anufacturing "rocesses s%own in $ig.15.

$igure 15 > T%e "rocess involving e,ui"ent "at%wa( of "roduction of CM via "rocess !irect

C%lorination L 6-(c%lorination. Tetsuo 8is%ide' 2009

b+ P/C &roduction &rocesses

18



enerall( t%e sus"ension "ol(eriation "rocess is ado"ted to anufacture PC. $irst'

t%e raw aterial CM is "ressuried and li,uefied' and t%en fed into t%e "ol(eriation reactor'

w%ic% contains water and sus"ending agent in advanced. Troug% %ig%/s"eed agitation wit%in t%e

reactor' icro "articles of CM are obtained. 8e-t' t%e initiator for "ol(eriation is fed into t%e

reactor' and PC is "roduced b( reaction under a few atos"%eric "ressures at #0/)0 ℃ .

PC obtained t%roug% sus"ension "ol(eriation is sus"ended in water as icro "articles of 50

200 N diaeter in slurr( for. T%erefore' slurr( disc%arged fro t%e "ol(eriation reactor

is de%(drated' dried and t%e "article sie atc%ed b( screening to (ield PC in t%e for of w%ite

"owder. T%e unreacted CM is entirel( recovered t%roug% t%e stri""ing "rocess' and after

refining' rec(cled as raw aterial for reuse in t%is "rocess $ig.5. &ulsion "ol(eriation

"rocess and bul+ "ol(eriation "rocess are also ado"ted.

$igure 1) > T%e PC "ol(eriation "rocess flow diagra involving e,ui"ent. Tetsuo

8is%ide' 2009

5.2.4 Product s&ecification follo*ing standard

P/C PIP# P89ICA$ P0P#TI#

:#N#A$ A:@& T&4T M&T;6!

Cell classification 12#5# A4TM !19#

Ma-iu 4ervice Te". 1#0 ℉

Color J%ite ' !ar+ re(

4"ecific gravit('

g7cu. 3 ℉

1.#0 =7/ .02 A4TM !*2

Jater absor"tion B increase

2# %rs 25 ℃

0.05 A4TM !50

19



;ardeness ' Roc+well 110/ 120 A4TM !95

PoissonOs Ratio 3 ℉ 0.#10

;aen/Jillias factor CF 150

"ec'anical

Tensile strengt%' "si 3

℉

#50 A4TM !)39

Tensile odulus of elasticit('

"si 3 ℉

#20000 A4TM !)39

$le-ural strengt% ' "si 3

℉

1# #50 A4TM !*0

$le-ural odulus' "si 3

℉

3)0 000 A4TM !*0

Co"ressive strengt% '"si

3 ℉

* )00 A4TM !)*5

Iod i"act ' notc%ed' ft/lb7in

3 ℉

0.5 A4TM !25)

T%eral

Coefficient of linear

e-"ansion in7in7 ℉

2.* - 10/5 A4TM !)*)

Coefficient of t%eral

conductivit(

Jatt 77D

0.1# A4TM C1

;eat deflection te"erature

under load 2)# "siQ

annealed

10 A4TM !)#9

4"ecific %eat ' Cal7 ℃ 7g 0.25 A4TM !2))

20



&lectrical

!iaelectric strengt%' volts7il 1' #13 A4TM !1#*

!iaelectric constant' )0 ;'

30 ℉

3.0 A4TM C150

olue resistivit(' o%7c

*5 ℃

1.2 - 1012 A4TM !25

;arvel PC "i"e is non/

electrol(tic

$ire "erforance

$laabilit( rating /0 @:/*#

$lae s"read inde- 10

$lae s"read 0/25 @:C4o+e generation 90/225 @:C

$las% ignition te". 30 ℉

Average tie of burning

sec.

5 A4TM !)35

Average e-tent of burning

10

?urning rate in7in 4elf&-tinguis%ing

4oftening starts a""ro-. 250 ℉

Material becoe viscous 350 ℉

Material carbonies #25 ℉

:iiting o-(gen inde- :6I #3 A4TM !29)3

Clean roo aterial

flaabilit( test

87A $M #*10

4ource> Professional Plastic Inc.

;0<C0# P/CIN<$AT#% P0!# CA,$# P0P#TI#

21



?A4IC C684TR@CTI68

Conductor aterial Co""er or Aluiniu

Conductor s%a"e Circular stranded or

Co"acted circular strandedInsulation PC

?edding PC Aror alvanised 4teel wires

4%eat% aterial PC

22



P%(sical state solid

!ensit( 1.12/1.5 g7c36dor 6dourless

Melting "oint 221/29# ℉

4olubilit( in water 8ot soluble

23



5.3 %efinition of end &roduct to consumer

5.3.1 <NP$ATICI=#% P0$9/IN9$ C8$0I%# )<P/C+ P0P#TI#

P'(sical %escri&tion Pro&erties

A&&earance> 6"a,ue rigid solid tubes' diaeters fro 15 to 300 ' lengt%s u" to )' various

colours' wit% or wit%out Kointing soc+ets.

,oiling &oint "elting &oint> 4oftening "oint S5 ℃ . !eco"osition initiates at

a""ro-iatel( 1#0 ℃

elatie densit(> 1.3/1.)

;lammabilit( limits> cobustible' self/e-tinguis%ing

olubilit( in *ater> Insoluble

P0P#TI# 0;;##% ,9 T8# P0%<CT

P/C PIP#

Advantages of "lastic "i"es>

1. Plastic "i"es are lig%t in weig%t' toug%' resistant to c%eical attac+ and available in large

lengt%s.2. T%e( reduce t%e cost of %andling' trans"ortation and installation.3. :ess nuber of Koints facilitates t%e s"eed and reduce c%ances of lea+age#. T%e( are rust resistant.5. T%eir ada"tabilit( to eart% oveents is su"erior.). T%ese "i"es %ave good elastic "ro"erties.. 4oot% internal surface of t%e "i"es offer less friction.

!isadvantages of "lastic "i"es>

1. T%e( easil( crac+ed2. At %ig%er te"eratures' t%e strengt% of "lastic "i"es reduces.

3. Plastic "i"e are not installed in %ig% te"erature.

;0<C0# P/CIN<$AT#% P0!# CA,$#

24



Advantages of "lastic cables>

1. C%ea"2. !urable3. Jidel( available

!isadvantages of "lastic cables>

1. ;ig%est dielectric losses2. Melt at %ig% te"eratures3. Contain %alogens#. 8ot suitable for M7; cables

<NP$ATICI=#% P0$9/IN9$ C8$0I%# )<P/C+

Advantages of @PC "i"es>

1. It is not corroded2. :ig%t weig%t3. &as( and ,uic+ to install#. &-cellent %(draulic5. 8on flaable). $le-ible and resistance to brea+age. Resistance to biological growt%9. ;ig% life s"an

!isadvantages of @PC "i"es>

1. !rainage nois(2. ?earing ca"acit( is wea+3. ;eat resistance is "oor #. 4tiffness

5.4 ;uture issues regarding bot' intermediate and end &roducts

T%e ost coon future issues relatable to PC is in its dis"osal "rocess. PC contains

%eav( etal additives suc% as lead' organotin and cadiu usuall( found in t%e slag and fl(

as% after incineration. Currentl(' PC is res"onsible for about 20B to 30B of all cadiu

entering incinerators. T%e slag and fl( as% fro t%e incineration "rocess are usuall( landfilled.

T%is could "otentiall( cause leac%ing of %eav( etals and containate ground water.

25



6ne of t%e "robles faced w%en tr(ing to dis"ose PC is t%e fact t%at it is non/

biodegradable. T%us' it cannot be bro+en down in atter of wee+s or ont%s a+ing it

i"ossible to be destro(ed naturall(. T%e global "roduction of PC currentl( stands at about 20

illion tonnes "er (ear. T%is %ig% aount eans t%at atte"ting to dis"ose wastes PC b(

bur(ing t%e is not sustainable given t%e liited aount of land on t%e eart%. $urt%erore'

additives suc% as "%t%alates and %eav( etals a( containate ground water fro landfilled

PC.

In t%eor(' PC are able to be rec(cled. T%is is done t%roug% a series of crus%ing'

grinding and elting "rocess. ;owever' t%ere are several constraints in t%e actual "rocess to

rec(cle PC.

6ne of t%e constraints in rec(cling PC is t%e need to sort t%e waste into generic

aterials. T%e level of i"urities is an i"ortant as"ect in deterining t%e ,ualit( of t%erec(clate. &-a"les of i"urities are ot%er "ol(ers and reinforceent aterials. T%us' it is

i"ortant to first deterine t%e co"osition of PC. ;owever' t%is is visuall( and ec%anicall(

i"ossible. T%is is due to PC waste streas norall( being a co"le- i- of aterials

coing fro various sources. T%is causes rec(cling of PC tec%nicall( and econoicall( ver(

difficult. ?ritis% Plastics $ederation states t%at PC based "roducts suc% as t%e das% board in a

car is unar+ed' fro a variet( of sources and in a for w%ere disassebl( would be ver(

costl( if not i"ossibleU.

PC also needs to be elted for it to be able to be rec(cled. T%e act of elting PC will

release %(drogen c%loride w%ic% causes ot%er s"litting "rocesses in t%e PC to s"eed u". T%e

"rocess is called autocatal(tic corrosion and causes t%e ,ualit( of t%e end "roduct to dro". T%is

is t%e reason as to w%( ost "rocess of rec(cling PC results in a downc(cling "rocess. !ue to

t%is' ost rec(cled PC is unsuitable for its original "ur"ose. ?ritis% Plastic $ederation states

t%at' t%e VdowngradingO nature of PC rec(cling "rocess liits t%e nuber of ties t%at it can be

rec(cled' eaning t%at t%e "roble of dis"osal is erel( "ost"oned.

Anot%er constraint is regarding t%e ar+et. Plastic rec(clate %as a ver( sall ar+et

deand. A re"ort on general "lastics rec(cling' Plastic and Rubber Jee+l( dated on 1**3

re"orts t%at "rocessors are reluctant to acce"t rec(cled aterialU and t%at it is clear t%at

unsubsidied rec(clate cannot reall( trade against virgin aterialU. Anot%er re"ort b( t%e ?ritis%

Plastic $ederation states t%at t%ere are serious restrictions in t%e ar+et o""ortunities for

rec(cled "lastics' regardless of costU and t%at t%ere is a continuing need to find financiall(

26



viable eans of addressing waste anageent issues to allow rec(clates to be sold at ar+et

"riceU.

In order to overcoe t%is "roble' t%e ?ritis% Plastic $ederation "ro"oses t%at a new

ar+et focusing on "lastic rec(clate ust be created. $or PC' t%is would ean new wa(s and

a""lication for PC as well as a "ossible crowding/out of ore environentall( sound c%lorine

free alternatives. T%is would also ean t%at soe "roduct would include to-in c%eicals and

%eav( etals li+e cadiu and tin. T%us' it is i"ortant to bear in ind t%at t%is sort of rec(cling

%as no environental value.

Anot%er issue regarding PC rec(cling is t%at t%e "rocess itself results in eission.

;(drogen and benene is released during crus%ing and grinding. 6rganoc%lorines are released

w%en PC coating is burnt off co""er cables. PC a( also cause eissions of dio-in to

increase w%en it %as containated aterials during t%e aterialsO rec(cling "rocess. Accordingto ;MIP figures' dio-in eissions fro scra" etal wit% PC is relativel( %ig%erQ at about

20.0Ng I/T&W "er tonne w%en co"ared to scra" etal wit% no c%lorine at 0.Ng I/T&W "er

tonne.

&ven t%oug% t%e PC industr( is troubled in "roving t%e rec(clabilit( of its "roduct' it is

actuall( negligible. Association of Plastic Manufacturers in &uro"e %as re"orted t%at "ost/user

PC "lastic waste rec(cled was at a eager 0.)B. +ee" in ind t%at "ost/consuer aterial

rec(cling is not to be confused wit% "re/consuer waste or also +nown as offcut re"rocessing.

T%e re"rocessing of "lastic industr( scra" creates less "robles co"ared to "ost/consuer

rec(cling.

Anot%er strateg( ta+en to overcoe t%e issues related to PC is PC Agreeent. T%e

%istor( of PC agreeent started out w%en an Action Plan on t%e reduction of PC is "resented

out in 1*99. To negotiate wit% t%e "arties involved' t%e Action Plan resulted in an VAgreeent

Regarding t%e @se of PCO or +nown as PC Agreeent.

Aong t%e content of t%e PC Agreeent is t%e PC 4trateg(. T%is strateg( includes a

nuber of initiatives to be considered in t%e PC area. T%e initiatives is directed towards

%andling t%e "robles caused b( t%e consu"tion of PC.

T%e PC 4trateg( includes si- ain goals in its i"leentation. T%e( are>

1. 8ew PC "roducts ust be free of additives containing environental containants and

substances w%ic% are %arful to %ealt%.

27



2. PC "roducts w%ic% are difficult to se"arate ust be substituted as far as "ossible.3. As far as "ossible' PC ust be +e"t awa( fro incineration "lants.#. Relevant treatent tec%nologies ust be develo"ed.5. Rec(clable PC ust be collected and regenerated.). Reuse of PC containing %eav( etals ust be liited.

T%e PC 4trateg( %as "ro"osed an( new initiatives in %andling issues related to

"roduction and usage of PC. Aong t%e initiatives listed in t%e strategies are>

• PC ust be se"arated and non/reusable PC ust be landfilled

• Consideration of "ossibilities to i"ose ta- on new PC "roducts

• ?an on lead as a stabilier or "igent in PC

• Action Plan to reduce and "%ase out t%e use of "%t%alates

• P%asing out environental containants and substances w%ic% are %arful to %ealt%

• Controlled rec(cling

• Inforation activities' including declaration' eco/labeling and bu(ing guidelines

• !evelo"ent of cleaner "roducts

28



5.5 #N/I0N"#NTA$ A;#T9 AN% 8#A$T8 C0NI%#ATI0N

8owada(s' environental' safet( and %uan %ealt% considerations regarding t%e

"roductions of Pol(vin(l C%loride PC "roducts %ave been one of t%e largest t%at "eo"le

around t%e world tal+ed about. T%us' we will discussed about t%e as"ects of t%e environental

awareness and safet( and %uan %ealt% considerations t%at a( affects t%e "rocess of PC

"roductions and soe as"ects t%at affects t%e counit( around t%e "lants and also

i"roveents ade along wit% t%e wa(s to overcoe t%e "robles.

$igure 1> &-a"le of "%t%alate resin

4ource> ignes%waran' 2003

Conse,uentl(' regarding to t%e bot% environental awareness and safet( and %ealt%

considerations' "roductions of PC involved a et%od called "lasticisation w%ic% used

"%t%alate "lasticisers as one of t%e resin in t%e "rocess Patric+' 2005. P%t%alate "lasticisers

%ave negative i"act on %uan %ealt% and also for environent. T%is resin "owder can

odulating t%e environental because of its dangerous "ro"erties w%ile for t%e %uan %ealt%'

t%e substance is ver( dangerous to t%e %uan re"roductive s(ste suc% as barren and also

can affects t%e unborn c%ild t%at will cause 4(ndroe !own "roble later. Moreover' t%e

a""lications of t%is resin substance %ave been widel( used in t%e counit(. As e-a"le' !I8P'

t%e ost coonl( used "lasticiser in soft to(s and ites intended to be "ut into c%ildrenOs

out%s' %as %ad a "ositive &uro"e and @nited 4tates of Aerica Consuer Product 4afet(

Coission ris+ assessent w%ic% "rovided t%at recoended igration liits %ave been

ad%ered to Patric+' 2005. !&;P is t%e onl( "%t%alate t%at %as &uro"ean P%araco"oeia

a""roval for fle-ible PC edical devices. T%ere %as been soe acadeic wor+ carried out to

reduce !&;P igration fro fle-ible PC.

29



Anot%er issues on t%e environental and %uan %ealt% is t%e used of ver( cost effective

%eat stabilisers w%ic% is lead/based stabilisers in t%e PC a""lications suc% as "i"e' fittings and

"rofile es"eciall( in &uro"e and $ar &ast regions. $urt%erore' t%e great "ro"erties of t%e lead/

based stabilisers w%ic% is good insulation resistance %ave alread( ade it as a ver( suitable

candidate to be used in t%e PC in wire and cable across t%e world in t%is last few (ears. &ven

t%oug% t%e to-icit( of t%e stabilisers %ave been controlled' "articularl( in relation to wor+er

e-"osure' t%e &uro"e %aard classification and labelling t%at focuses on wor+er "rotection of

lead stabilisers as re"roto-ic' %arful' dangerous for environent and also t%e "resence of t%e

%eav( etal causing issues for waste anageent strategies ignes%waran' 2003.

:ast but not least' t%e issues of t%e rec(cling and solid waste dis"osal %ave alread(

been one of t%e biggest "robles in t%is %ig% tec%nolog( globalisation era. T%ere are two

et%ods t%at used in t%e rec(cling w%ic% are incineration and rec(cling Patric+' 2005.

Incineration %as issues of "erce"tion concerning dio-ins and acid generation' wit% dis"osal of

t%e furnace residue also seen to be "robleatical. In addition' t%e "ublic "erce"tion of

incineration as a eans of energ( recover( is not "ositive. Moreover' t%e "ossibilit( of landfill

dis"osal is also a c%allenge' due to concerns about "otential leac%ing out of %eav( etals and

"%t%alates as entioned before. T%e s%ortages of suitable areas for landfill generall( and even

ore so for %aardous waste will severel( restrict t%is dis"osal route in t%e future. Rec(cling of

"ost/consuer waste is in its infanc(' as far as t%e "ol(er industr( is concerned. T%ere are

an( issues concerning collection' se"aration' and "rocessing into suitable a""lications. T%e

"riar( issue is' of course' t%e ca"ital costs associated wit% a rec(cling o"eration in co"arison

to current costs of virgin aterial "rocessed into e-isting a""lications.

T%erefore' since t%e "robles %ave been occurred for a decade' soe coittee is

attracted to discuss on t%e wa(s to overcoe and solved t%e "robles caused b( t%e PC

a""lications around t%e world. In t%e "ers"ectives of t%e safet( easures' &uro"ean

Coissions %ave set new rules regarding to t%e environental' safet( and %ealt% issues in

order to "roote recover( of PC waste for use in t%e anot%er fields of constructions and

anufacturing Patric+' 2005. T%e ain obKectives of introducing t%is rules is to avoid PC

being discarded into t%e landfill or incinerated because PC waste also can caused carbon andcadiu eissions into t%e atos"%ere w%ic% also dangerous for %uan res"irator( s(stes.

T%e second et%od t%at can be done to overcoe t%is "robles is b( running t%e waste

treatent b( using Recovin(l or in(loo" "rocess. T%is "rocess is a ec%anical rec(cling

"rocess using a solvent to se"arate PC fro ot%er aterials. ?( collecting tonnage of t%e PC

30



waste' it can be rec(cled into t%e anot%er a""lications suc% as coating for swiing "ools and

%oses w%ile in t%e eantie can avoids fro e-tensivel( using t%e virgin PC.

6. eferences

Aus. 2009. PC' fro %tt">77www.ausetute.co.au7"vc.%tl

CI&C. 201#. Pol( C%loroet%e Pol(vin(l c%loride' fro

%tt">77www.essentialc%eicalindustr(.org7"ol(ers7"ol(c%loroet%ene.%tl

Tetsuo 8is%ide. 2009. PC $act ?oo+ Pol(vinv(l C%loride Retrieved fro

%tt">77www.vec.gr.K"7englis%7fact7"vcXfactXboo+Xe/all."df

Patric+' 4. . 2005. Practical uide to Pol(vin(l C%loride. @nited Dingdo> Ra"ra

Tec%nolog( .

ignes%waran' A. 2003. Pol(vin(l C%loride. <aland%ar> C%eical &ngineering Petroc%eical

Tec%nolog(.

%tt">77+noea.co7(-"t"ab7crude/oil/"rice/forecast/long/ter/2015/to/2025/data/and/c%arts

%tt">77www.inde-undi.co7g7r.as"-YvF99

%tt">77www.docbrown.info7"age0#76ilProducts0).%t

%tt">77resources.%s.vic.edu.au7science7resources7files7Crac+ingB20%(drocarbons."df

A8 I8TR6!@CTI68 T6 P&TR6:&@M R&$I8I8 A8! T;& PR6!@CTI68 6$ @:TRA :6J

4@:$@R A46:I8& A8! !I&4&: $@&:' Mat%Pro' 6ctober 2#' 2011

reen"eace @D. 1**. What's wrong with PVC? @nited Dingdo> reen"eace Publication.

T%e Ministr( for &nvironent and &nerg(. 1***. PVC Strategy Status Report and Future

Initiative.

31

http://knoema.com/yxptpab/crude-oil-price-forecast-long-term-2015-to-2025-data-and-charts

http://www.indexmundi.com/g/r.aspx?v=88

http://www.docbrown.info/page04/OilProducts06.htm

http://resources.mhs.vic.edu.au/science/resources/files/Cracking%20hydrocarbons.pdf

http://knoema.com/yxptpab/crude-oil-price-forecast-long-term-2015-to-2025-data-and-charts

http://www.indexmundi.com/g/r.aspx?v=88

http://www.docbrown.info/page04/OilProducts06.htm

http://resources.mhs.vic.edu.au/science/resources/files/Cracking%20hydrocarbons.pdf



7. A&&endices

'igure( &ure &#C )o*der

'igure( Ca+le coating *ith &#C

'igure( ,ain coat "ade + &#C

Documents

Final Report Production PVC