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This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration under grant agreement No 280756.

DEMINERALIZED WATER LOOP CLOSURE IN PVC PROCESS

TOWARDS WASTE WATER RECYCLING FOR POLYMERIZATION PURPOSES

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UNSUSTAINABLE WORLD

ENERGY IRRATIONAL CONSUMPTION

UNCONTROLLED WASTE GENERATION

ABUSIVE WATER USE

TODAY’S ECONOMICAL GROWTH MEANS

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LOCATION OF INOVYN ESPAÑA

• Martorell, Barcelona • Production of PVC since 1972 (former SOLVIN)

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WATER AS RAW MATERIAL

VINYL CHLORIDE

PVC

ETHYLENE

THERMIC ENERGY

WATER

SALT RECOVERED FROM SURIA

ELECTRIC POWER

Na(OH)

SODIUM HYPOCHLORITE

HYDROCHLORIC ACID

HYDROGEN

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GOAL AT INOVYN ESPAÑA SIGNIFICANT WATER USE REDUCTION

CURRENT WATER INTAKE

230m3/h OTHER SITE PROCESSES

130m3/h

E4Water: 25m3/h

CURRENT PVC PROCESS 100m3/h

75m3/h

GRO

UN

D IN

TAKE

SEA

DIS

CHAR

GE

UP TO 657,000m3/y OF WATER INTAKE REDUCTION

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CURRENT LAYOUT & FUTURE E4Water

Autoclave Stripping Centrifuge PCT MBR+RO

Reclaimed water to process

Dryer PVC resins Monomer Additives

Demin. water

Wastewater (RO)

Recycled water

Waste biosludge (MBR)

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• Poly-vinyl alcohol < 1 mgL-1 • N-NH4

+ < 2 mgL-1 • BOD5~0

• Conductivity < 10 μScm-1

• Al < 0.1 mgL-1 • TOC < 10 mgL-1

RECYCLED WATER REQUIREMENTS

RECYCLED WATER MUST ACHIEVE DEMINERALIZED GRADE

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BIOLOGICAL DEGRADATION IN MBR OF POLY-VINYL ALCOHOL NEVER TESTED WITH PVC WASTE WATER

WASTE WATER NEVER USED BEFORE TO PRODUCE

DEMINERALIZED WATER IN PVC INDSUTRY

UNCERTAINTY USING THIS DEMINERALIZED WATER AT POLYMERIZATION STAGE

CHALLENGES AND INNOVATION

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OBJECTIVES

1

2

3

Demonstrate water close-up technical feasibility

Water must be used in PVC polymerization

Economical feasibility study. Drivers for implementation

4 Modelling for optimization & LCA-LCC studies

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CHOSEN PILOTING TECHNOLOGIES

LAB TEST TO SELECT PILOT TECHNOLOGY

JUSTIFICATION

MBR

RO

SHOWN OPTIMAL BIOLOGICAL DEGRADATION REDUCED SPACE & MODULAR

COST EFFECTIVE

RO LESS ELECTRICITY CONSUMPTION (1st UNSUSTAINABILITY)

WIDE WORKING RANGE

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1m3/h OF WATER TREATMENT 1year PILOTING

TESTED AEROBIC/ANOXIC CONDITIONS TESTED DIFFERENT R.O. YIELDS

SUCCESSFULLY ACHIEVED WATER QUALITY GOALS

PILOT TEST

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GRAPHICAL RESULTS

PILOT TEST

time, days0 50 100 150 200 250

rem

oval

, %

0

20

40

60

80

100

PVA,

mgL

-1

20

40

60

80

100

120

140

160

180

%COD removal% PVA removal% BOD removalPVA in feed

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ARRANGEMENT FOR FULL SCALE-UP

• Sludge adaptation period 2 to 4 weeks

• Phosphorus must be added

• HRT 6h • MLSS range 8-10g/l • Flux range 22-26 LMH • R=6

MBR • Two pass • Two stages per pass • Antiscalant dosage • Biofouling control by

biocide • Working TºC < 30ºC • Recovery range 60-75%

RO

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PVC SHOWN NO DIFFERENCE BETWEEN USING “FRESH” OR “RECYCLED” DEMINERALIZED WATER

POLYMERIZATION TRIALS

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“FRESH” “RECYCLED”

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POLYMERIZATION TRIALS

Demin water #1

Demin water #2

MBR – RO water #1

MBR – RO water #2

K value 58,4 58,3 57,9 58,4

Bulk density g/ml 0,527 0,535 0,531 0,534

D50 µm 122 116 120 121

Span 0,74 0,66 0,72 0,73

WI 70,2 71,5 71,7 70,9

b* 4,34 4,30 3,93 4,34

CAP 15min % 87,9 91,0 88,1 93,1

Porosity % 20,6 20,1 20,5 20,2

K-58 PVC GRADE

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PRE-BASIC DESIGN

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1.9M€ FOR 50m3/h TREATMENT 2.5M€ FOR 100m3/h TREATMENT

BUDGET ESTIMATE

• Treated flowrate above 50m3/h • Fresh demin. water above 1,25€/m3

• 15 years depreciation FEASIBLE

• Drought forces above 3% PVC production reduction – Return < 1 year

INOVYN FEASIBLE

IF…

OR…

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STRONGER POSITION FACING DROUGHTS AS PRODUCTION LOSS IS AVOIDED

STRATEGY

Production restriction without

E4Water (%)

Investment recovery with E4Water (months)

36 1 25 2 15 3 10 4 5 8 3 13

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FULLY FUNCTIONAL MODEL DONE (TUB) & LCA (IVL)

SITE MODELING AND LCA

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PROJECT REPLICATION

The MBR lab scale • confirms the results obtained by the previous test

performed by VITO (flat sheet IPC) and UCM with the Zeeweed membrane,

• and demonstrates the feasibility of the application of this technology to the range of PVC-S wastewaters at Solvay.

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PROJECT REPLICATION

• S-PVC (INOVYN) • S-PVC + fillers • S-PVC +fillers

+copo

PVC effluent family

• all European Solvay/inovyn plants

PVC plants

• one wastewater treatment route

PVC effluent

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QUESTIONS

Water is the driving force of all nature. Leonardo da Vinci