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1 Ford, Bacon & Davis, LLC Polyvinyl Chloride

Polyvinyl Chloride - AIChE | The Global Home of Chemical ...€¦ · Polyvinyl Chloride • Review Chlorine and Vinyl Chloride Monomer (VCM) Process Technologies • Provide Overview

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  • 1Ford, Bacon & Davis, LLC

    Polyvinyl Chloride

  • • Review Chlorine and Vinyl Chloride Monomer (VCM) Process Technologies

    • Provide Overview Of Polyvinyl Chloride (PVC) Process

    • Identify VCM Safe Handling Practices• Explore Equipment Design Examples From PVC

    Processes

    Ford, Bacon & Davis, LLC 2

  • Chlorine

    Ford, Bacon & Davis, LLC 3

  • Ford, Bacon & Davis, LLC 4

    eurochlor.org

  • Ford, Bacon & Davis, LLC 5

  • Ford, Bacon & Davis, LLC 6

    Siemens

  • Ford, Bacon & Davis, LLC 7

    Markel Eclipse Membranes Brochure

  • Ford, Bacon & Davis, LLC 8

    ELECTROLYTIC CELL

    BRINE STORAGE

    BRINE PURIFICATION

  • Ford, Bacon & Davis, LLC 9

    Steam Requirements

  • Ford, Bacon & Davis, LLC 10

    • Mercury

    • Diaphragm

    • Membrane

  • Ford, Bacon & Davis, LLC 11

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

  • Ford, Bacon & Davis, LLC 12

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

    Components 2 – Metal Anodes3 – Mercury Cathodes4 – Mercury Circulating Pump5 – Decomposer7 – Graphite Packing

    Inlet Streams6 – Water10 – Brine (1 = Brine Level)

    Outlet Streams8 – Caustic Liquor 9 – Mercury11 – Brine12 – Hydrogen14 – Chlorine (13 = Chlorine Vapor)15 – Wash Water

  • Ford, Bacon & Davis, LLC 13

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

  • Ford, Bacon & Davis, LLC 14

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

  • Ford, Bacon & Davis, LLC 15Production Chlor-Alkali – Best Available Techniques, JRC 2014

  • Ford, Bacon & Davis, LLC 16

    Chlor-Alkali Industry - Energy and Environmental Profile Of US Chemical Industry, Chapter 6

    Diamond MDC Type

  • Ford, Bacon & Davis, LLC 17

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

    Hooker H Type

  • Ford, Bacon & Davis, LLC 18

    Occidental

  • • Diaphragm– Originally Asbestos– Tephram (Non-Asbestos)– Polyaramix (Non-Asbestos)– Life: 200 to 400 Days

    • Anode Electrodes– Coated Titanium– 8 to 15 Years

    • Cathode Electrodes– Carbon Steel– 5 to 15 Years

    Ford, Bacon & Davis, LLC 19

  • Ford, Bacon & Davis, LLC 20

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

  • Ford, Bacon & Davis, LLC 21

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

  • Ford, Bacon & Davis, LLC 22

    Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.

  • Ford, Bacon & Davis, LLC 23The Chlor-Alkali Industry, Ch. 6 - Energy and Environmental Profile Of US Chemical Industry

  • Ford, Bacon & Davis, LLC 24

    Teknik Elektrokimia

  • Ford, Bacon & Davis, LLC 25

    TRANSFORMER

    TRANSFORMER

    TRANSFORMER

    RECTIFIER

    RECTIFIER

    RECTIFIER

    HIGHVOLTAGE AC

    LOWVOLTAGE AC

    LOWVOLTAGE DC

    CELL1

    CELL2

    CELL100

    CELL101

    . . .

    CELL1

    CELL2

    CELL100

    CELL101

    . . .

    CELL1

    CELL2

    CELL100

    CELL101

    . . .

    LINE 1

    LINE 2

    LINE 3

    CELL POWER REQUIREMENT = 170 MW

    OTHER POWER REQUIREMENT = 32 MW

    TOTAL POWER REQUIREMENT = 202 MW 100%

    84%

    16%

    150 kA @ 370 V DC

    150 kA @ 370 V DC

    150 kA @ 370 V DC

    3.5 V 3.5 V 3.5 V 3.5 V

    TOTAL CELL VOLTAGE: 101*3.5 V = 353.5 VOTHER VOLTAGE DROPS: 16.5 VTOTAL VOLTAGE DROP: 370 V

    3.5 V 3.5 V 3.5 V 3.5 V

    3.5 V 3.5 V 3.5 V 3.5 V

    303*150 kA*0.95 = 43,202 kA

  • BRINE GENERATION(SALT DOME)

    RAW BRINEHEATING/REACTION

    BRINECLARIFICATION

    UNDERFLOWFILTRATION

    SOLIDS TO DISPOSAL

    RECYCLE WATER

    CLARIFED BRINE TOPREHEATING

    Ford, Bacon & Davis, LLC 26

  • Ford, Bacon & Davis, LLC 27

    ELECTROLYTICCELLS

    BRINE PREHEATING

    HYDROGEN COOLING

    HYDROGEN COMPRESSION

    HOT SATURATED HYDROGEN HOT SATURATED CHLORINE TO COOLING

    WEAK CELL LIQUORTO CAUSTIC

    EVAPORATORS

    HYDROGEN TO PURIFICATION

    CONDENSED WATERTO DRAIN

    CONDENSED WATERTO DRAIN

    BRINE SATURATION

    SALT RECYCLEFROM CAUSTICCENTRIFUGES

    COLD BRINE FROMPURIFICATION

    HOT BRINE HOT SATURATED BRINE

    COOLED HYDROGEN

    COLD HYDROGEN

  • HOT WET CHLORINE FROM ELECTROLYTIC CELLS

    CHLORINEDRYING

    SPENT SULFURICACID TO UTILITIES

    98% SULFURICACID

    CHLORINECOMPRESSION

    CHLORINELIQUEFACTION

    TAIL GAS TREATMENT

    VENT TO ATMOSPHERE

    LIQUID CHLORINETO STORAGE

    CHLORINECOOLING

    CONDENSATESTRIPPING

    STRIPPED CONDENSATERECYCLE TO BRINE

    LIQUID CHLORINE FOR COOLING

    Ford, Bacon & Davis, LLC 28

  • CAUSTICEVAPORATION

    WEAK CELL LIQUORFROM ELECTROLYTIC

    CELLS

    SALTREMOVAL

    CAUSTIC PRODUCTTO STORAGE

    EVAPORATEDWATER

    RECYCLE SALTTO

    BRINE SATURATOR

    CONCENTRATED CAUSTIC

    Ford, Bacon & Davis, LLC 29

  • Vinyl Chloride Monomer(VCM)

    Ford, Bacon & Davis, LLC 30

  • WATERREMOVAL

    EDCDISTILLATION

    VCMCRACKING

    WATER

    CRUDE ETHYLENEDICHLORIDE (EDC)

    CHLORINE

    ETHYLENE

    OXYGENOXYHYDRO-

    CHLORINATION

    DIRECTCHLORINATION

    EDCLIGHT ENDS

    EDCHEAVY ENDS

    DISTILLEDEDC

    VCMDISTILLATION

    HCL

    VINYLCHLORIDE

    (VCM)

    VCM & HCL

    Ford, Bacon & Davis, LLC 31

  • Ford, Bacon & Davis, LLC 32

    Vinnolit VCM Process

  • Ford, Bacon & Davis, LLC 33

    Vinnolit VCM Process

  • Ford, Bacon & Davis, LLC 34

    Vinnolit VCM Process

  • Ford, Bacon & Davis, LLC 35

    Vinnolit VCM Process

  • Ford, Bacon & Davis, LLC 36

    Vinnolit VCM Process

  • Polyvinyl Chloride(PVC)

    Ford, Bacon & Davis, LLC 37

  • Ford, Bacon & Davis, LLC 38

    Vinyl Chloride

    (VCM)

    Poly Vinyl Chloride

    (PVC)

    . . .. . .

    Organic Peroxide

    Initiator

  • • Thermosetting– Cross-Linking During Curing– High Temperature Applications– Polyurethane, Polyester, Vinyl Ester, Epoxy

    • Thermoplastic– No Cross-Linking During Curing– Recyclable / Remoldable– Polyethylene, Polypropylene, PVC

    Ford, Bacon & Davis, LLC 39

  • • Suspension– > 80% Market– Multiple Purposes (Pipe, Building Materials, Medical

    Products)• Emulsion

    – < 10% Market– Very Small Particle Size (Latex)– PVC Coatings

    • Bulk / Mass– < 5% Market– Hard Plastic Sheets/Bottles

    Ford, Bacon & Davis, LLC 40

  • • In Water Suspension• Exothermic / Organic Peroxide Initiator• Multiple Recipes

    – Pipe Grade– Film Grade

    • Batch Reaction– Reactors Clustered In Trains– Transition From Batch To Continuous Operation

    • VCM Recovery And Reuse– 90% Conversion– Minimize VCM Losses

    Ford, Bacon & Davis, LLC 41

  • Ford, Bacon & Davis, LLC 42

    REACTOR TRAIN NO. 1

    REACTOR TRAIN NO. 2

    REACTOR TRAIN NO. 3

    DISPERSANTSTORAGE

    VCMSTORAGE

    VCMWEIGH TANKS

    DI WATERSTORAGE

    RVCMCOMPRESSION

    RVCMSTORAGE

    TRAIN NO. 1SLURRY

    STRIPPING

    TRAIN NO. 1SLURRY

    STRIPPING

    TRAIN NO. 1SLURRY

    STRIPPING

    TO DRYERTRAIN NO. 1

    TO DRYERTRAIN NO. 2

    TO DRYERTRAIN NO. 3

    RVCMCONDENSING

    RVCMWEIGH TANKS

  • Reactor Step Minutes Hours

    Charge / Heat Up 45 0.75

    Reaction 165 2.67

    Pressure Drop 30 0.50

    Blowdown / Recovery / Wash 60 1.00

    Total 300 5.00

    Ford, Bacon & Davis, LLC 43

  • Ford, Bacon & Davis, LLC 44

    INITIATOR

    M

    REACTOR

    DEMINERALIZED WATER

    DISPERSANT

    VINYL CHLORIDE

    RECOVERED VINYL CHLORIDE

    PVC SLURRY

    VCM RECOVERY

    AIR EVACUATION

  • Ford, Bacon & Davis, LLC 45

    DEMINERALIZED WATER

    DISPERSANT

    VINYL CHLORIDE

    INITIATOR

    M PVC SLURRY

    VCM RECOVERY

    AIR EVACUATIONRECOVERED VINYL CHLORIDE

    REACTOR

  • Ford, Bacon & Davis, LLC 46

    • Particle Size Control

    • Uniform Particle Size Distribution

    • Particle Porosity

    DEMINERALIZED WATER

    DISPERSANT

    VINYL CHLORIDE

    INITIATOR

    M PVC SLURRY

    VCM RECOVERY

    AIR EVACUATIONRECOVERED VINYL CHLORIDE

    REACTOR

  • Ford, Bacon & Davis, LLC 47

    DEMINERALIZED WATER

    DISPERSANT

    VINYL CHLORIDE

    INITIATOR

    M PVC SLURRY

    VCM RECOVERY

    AIR EVACUATIONRECOVERED VINYL CHLORIDE

    REACTOR

  • Ford, Bacon & Davis, LLC 48

    DEMINERALIZED WATER

    DISPERSANT

    VINYL CHLORIDE

    INITIATOR

    M PVC SLURRY

    VCM RECOVERY

    AIR EVACUATIONRECOVERED VINYL CHLORIDE

    REACTOR

  • Change Purpose

    Reactor Size Larger Batches

    Closed Mode Operation Minimize Reactor Openings / Process Steps

    External VCM Removal Reduce Reactor Cycle Time / Continuous Slurry Stripping

    Preheating Demin Water Reduce Reactor Cycle Time

    Clean Wall Technology Reduce Reactor Cleaning Frequency / Increase Uptime

    Ford, Bacon & Davis, LLC 49

  • Ford, Bacon & Davis, LLC 50

    M

    REACTOR

    MW

    TVCHILLED WATER SUPPLY

    CHILLED WATER RETURN

    TODRAIN

    PV

  • Ford, Bacon & Davis, LLC 51

    0.00

    2.00

    4.00

    6.00

    8.00

    10.00

    12.00

    14.00

    16.00

    0 7 14 21 29 36 43 50 57 64 72 79 86 93 100 107 114 122 129 136 143

    Heat

    Tra

    nsfe

    r (M

    M B

    tu/h

    r)

    Time (Minutes)

    Reaction Heat Transfer Vs Time

    Total Reaction Heat Removal:

    28.7 MM Btu/hr

  • Ford, Bacon & Davis, LLC 52

    0

    100

    200

    300

    400

    500

    600

    700

    0 7 14 21 29 36 43 50 57 64 72 79 86 93 100 107 114 122 129 136 143

    Chill

    ed W

    ater

    Flo

    w R

    ate

    (gpm

    )

    Time (Minutes)

    Chilled Water To Reactor Vs Reaction Time

  • Ford, Bacon & Davis, LLC 53

    REACTOR

    TOVENT RECOVERY

    COOLING WATER SUPPLY

    CHILLED WATER

    CHILLED WATER

    COOLING WATER RETURN

  • Ford, Bacon & Davis, LLC 54

    ConventionalReactor

    High-PerformanceReactor

  • Ford, Bacon & Davis, LLC 55

    Pfaudler RCI Agitator Impeller

    • Radial Design

    • High Shear (Low Efficiency)

    • Poor Pumping

    • Long History With PVC Reactors

  • Ford, Bacon & Davis, LLC 56

    STEAM

    STRIPPED SLURRY TO DRYING

    VENT TO VCM RECOVERY

    SLURRYSTRIPPER

    STRIPPERFEED TANK

    PVC SLURRYFROM REACTORS

    FICLIC

    FEED – BOTTOMSEXCHANGER

  • Ford, Bacon & Davis, LLC 57

    Low Pressure Drop

    Low Fouling

    Low Efficiency

  • Ford, Bacon & Davis, LLC 58

  • Ford, Bacon & Davis, LLC 59

    RECOVERED VCMSTORAGE VESSEL

    VENT GAS TO INCINERATION

    VCM FROMTRAIN 1

    VCM FROMTRAIN 2

    VCM FROMTRAIN 3

    CWS CHS RFS

    RFRCHRCWR

    VCMCOMPRESSORS

    VCMVENT

    CONDENSERS

    RVCM TO REACTORS

  • Ford, Bacon & Davis, LLC 60

    Gardner Denver Nash

    Compressor

  • Ford, Bacon & Davis, LLC 61Gardner Denver Nash

  • RECOVERED VCMSTORAGE VESSEL

    VENT GAS TO INCINERATION

    VCM FROMTRAIN 1

    VCM FROMTRAIN 2

    VCM FROMTRAIN 3

    CWS CHS RFS

    RFRCHRCWR

    VCMCOMPRESSORS

    VCMVENT

    CONDENSERS

    RVCM TO REACTORS

    VCMGAS HOLDER

    Ford, Bacon & Davis, LLC 62

  • Ford, Bacon & Davis, LLC 63

  • Ford, Bacon & Davis, LLC 64

  • Ford, Bacon & Davis, LLC 65

    RECOVERED VCMSTORAGE VESSEL

    VENT GAS TO INCINERATION

    VCM FROMTRAIN 1

    VCM FROMTRAIN 2

    VCM FROMTRAIN 3

    CWS

    CWR

    VCMCOMPRESSORS

    VCMVENT

    CONDENSER

    RVCM TO REACTORS

    VCMGAS HOLDER

    VCMGAS

    MEMBRANESEPARATOR

  • Ford, Bacon & Davis, LLC 66

  • PVC SLURRY TANK

    CENTRIFUGE FEED

    PUMP

    PVC SLURRYFROM

    STRIPPER

    DECANTINGCENTRIFUGE

    PVC WET CAKE TO DRYER

    WATERTO

    TREATMENT

    Ford, Bacon & Davis, LLC 67

  • Ford, Bacon & Davis, LLC 68

  • Ford, Bacon & Davis, LLC 69

  • Ford, Bacon & Davis, LLC 70

    VENTTO

    ATMOSPHERE

    VENTTO

    ATMOSPHERE

    VENTTO

    ATMOSPHERE

    PVC TO STORAGE

    FLASHDRYER

    FLUID BED

    DRYER

    SCREENER

    STEAM

    CONDENSATE

    STEAM

    CONDENSATE

    PVC WET CAKE FROMCENTRIFUGE

    FILTERRECEIVER

    PRESSUREBLOWER

    VACUUMBLOWER

    FLASHDRYER

    CYCLONE

    FLUID BED DRYER

    CYCLONE

    FLASHDRYER

    EXHAUST FAN

    FLUID BEDDRYER

    EXHAUST FAN

    FLASH DRYERSUPPLY FAN

    FLASH DRYERAIR HEATER

    FLUID BED DRYER SUPPLY FAN

    FLUID BED DRYERAIR HEATER

    SCREWFEEDER

  • Ford, Bacon & Davis, LLC 71

    Constant Rate

    Falling Rate

    McCabe, 4th Ed., “Drying Of Solids”

    External

    Internal

  • Ford, Bacon & Davis, LLC 72

    VENTTO

    ATMOSPHERE

    VENTTO

    ATMOSPHERE

    VENTTO

    ATMOSPHERE

    PVC TO STORAGE

    FLUID BEDDRYER

    SCREENER

    STEAM

    CONDENSATE

    STEAM

    CONDENSATE

    PVC WET CAKE FROMCENTRIFUGE

    FILTERRECEIVER

    VACUUMBLOWER

    PRESSUREBLOWER

    BACKMIX

    EXHAUST FAN

    PLUGFLOW

    EXHAUST FAN

    BACK MIXSUPPLY FAN

    PLUG FLOWSUPPLY FAN

    PLUG FLOWAIR HEATER

    BACK MIXAIR HEATER

    SCREWFEEDER

  • Ford, Bacon & Davis, LLC 73

    STEAM COIL

    STEAM COIL

    STEAM COIL

    STEAM COIL

    ADJUSTABLE HEIGHTWEIR

    BACK MIX SECTION PLUG FLOW SECTION

    FEEDINLET

    ADJUSTABLE HEIGHTWEIR

    STEAM COIL

    SOLIDS FLUID LEVELSOLIDS FLUID LEVEL

    HOT FLUIDIZING AIR HOT FLUIDIZING AIR

    TOPVIEW

    SIDEVIEW

  • Ford, Bacon & Davis, LLC 74

    HOUSING

    BASEPLATE

    BELT DRIVE

    COMPANION FLANGES

    EXPANSION JOINTS

    ELECTRICMOTOR

    INLET VANES

    OUTLET INLET

    BEARING LUBRICATION

    ACCESSDOOR

    EXTERNALINLET VANES

    HOUSINGDRAIN

  • Ford, Bacon & Davis, LLC 75

  • Ford, Bacon & Davis, LLC 76

  • Ford, Bacon & Davis, LLC 77

    Rotex

  • Ford, Bacon & Davis, LLC 78

    Flex-Kleen Model CT

  • BlowerOutlet

    Ford, Bacon & Davis, LLC 79

    Inlet Silencer

    Inlet Air Filter

    Outlet Silencer

    Blower

    Belt Drive With Guard

  • Ford, Bacon & Davis, LLC 80

    Safety Filter / Silencer /

    Vacuum Breaker

    Blower

    Belt Drive With Guard

    Outlet Silencer

    BlowerOutlet

  • Ford, Bacon & Davis, LLC 81

    RotorLobe

    Rotor and Shaft

    BasePlate

    RotorTip

    1 - Case2 - Heat Dissipation Ribs 3 – Bearing Housing4 - Oil Fill5 - End Plate6 – Shaft Splines For Timing Gears

    4

  • Ford, Bacon & Davis, LLC 82

  • Ford, Bacon & Davis, LLC 83

    Coperion K-TRON Aerolock

    Vented Shear Protector

  • • Reduce Batch Cycle Time

    • Reduce Energy Cost Per Batch

    • Minimize VCM Exposure Risk To Personnel

    Ford, Bacon & Davis, LLC 84

    Slide Number 1ObjectivesChlorineChlorine TreeChlorine Tree – C2 DerivativesCaustic-ChlorineCaustic - Chlorine ProcessSalt Dome To Electrolytic Cell ChlorovinylsElectrolytic Cell TechnologyMercury Electrolytic CellMercury RecycleCaustic-Chlorine Process – MercuryDiaphragm Electrolytic CellDiaphragm Electrolytic CellDiaphragm Electrolytic CellDiaphragm Electrolytic CellDiaphragm Cell RowDiaphragmsCaustic-Chlorine Process – DiaphragmMembrane Electrolytic CellCaustic-Chlorine Process – MembraneCell Technology ComparisonCell Technology ComparisonCell Power Distribution (1500 TPD Cl2)Brine TreatmentBrine ConversionChlorineCausticVinyl Chloride Monomer�(VCM)VCM OverviewDirect ChlorinationOxychlorinationEDC DistillationVCM CrackingVCM DistillationPolyvinyl Chloride�(PVC)VCM PolymerizationPlastic TypesCommercial PVC TechnologiesSuspension ProcessPVC OverviewTypical Reactor Cycle TimePVC ReactorDemineralized WaterDispersantVinyl ChlorideInitiatorIncreasing PVC ProductionJacket CoolingHeat TransferChilled Water MakeupVent CondenserVinnolit High-Performance ReactorReactor Agitator ImpellerSlurry StrippingBaffle TraysSpiral Heat ExchangerVCM RecoveryLiquid Ring CompressorsVCM Recovery CompressorsVCM Gas HolderWet-Seal Gas HolderDry-Seal Gas HolderMembrane SeparationMembrane SeparatorPVC DewateringDecanting CentrifugeDecanting CentrifugeFD-FB PVC DryerDrying CurveBM – PF Fluid Bed DryerBM – PF Fluid Bed DryerCentrifugal FanAir HeaterCyclonesScreenerFilter Receiver Pressure Blower PackageVacuum Blower PackageStraight Rotary Lobe BlowerRotary ValveRotary Valve VentingSummary – PVC Design Drivers