1 DESCRIPTION OF THE COMMODITY

1.1 Definition of PVC

Polyvinylchloride (PVC) is one of the widely used synthetic polymers which can be used in
many industries like packaging, automobiles, electrical, medical, sports and construction. It
poses property of being resistant to corrosion, chemicals, and UV light, making it suitable for
outdoor and industrial applications. Compared to many other materials, PVC is relatively
lightweight, which makes it easier to transport and install. It can be prepared by different
polymerization techniques. Multiple additives like lubricants, fillers, processing aids, pigments,
blowing agents, antioxidants, anti-aging agents, UV absorbers, etc., are used to tailor its
properties. It can be processed by different techniques to manufacture different products.
Different additives, processing techniques, properties, and applications are discussed in this text.

1.2 Classification of PVC

PVC resin can be classified based on various criteria, including its molecular structure,
processing methods, and applications and others. Here are the main classifications:

1.2.1 Classification of PVC by Molecular Weight

 Low Molecular Weight PVC: Often used in applications requiring high flexibility, such
as coatings and adhesives.

 High Molecular Weight PVC: Typically used for structural applications like pipes and
fittings due to its strength and durability.

1.2.2 Classification of PVC by type:

 Rigid PVC: Un-plasticized PVC used for pipes, doors, windows, and other construction
materials.
 Flexible PVC: Contains plasticizers to increase flexibility, used in flooring, cables, and
inflatable products.

1.2.3 Classification of PVC By Processing Method

 Suspension PVC: The most common form, produced through suspension
polymerization, used in a wide range of applications.
 Emulsion PVC: Produced via emulsion polymerization, often used for coatings and
adhesives.
  Bulk (or Mass) PVC: Produced through bulk polymerization, typically used in
applications where high purity is required.

1.2.4 Classification of PVC By Additives Used:

 Plasticized PVC: Contains added plasticizers to enhance flexibility.

 Non-Plasticized PVC: Lacks plasticizers, providing rigidity and strength.

1.3 Use of PVC Resin

PVC resin is widely used across various industries due to its versatility and favorable properties.
Here are some of the primary uses of PVC resin:

1.3.1 Construction and Building Materials

 Pipes and Fittings: Commonly used in plumbing, drainage, and irrigation systems.
 Siding and Roofing: Durable exterior cladding and roofing materials.
 Windows and Doors: Frames that are resistant to weathering and provide good insulation.
 Flooring: Vinyl flooring, including tiles and sheets, is popular for its durability and ease
of maintenance.

1.3.2 Electrical Applications

 Wiring Insulation: Used in insulation for electrical cables and wires due to its excellent
dielectric properties.
 Conduit: PVC conduit is used for protecting electrical wiring.

1.3.3 Healthcare

 Medical Devices: Used in products like IV bags, tubing, and containers due to its safety
and being sterilized.
 Disposable Products: Common in gloves, blood bags, and other single-use medical items.

1.3.4 Consumer Goods

 Toys: Many children’s toys are made from PVC due to its mold-ability and safety when
properly formulated.
 Household Items: Includes items like shower curtains, tablecloths, and storage containers.

1.3.5 Automotive

 Interior Components: Used for dashboards, door panels, and seat covers due to its
durability and aesthetic appeal.
 Under-the-Hood Applications: Components that require resistance to chemicals and high
temperatures.

1.3.6 Packaging

 Flexible Films: Used for shrink wrap, food packaging, and blister packs.
 Containers: PVC is used for rigid containers in packaging applications.

1.3.7 Sports and Leisure

 Inflatable Products: Such as pool toys, air mattresses, and sports balls.
 Protective Gear: Used in items like shin guards and other protective equipment.
1.4 Quality standard of the commodity

The quality standard of the product is primary issue in production and marketing of the product.
The quality standards for PVC (Polyvinyl Chloride) can vary depending on the specific
application, industry requirements, and regulatory frameworks These standards typically cover
various aspects, including material properties, manufacturing processes, and performance
criteria. Here’s a comprehensive overview of the key quality standards and considerations for
PVC resin:

Material Specifications: Material specifications for PVC (Polyvinyl Chloride) detail the
requirements that the material must meet to ensure its suitability for specific applications.
Here are key aspects typically included in PVC material specifications:
Manufacturing Standards: Production standards for PVC (Polyvinyl Chloride) ensure
that the manufacturing processes yield high-quality products that meet industry
requirements and safety regulations. Regular inspection and testing during production to
ensure adherence to specifications. Checking for defects that will lead to inconsistencies
is also mandatory after production.
Performance Criteria: These criteria often encompass various physical, mechanical,
thermal, and chemical properties.
Safety and Compliance: Safety and compliance for PVC (Polyvinyl Chloride) involve
adhering to regulations and standards designed to protect human health and the
environment.
Environmental Considerations: Environmental considerations for PVC (Polyvinyl
Chloride) are crucial due to the potential impact of its production, use, and disposal on
the environment. Major issues to be considered here are: material sourcing, production
impact, recycling the product and waste management. Certifications for environmentally
friendly production processes are also required.

Internationally high quality PVC resin exhibits the following major characteristics.

 High Tensile Strength

 Good Elongation at break
 Robust Impact Resistance
 Thermally stable
 Resistance to acids and bases
 Flame retardant
 Good insulator of electricity
 Good recyclability
2 PVC RESIN PRODUCTION PROCESS AND TECHNOLOGY SELECTION
2.1 PVC Production process
The production process of PVC (Polyvinyl Chloride) involves several key steps, from the
synthesis of the vinyl chloride monomer (VCM) to the polymerization and processing into final
products. Below are some the major processes encountered in the production process of PVC.

2.1.1 Production of Vinyl Chloride Monomer (VCM)

 Chlorination of Ethylene:
o Ethylene, derived from natural gas or crude oil, is reacted with chlorine to
produce Ethylene Dichloride (EDC).
 Dehydrochlorination of EDC:
o EDC is then subjected to a thermal or catalytic process to remove hydrochloric
acid (HCl), yielding VCM

2.1.2 Polymerization

Once VCM is produced, it undergoes polymerization to form PVC. This can be done through
several methods:

 Suspension Polymerization: VCM is dispersed in water with additives and polymerized

in small droplets. This method is commonly used for producing rigid PVC.
 Emulsion Polymerization: VCM is emulsified with water and surfactants. This process
typically produces softer and more flexible PVC.
 Bulk Polymerization: VCM is polymerized in the absence of solvents, resulting in a
high-purity product. This method is often used for high-performance applications.

2.1.3 Processing and Compounding

After polymerization, the PVC resin may be processed and compounded to enhance its properties
for specific applications:

 Compounding: PVC is blended with various additives, such as stabilizers,

plasticizers, fillers, and colorants, to achieve desired physical and chemical
properties.
2.2 Equipment required in the Production of PVC from limestone

Producing PVC from limestone involves multiple steps and requires various pieces of equipment
throughout the process. Here’s an overview of the key equipment needed for each stage of
production:

2.2.1 Limestone Processing Unit:

Crusher and Grinder: crushers are used to prepare limestone by breaking it down into
smaller, manageable sizes before further processing in a kiln

Kiln: A kiln is a vital piece of equipment in various industrial processes, including the
production of PVC from limestone. Kilns are primarily used for the calcination of
limestone to produce lime (calcium oxide).

2.2.2 Chlor-alkali Processor

The chlor-alkali process is an industrial method for producing chlorine and sodium hydroxide
(caustic soda) from sodium chloride (salt) and water through the electrolysis of brine. The
chlor-alkali process involves several key steps: major processes are the following:

 Brine Preparation: Salt (sodium chloride) is dissolved in water to create a saturated

brine solution.
 Filtration: Impurities are removed to ensure high purity in the electrolysis process.
 Electrolytic Cells: Equipment where electrolysis occurs to produce chlorine and sodium
hydroxide.

2.2.3 Equipment for the Production of Vinyl Chloride Monomer (VCM)

 Reactors: For the reaction between ethylene and chlorine to produce 1,2-
dichloroethane (EDC).
 Distillation Columns: Used to separate and purify EDC and convert it into VCM
through thermal dehydrochlorination.

2.2.4 Polymerization Equipment

 Polymerization Reactors: Equipment where VCM is polymerized to form PVC.

This can include: Batch Reactors which is for smaller scale or specific
formulations and Continuous Reactors for larger scale production.

2.2.5 Additive Mixing and Compounding equipment

In the production of PVC (polyvinyl chloride), the mixing and compounding of additives
is a critical step that enhances the properties and performance of the final product.
 Various types of equipment are used in this process to ensure uniform distribution of
additives and achieve the desired formulation. These can be:

 Mixers and Blenders: For blending PVC resin with various additives (stabilizers,
plasticizers, fillers).
 Extruders: Equipment for shaping the compounded PVC into final products.

2.2.6 Product Handling and Storage

After compounding, the PVC material needs to be handled, stored, and prepared for
distribution without compromising its quality. This can compromises the following:

 Storage Tanks: For storing raw materials (lime, brine, chlorine) and finished
products (PVC, additives).
 Cooling Systems: used to cool down products after processing.

2.2.7 Safety and Control Systems

 For ensuring safe operation, monitoring parameters (temperature, pressure), and

controlling processes.
2.2.8 Process Flow Diagram
 2.3 Summary of Machinery and Equipment Requirement

Unit Process or
S/n Major Machinery required Purpose(Application)
operation

Used to prepare calcium oxide

Limestone
01  Crusher and kilns from calcium carbonate by a
Processing Unit:
process called calcination

 Brine processing section

Chlor-alkali Used to produce chlorine and
02  Filters and
Processor sodium hydroxide (caustic soda)
 Electrolytic cells

Vinyl Chloride
 Reactors Used to produce 1,2-
03 Monomer (VCM)
 Distillation columns dichloroethane (EDC).
processors

Polymerization Equipment where VCM is

04  Polymerization Reactors
Equipment polymerized to form PVC

Additive Mixing
Used to mix various ingredients
05 and Compounding  Mixers and extruders
and form the final PVC
equipment

06 Control unit  Electric control system To operate the machinery

Auxiliary machines

For instrumentation of
1 Compressed air Compressors
machineries

Supply electric power during

2 Standby power Generator
main grid power outage

Table …... list of machinery and equipment

2.4 Building Units and Requirements for PVC production
Processing areas should be so designed and equipped as to allow adequate working space and so
staffed as to allow free movement of workers and to facilitate the free movement and cleaning of
movable equipment. Adequate staffing is essential to ensure unrestricted movement of workers
and facilitate the cleaning and movement of equipment. Production and Assembly hall and
Stores (Raw material or finished product or Work shop) are among the major buildings that are
important for the factory of PVC production. Construction requirements and cares to be taken to
the product in this processing area are as follows:

Factory Building

Foundation

Sound and stiff foundation to bear load of machineries should be provided.

Floor

Concrete slab is more suitable for floor or other suitable material which is finished smooth,
impervious and non- slip. Flooring material used should be easy to clean and laid to an even
surface that is free from cracks, crevices and open joints.

Sub surface drainage

Reinforced concrete structure provided with a suitable slope

Openings

The openings should be metal, open for adequate light and ventilation system.

Finished product store (optional)

The block should be reserved for the purpose and is separated from production area and other
storage areas. Should be free from dampness, sufficient openings must be provided so that it is
well ventilated
Auxiliary Facilities

These buildings may be included in to the facilities of the canned soups manufacturing project as
per the need and size of the project:

 Office and Administration block

 Staff canteen
 Spare part store/Garage
 Generator House
 Shower, toilet and changing room (separate for each sex)
 Guard house

General Site Work

 The Compound of the plant should be graded to ensure proper drainage and also be
maintained in a clean and hygienic state.
 Sufficient Septic tanks with two chambers including a percolation ditch should be
provided.
 Site sanitary and Site Electrical installation works shall be provided following the
standard and working drawings.
 Walkways, driving ways and parking areas shall be constructed at least with semi dressed
stone bedded with selected material and pointed with cement mortar.
 To foster the raw materials supply and finished products dispatching processes, access
roads to the project shall be well graded and compacted with selected material to the
proper thickness so that heavy trucks can pass easily.
 Fence shall be barbed wire with concrete post and Metal gate.