Polyvinyl Chloride - AIChE | The Global Home of Chemical ...€¦ · Polyvinyl Chloride • Review...
Transcript of Polyvinyl Chloride - AIChE | The Global Home of Chemical ...€¦ · Polyvinyl Chloride • Review...
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1Ford, Bacon & Davis, LLC
Polyvinyl Chloride
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• 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
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Chlorine
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eurochlor.org
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Siemens
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Markel Eclipse Membranes Brochure
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ELECTROLYTIC CELL
BRINE STORAGE
BRINE PURIFICATION
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Steam Requirements
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• Mercury
• Diaphragm
• Membrane
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
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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
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
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Ford, Bacon & Davis, LLC 15Production Chlor-Alkali – Best Available Techniques, JRC 2014
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Chlor-Alkali Industry - Energy and Environmental Profile Of US Chemical Industry, Chapter 6
Diamond MDC Type
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
Hooker H Type
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Occidental
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• 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
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
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Chlorine and Sodium Hydroxide, Kirk-Othmer 4 Ed.
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Ford, Bacon & Davis, LLC 23The Chlor-Alkali Industry, Ch. 6 - Energy and Environmental Profile Of US Chemical Industry
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Teknik Elektrokimia
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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
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BRINE GENERATION(SALT DOME)
RAW BRINEHEATING/REACTION
BRINECLARIFICATION
UNDERFLOWFILTRATION
SOLIDS TO DISPOSAL
RECYCLE WATER
CLARIFED BRINE TOPREHEATING
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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
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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
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CAUSTICEVAPORATION
WEAK CELL LIQUORFROM ELECTROLYTIC
CELLS
SALTREMOVAL
CAUSTIC PRODUCTTO STORAGE
EVAPORATEDWATER
RECYCLE SALTTO
BRINE SATURATOR
CONCENTRATED CAUSTIC
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Vinyl Chloride Monomer(VCM)
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WATERREMOVAL
EDCDISTILLATION
VCMCRACKING
WATER
CRUDE ETHYLENEDICHLORIDE (EDC)
CHLORINE
ETHYLENE
OXYGENOXYHYDRO-
CHLORINATION
DIRECTCHLORINATION
EDCLIGHT ENDS
EDCHEAVY ENDS
DISTILLEDEDC
VCMDISTILLATION
HCL
VINYLCHLORIDE
(VCM)
VCM & HCL
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Vinnolit VCM Process
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Vinnolit VCM Process
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Vinnolit VCM Process
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Vinnolit VCM Process
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Vinnolit VCM Process
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Polyvinyl Chloride(PVC)
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Vinyl Chloride
(VCM)
Poly Vinyl Chloride
(PVC)
. . .. . .
Organic Peroxide
Initiator
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• Thermosetting– Cross-Linking During Curing– High Temperature Applications– Polyurethane, Polyester, Vinyl Ester, Epoxy
• Thermoplastic– No Cross-Linking During Curing– Recyclable / Remoldable– Polyethylene, Polypropylene, PVC
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• 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
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• 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
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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
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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
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INITIATOR
M
REACTOR
DEMINERALIZED WATER
DISPERSANT
VINYL CHLORIDE
RECOVERED VINYL CHLORIDE
PVC SLURRY
VCM RECOVERY
AIR EVACUATION
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DEMINERALIZED WATER
DISPERSANT
VINYL CHLORIDE
INITIATOR
M PVC SLURRY
VCM RECOVERY
AIR EVACUATIONRECOVERED VINYL CHLORIDE
REACTOR
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• 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
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DEMINERALIZED WATER
DISPERSANT
VINYL CHLORIDE
INITIATOR
M PVC SLURRY
VCM RECOVERY
AIR EVACUATIONRECOVERED VINYL CHLORIDE
REACTOR
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DEMINERALIZED WATER
DISPERSANT
VINYL CHLORIDE
INITIATOR
M PVC SLURRY
VCM RECOVERY
AIR EVACUATIONRECOVERED VINYL CHLORIDE
REACTOR
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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
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M
REACTOR
MW
TVCHILLED WATER SUPPLY
CHILLED WATER RETURN
TODRAIN
PV
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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
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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
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REACTOR
TOVENT RECOVERY
COOLING WATER SUPPLY
CHILLED WATER
CHILLED WATER
COOLING WATER RETURN
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ConventionalReactor
High-PerformanceReactor
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Pfaudler RCI Agitator Impeller
• Radial Design
• High Shear (Low Efficiency)
• Poor Pumping
• Long History With PVC Reactors
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STEAM
STRIPPED SLURRY TO DRYING
VENT TO VCM RECOVERY
SLURRYSTRIPPER
STRIPPERFEED TANK
PVC SLURRYFROM REACTORS
FICLIC
FEED – BOTTOMSEXCHANGER
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Low Pressure Drop
Low Fouling
Low Efficiency
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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
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Gardner Denver Nash
Compressor
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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
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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
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PVC SLURRY TANK
CENTRIFUGE FEED
PUMP
PVC SLURRYFROM
STRIPPER
DECANTINGCENTRIFUGE
PVC WET CAKE TO DRYER
WATERTO
TREATMENT
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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
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Constant Rate
Falling Rate
McCabe, 4th Ed., “Drying Of Solids”
External
Internal
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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
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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
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HOUSING
BASEPLATE
BELT DRIVE
COMPANION FLANGES
EXPANSION JOINTS
ELECTRICMOTOR
INLET VANES
OUTLET INLET
BEARING LUBRICATION
ACCESSDOOR
EXTERNALINLET VANES
HOUSINGDRAIN
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Rotex
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Flex-Kleen Model CT
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BlowerOutlet
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Inlet Silencer
Inlet Air Filter
Outlet Silencer
Blower
Belt Drive With Guard
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Safety Filter / Silencer /
Vacuum Breaker
Blower
Belt Drive With Guard
Outlet Silencer
BlowerOutlet
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RotorLobe
Rotor and Shaft
BasePlate
RotorTip
1 - Case2 - Heat Dissipation Ribs 3 – Bearing Housing4 - Oil Fill5 - End Plate6 – Shaft Splines For Timing Gears
4
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Coperion K-TRON Aerolock
Vented Shear Protector
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• Reduce Batch Cycle Time
• Reduce Energy Cost Per Batch
• Minimize VCM Exposure Risk To Personnel
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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