VELLORE INSTITUTE OF TECHNOLOGY

(VIT UNIVERSITY)

KATPADI, VELLORE - 632 014

SCHOOL OF CHEMICAL ENGINEERING (SCHEME)

INTERNSHIP TRAINING REPORT AUGUST 2023

DHARANGADHRA CHEMICAL WORKS PRIVATE LTD

SUBMITTED BY

PS SREERAM (21BCM0136)
(BATCH: 2021-2025)

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 DECLARATION BY STUDENTS

We hereby declare that this “TRAINING REPORT- AUGUST 2023” is our genuine work
and no part of it has been reproduced from any other record or reports.

SREERAM P S
(21BCM0136)

DECLARATION BY GUIDE

PVC PLANT

MR. RUBAN KUMAR (GENERAL MANAGER).

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INDEX

SNO TITLE PAGE NO

1 INTRODUCTION 4

2 STORAGE SYSTEM 4

3 REACTOR AND ITS MECHANISM 8

4 BLOWDOWN PROCESS 13

5 RVC PLANT 15

6 DRYING PROCESS AND PACKING 17

7 BLOCK DIAGRAM 21

8 CONCLUSION 21

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Introduction
Vinyl Chloride Monomer is what "VCM" stands for in the industry. It is a gas that is odourless and
colourless, and it has a faintly sweet smell. PVC, also known as polyvinyl chloride, is a versatile and
commonly used type of plastic. The production of PVC requires the use of the raw material vinyl
chloride monomer. The chlorination of ethylene, a gas that is composed of hydrocarbons, is the
primary method by which the chemical industry produces VCM. To produce vinyl chloride monomer,
this chemical reaction requires the presence of a catalyst and the introduction of chlorine gas to
ethylene.

C2H4 (ethylene) + Cl2 (chlorine) → CH2=CHCl (Vinyl Chloride Monomer) + HCl (hydrochloric acid)

The presence of a double bond between the carbon atoms in the vinyl chloride monomer makes it
highly reactive. As a result of this reactivity, vinyl chloride monomer is an excellent candidate for
polymerization. The next step in the production of PVC involves polymerizing VCM molecules together
to create long-chain PVC molecules. These molecules can then be processed into various forms,
including pipes, cables, films, and more. It is essential to be aware that vinyl chloride monomer is
regarded as a hazardous substance, and that the manipulation and production of this substance must
adhere to stringent safety measures because it is flammable and may pose potential risks to one's
health. During production and use, appropriate safety measures are implemented to protect both the
workers and the environment from potential hazards.

Benefits of using VCM for the manufacturing of PVC resins

• Purity: VCM can be purified to a high degree, which guarantees that the PVC resin and
powder that are produced are free of any impurities that could affect the material's
performance or stability.
• Versatility: The powdered form of the PVC resin that is produced from VCM can be
further processed into a variety of other forms. Because of its versatility, PVC powder
can be used for a diverse array of purposes, including the production of pipes, cables,
films, coatings, and even more.
• It is more cost-effective than other starting materials for the production of PVC, which
is one of the many reasons why VCM is the material of choice in a variety of industrial
processes.

THE STORAGE SYSTEM OF VCM

STORAGE TANKS
When it comes to certain applications, spherical storage tanks are frequently preferred over
bullet tanks due to the many benefits that the former type provides. The primary focal points
of these benefits are security, structural soundness, and effective utilization of available space.
The following is a succinct overview of the benefits of spherical storage tanks:
o Uniform Stress Distribution In comparison to bullet tanks, which have a cylindrical
shape with flat ends, spherical tanks distribute stress more uniformly across their entire
surface. Spherical tanks are inherently stronger and better equipped to handle both

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 internal pressure and external forces as a result of the uniform stress distribution
provided by their shape.
o Reduced Risk of Metal Fatigue and Potential Failure Under Pressure Spherical tanks
have no sharp corners or edges, which eliminates any potential stress concentration
points. As a result, there is a reduced risk of metal fatigue and potential failure under
pressure.
o Higher Capacity-to-Volume Ratio: Spherical tanks offer a higher volume-to-surface
area ratio than cylindrical tanks, which means they can store a larger volume of material
within a smaller footprint. This advantage gives spherical tanks an advantage over
cylindrical tanks in terms of capacity. This is especially helpful in situations in which
space is either scarce or prohibitively expensive.
o Increased Visibility Because the interior of spherical tanks is more visible, it is much
simpler to visually inspect the tank's level and condition. Spherical tanks also have a
lower profile, which means they take up less space. This can be an extremely important
consideration for industries in which the substance being stored calls for routine
maintenance or inspection.
o Spherical tanks are considered safer for storing hazardous materials such as liquefied
gases or volatile chemicals due to their structural integrity and reduced risk of stress-
related failures. This makes them a more desirable option for storing these types of
substances. They have a lower risk of rupturing catastrophically.
o Lower Maintenance Needs: In general, spherical tanks have lower maintenance needs
compared to bullet tanks, which may require more frequent inspection and maintenance
at the flat ends and seams. Spherical tanks also have fewer potential leak points.

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Aesthetically speaking, spherical tanks typically have a more aesthetically pleasing and iconic
appearance, which is something that can be taken into consideration in projects where visual
aesthetics play an important role.
However, it is essential to keep in mind that the decision between spherical and bullet tanks is
influenced by a wide range of considerations, such as the nature of the application, the amount
of space that is available, the associated costs, and the necessary levels of safety. Even though
spherical tanks provide several benefits, it is not always the case that they are the most practical
or cost-effective solution for every storage requirement. A comprehensive analysis of the one-
of-a-kind needs of the project or industry at hand should serve as the foundation for choosing
the type of tank to use.

SAFETY MEASURES TO BE TAKEN DURING THE LOADING AND UNLOADING OF

VCM
Due to the hazardous nature of vinyl chloride monomer (VCM), it is necessary to take stringent
safety precautions during the loading and unloading of VCM. VCM is combustible, toxic, and,
if not handled correctly, can present risks to one's health. The following are some of the most
important safety precautions that must be observed during the loading and unloading of VCM
into tanks:
Training and Qualifications: The loading and unloading processes ought not to involve
anybody who isn't properly trained and qualified to do those jobs. They should have a complete
comprehension of the characteristics of VCM, in addition to the safety protocols and
emergency procedures.
Personal Protective Equipment or (PPE):
• Put on the appropriate personal protective equipment (PPE), such as gloves that are
resistant to chemicals, safety goggles, a face shield, a chemical-resistant suit, and
chemical-resistant boots.
• Make sure that all of the personal protective equipment is in good condition and that it
fits correctly.
Area With Adequate Airflow:
• To reduce the likelihood of being exposed to VCM vapours, loading and unloading
should take place in an area with adequate ventilation.
• Make use of systems for local exhaust ventilation to collect and get rid of any vapor of
VCM that may have been released.
• Sparks and open flames are not permitted.
• In the area designated for loading and unloading, it is strictly forbidden to smoke and
to have any open flames or sources of sparks.
• Make sure that all of the electrical equipment is resistant to explosions and is correctly
grounded.
Equipment in Case of Emergencies:
• Eyewash stations, safety showers, and fire extinguishers are examples of important
pieces of equipment that should be kept close at hand in case of an emergency.

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 • Make sure that the staff has been properly educated on how to operate this apparatus.
Monitoring for Leaks and Performing Detections:
• Utilize gas detectors in addition to other monitoring equipment to conduct continuous
checks for VCM leaks.
• Install warning systems to keep personnel informed in the event of VCM spills or
concentrations that are too high.
The Loading and Unloading Procedures are as follows:
• Always adhere to the safety manuals and the regulations outlined procedures for
loading and unloading.
• Always make sure to use the equipment and connections intended specifically for
loading and unloading.
• It is important to avoid filling the tank to its maximum capacity as this can result in
leaks or spillage.

The Processes of Grounding and Bonding:

• To prevent the buildup of static electricity, all containers and equipment should be
grounded and bonded.
• Checking and maintaining the connections for grounding and bonding should be done
regularly.
Plan for Responding to Emergencies:
• In the event of an incident involving VCM, you should devise and disseminate a plan
for responding to it, which should include procedures for containing spills, evacuating
people, and administering first aid.
• It is important to ensure that all of the personnel are familiar with the plan, so you
should hold regular drills.
Labelling and displaying information appropriately:
Label clearly and conspicuously every container and tank that contains VCM with the
appropriate hazard warnings and safety information. Put up some caution signs in the area that's
used for loading and unloading.
Keeping Track of Records:
• Keep detailed records of the activities of loading and unloading, including the
quantities, dates, and personnel involved in each of these processes.
• Appoint a responsible individual to be in charge of monitoring the loading and
unloading process as well as responding to any emergencies that may arise. Make sure
that there are communication tools readily available for immediate contact.
• When working with volatile chemical materials (VCM), it is critical to ensure that all
applicable safety regulations and guidelines are followed. Referring to the specific
safety guidelines provided by regulatory agencies and the manufacturer of the VCM for
additional precautions and recommendations is something you should always do. To
prevent accidents and ensure the safe handling of vinyl chloride monomer, routine
safety training, and vigilance are both essential components.

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ROLES OF 20 M3 STORAGE TANK

One of the most common applications for a storage tank with a volume of 20 m3 is to be used
to temporarily store PVC resin at various stages of the manufacturing process. PVC resin might
need to be kept in storage before undergoing any additional processing, being put through
quality assurance testing, or being packaged. PVC production frequently calls for the utilization
of a wide variety of raw materials, such as vinyl chloride monomer (VCM), stabilizers,
plasticizers, and additives. Raw material storage is essential for this process. To store these raw
materials before incorporating them into the manufacturing process, a tank with a volume of
twenty cubic meters can be used. The blending of the Feedstock also happens inside this
reactor. In certain circumstances, various grades or kinds of PVC resins may be blended to
achieve particular qualities or qualities of a specific nature. Before the blended feedstocks are
introduced into the polymerization process, they can be mixed in and stored in a tank with a
volume of twenty cubic meters.
During the polymerization process, it is essential to keep a steady flow of materials going
through the buffer tank. This is because the polymerization will not be successful without it.
To maintain a constant supply of PVC resin to the processing equipment that comes after it, a
buffer in the form of a tank with a volume of 20 cubic meters can be used. Controlling the
Quality and Taking Samples Some of the PVC resin that's produced may need to be temporarily
stored to control the quality. It is possible to take samples from the storage tank and put them
through various tests to make certain that the resin satisfies the requirements set forth by the
specifications and the quality standards. Temporary Storage for Batch Processing In batch PVC
production processes, where materials are added incrementally, a tank with a volume of 20 m3
can serve as temporary storage for materials while they are waiting to be added to the reactor.
Keeping a surplus of PVC resin on hand can serve as a safety measure if production is disrupted
or fluctuates in a manner that was not anticipated. This guarantees that there will always be a
sufficient supply of resin for the processes that come after it. If the PVC resin is going to be
shipped to other facilities or customers, the 20 m3 storage tank can be used as a staging area
for packaging and loading onto vehicles if shipping is necessary. If there is a breakdown in
equipment or an upset in the process, having a storage tank with a capacity of 20 cubic meters
can provide a backup plan for storing PVC resin in a temporary location until normal operations
can be resumed. The production process, the layout of the plant, and the requirements for the
plant's logistics determine the specific use of a storage tank with a volume of 20 cubic meters
when producing PVC resin. It is essential to carefully plan and manage the storage and handling
of PVC resin to ensure the product's high quality as well as its safety and the most effective use
of resources.

REACTORS
To carry out the polymerization process in a manner that is both efficient and accurate during
the production of PVC (Polyvinyl Chloride) resins via suspension polymerization, specialized
reactors are utilized. These reactors are built with the capability of controlling a wide range of
parameters, including temperature, pressure, and agitation, to generate PVC particles with the
desired properties. The following is an explanation of the primary characteristics and roles that
are played by the reactors that are utilized in the process of suspension polymerization to
produce PVC resin:
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• Reaction Vessel: A reaction vessel, also known as a reactor, is the essential component
of the suspension polymerization process. Because of the reactive and corrosive nature
of the chemicals that are being used, including Vinyl Chloride Monomer (VCM), this
vessel is typically constructed out of stainless steel or other materials that are resistant
to corrosion.
• Agitation System: It is essential to properly agitate the mixture to keep the VCM
droplets uniformly suspended in the aqueous phase. To accomplish this goal, the
majority of suspension polymerization reactors utilize mechanical agitators or
impellers. A significant contribution to the production of fine PVC particles is made by
the agitators, which prevent the VCM droplets from combining into larger droplets.
• Regulation of Temperature regulation is essential for regulating both the rate at which
polymerization occurs and the properties of the PVC particles that are produced as a
result. The use of cooling coils or jackets is common practice to regulate and remove
the heat that is produced as a result of an exothermic polymerization reaction.
• Pressure Control To maintain the VCM in a liquid state, the reactor will need to be
pressurized. To prevent the VCM from evaporating, the pressure is typically kept at a
level that is just slightly higher than the vapor pressure of the VCM at the temperature
that is being used.
• The addition of initiators The reactor is then supplied with initiators, which kickstart
the polymerization reaction. The addition of the initiator is subjected to stringent
regulation to guarantee that the reaction will proceed at the desired speed. The process
may involve the addition of initiators in discrete stages or a continuous fashion
throughout.
• Dispersing Agents: Dispersing agents or surfactants are added to the reactor to stabilize
the VCM droplets and prevent coalescence. These agents contribute to the upkeep of a
consistent VCM suspension in the aqueous phase, which is necessary for proper
functioning.

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 • Mixing Zones: Reactors frequently feature multiple mixing zones, each of which is
dedicated to a particular stage of the polymerization process. There could be, for
instance, zones dedicated to the addition of initiators, polymerization, and coagulation.
• Safety Features: Due to the reactive and potentially hazardous nature of VCM, PVC
polymerization reactors are outfitted with safety features such as pressure relief
systems, emergency shut-off valves, and ventilation systems to deal with any accidental
release of VCM or other gases.
• Sampling and Monitoring: To collect samples and collect data on important parameters,
such as temperature, pressure, and pH, reactors are built with sampling ports and
instrumentation. The operators can use these measurements to ensure that the process
is operating within the desired parameters by ensuring that it is running successfully.
• Product Removal: Once the polymerization process is finished, the PVC particles are
typically coagulated and separated from the aqueous phase using blowdown techniques.
• Cleaning and Maintenance: To preserve the integrity of the product and guarantee the
consistency of the manufacturing process, reactors have to be cleaned and maintained
consistently. This includes removing any PVC that may have been left behind, cleaning
the surfaces, and inspecting the equipment for signs of wear and tear.
When it comes to producing PVC resins with the desired qualities, such as particle size,
molecular weight, and purity, the design and operation of suspension polymerization reactors
are both extremely important factors. Manufacturers can produce PVC resins that are tailored
to specific applications by carefully controlling the conditions of the reactor. These applications
can range from pipes and fittings to cables and films. When it comes to the planning and
operation of these reactors, safety, precision, and consistency are three of the most important
factors to take into account.

What happens inside the reactor?

To carry out the polymerization process in a manner that is both efficient and accurate during
the production of PVC (Polyvinyl Chloride) resins via suspension polymerization, specialized
reactors are utilized. These reactors are built with the capability of controlling a wide range of
parameters, including temperature, pressure, and agitation, to generate PVC particles with
the desired properties. The following is an explanation of the primary characteristics and roles
that are played by the reactors that are utilized in the process of suspension polymerization
for the production of PVC resin:

• Reaction Vessel: A reaction vessel, also known as a reactor, is the essential component
of the suspension polymerization process. Because of the reactive and corrosive nature
of the chemicals that are being used, including Vinyl Chloride Monomer (VCM), this
vessel is typically constructed out of stainless steel or other materials that are resistant
to corrosion.
• Agitation System: It is essential to properly agitate the mixture to keep the VCM
droplets uniformly suspended in the aqueous phase. To accomplish this, the majority
of suspension polymerization reactors utilize mechanical agitators or impellers. The
agitators prevent the VCM droplets from clumping together and contribute to the
production of fine PVC particles.
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 • Regulation of Temperature The regulation of temperature is essential for regulating the
rate of polymerization and the properties of the PVC particles that result from the
process. It is common practice to make use of cooling coils or jackets to regulate and
remove the heat that is produced by an exothermic polymerization reaction.
• Pressure Control To maintain the viscous phase mixture in a liquid state, the reactor
needs to be pressurized. To prevent the VCM from evaporating at the specified
temperature, the pressure is typically kept at a level that is slightly higher than the vapor
pressure of the VCM.
• The addition of initiators The reactor is then supplied with initiators, which kickstart
the polymerization reaction. The addition of the initiator is subjected to stringent
regulation to guarantee that the reaction will proceed at the desired speed. The process
may involve the addition of initiators in discrete stages or a continuous fashion
throughout.
• Dispersing Agents: Dispersing agents or surfactants are added to the reactor to stabilize
the VCM droplets and prevent coalescence. These agents contribute to the upkeep of a
consistent VCM suspension in the aqueous phase, which is necessary for proper
functioning.
• Mixing Zones: Reactors frequently feature multiple mixing zones, each of which is
dedicated to a particular stage of the polymerization process. There could be, for
instance, zones dedicated to the addition of initiators, polymerization, and coagulation.
• Safety Features: Due to the reactive and potentially hazardous nature of VCM, PVC
polymerization reactors are equipped with safety features such as pressure relief
systems, emergency shut-off valves, and ventilation systems to deal with any accidental
release of VCM or other gases.
• Sampling and Monitoring: To collect samples and collect data on important parameters,
such as temperature, pressure, and pH, reactors are outfitted with sampling ports and
instrumentation. The operators can use these measurements to ensure that the process
is operating within the desired parameters because the process is operating within them.
• Product Removal: After the polymerization process is finished, the PVC particles are
typically coagulated and then separated from the aqueous phase. The removal of
products from reactors can be accomplished through the use of a variety of
mechanisms, including filters and settling tanks.
• Cleaning and Maintenance: To preserve the integrity of the product and guarantee the
consistency of the manufacturing process, reactors have to be cleaned and maintained
consistently. This includes removing any PVC that may have been left behind, cleaning
the surfaces, and inspecting the equipment for signs of wear and tear.
When it comes to producing PVC resins with the desired qualities, such as particle size,
molecular weight, and purity, the design and operation of suspension polymerization reactors
are both extremely important factors. Manufacturers can produce PVC resins that are tailored
to specific applications by carefully controlling the conditions of the reactor. These
applications can range from pipes and fittings to cables and films. When it comes to the
construction and operation of these reactors, safety, precision, and consistency are three of
the most important factors to take into account

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Why only suspension polymerization?
Although suspension polymerization is the method of choice for the production of the vast
majority of PVC resin, it is essential to keep in mind that other methods, such as emulsion
polymerization and bulk polymerization, do have their uses in the production of specialized
PVC products or copolymers. On the other hand, suspension polymerization continues to be
the method of choice for the production of standard PVC resins because of its capacity to satisfy
the demanding requirements of a wide variety of businesses and applications.
• Suspension polymerization makes it possible to exert precise control over the particle
size distribution of the PVC resin that is produced as a result of the reaction. This feature
is referred to as "controlled particle size." This control is essential because various PVC
applications call for resins with particular particle size characteristics. Pipes and
fittings, for instance, might call for particles of a larger size, whereas films and coatings
might call for particles of a smaller size. Suspension polymerization enables precise
control over the resulting particle sizes to cater to a wide range of specifications.
• PVC resins that are created through suspension polymerization typically have high
molecular weights. This is because the polymerization method produces PVC resins.
This is beneficial because it leads to improved mechanical properties, such as tensile
strength and impact resistance, which makes the PVC suitable for a wide variety of
applications.
• Suspension polymerization is an effective method for minimizing the amount of
unreacted Vinyl Chloride Monomer (VCM) that is left in the final PVC resin. This
results in a low degree of unreacted monomer. VCM that has not been reacted poses a
risk to human health and safety due to the toxicity and flammability of the compound.
Suspension polymerization improves the safety of PVC resin by lowering the amount
of VCM that is still present after the process.
• Conditions of Uniform Reaction: Suspension polymerization keeps conditions of
uniform reaction throughout the reaction vessel, ensuring that VCM droplets are
distributed evenly. This prevents coalescence and makes it possible for efficient
polymerization, which ultimately leads to PVC resin properties that are consistent.
• Suspension polymerization is suitable for the production of PVC resins with a variety
of properties and characteristics as a result of its versatility. Suspension polymerization
can accommodate changes in the recipe as well as the additives, making it suitable for
this purpose.
• Ease of Handling: PVC resin that is produced through suspension polymerization is
typically in the form of a slurry. This makes it easier to handle and transport compared
to other forms of PVC resin, such as latex or solution-based resins.
When compared to other methods, such as emulsion polymerization, suspension
polymerization utilizes significantly less energy in the production process. The procedure uses
a fair amount of energy but is relatively efficient overall.

Different modes of Heat transfer inside the reactor

The particular heat transfer mechanisms and techniques used in VCM production reactors are
determined by the reactor design, the demands of the chemical reactions involved, and the

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requirement to control and maintain precise temperature conditions for safe and effective VCM
synthesis. To maintain the safety of the process and guarantee that the reactions proceed
optimally, proper temperature control is essential when producing VCM. The different modes
of heat transfer that take place inside the reactor
➢ Conduction: Conduction is the process by which heat is transferred through a solid
material without the material moving at all. Heat may be conducted through the reactor
vessel walls in VCM production reactors. To effectively transfer heat to or from the
reaction mixture, the walls of the reactor are typically built of materials that have good
thermal conductivity.
➢ Convection: The movement of the fluid itself causes convection, which is the transfer
of heat through a fluid (liquid or gas). Convection can happen inside a VCM production
reactor as the reaction mixture is stirred or agitated. To maintain consistent temperature
conditions for the chemical reactions required for the production of VCM, agitation
aids in the even distribution of heat throughout the reactor.
➢ Heating with Steam or Hot Water: Indirect heating techniques are used in some VCM
production processes to regulate the reaction's temperature. Coils or jackets encircling
the reactor vessel are used to circulate steam or hot water. The reaction mixture is heated
by conduction from steam or hot water through the reactor wall, maintaining the desired
temperature for the chemical reactions.
➢ Cooling: To regulate the reaction temperature in VCM production reactors, cooling may
be necessary in addition to heating. A cooling medium, such as chilled water or cooling
brine, can be circulated in the reactor vessel in jackets or coils to achieve cooling. To
reduce the temperature as needed, heat is transferred from the reaction mixture to the
cooling medium.

Blowdown processes

Unreacted Vinyl Chloride Monomer and other volatile impurities must be removed from the
PVC resin during the blow-down process for the PVC resin to function properly. The quality,
safety, and regulatory compliance of the finished PVC product depends on the completion of
this step. Not every VCM molecule will participate in the polymerization reaction when VCM

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is polymerized to create PVC resin. In the PVC product, some VCM might still be present but
unreacted. VCM is toxic and poses health risks, and its presence in the finished PVC product
is undesirable. It is therefore imperative to get rid of these unreacted VCM molecules. Other
volatile impurities, such as lingering initiators or solvents, may exist in the PVC resin in
addition to unreacted VCM. The safety and quality of the PVC resin may be impacted by these
impurities. During the blow-down procedure, the PVC resin is heated to a high temperature
while being vacuumed. The unreacted VCM and other volatile impurities vaporize as a result
of this process, leaving the PVC resin clean. To stop them from being released into the
environment, the VCM and impurities that were removed are typically captured and treated.
To Ensure the Quality and Safety of PVC resins by lowering the VCM content and removing
volatile impurities, the blow-down process aids in ensuring that the PVC resin meets quality
standards and safety requirements. This is particularly crucial if the PVC resin is used in
products like food packaging or medical equipment, where high purity and low toxicity are
required.

Role of Nash pump in blow down process

A Nash pump, specifically a liquid ring vacuum pump, is essential to the blowdown procedure
in the manufacture of PVC resin. The final PVC product is safe, high-quality, and compliant
thanks to the vacuum it generates to effectively remove volatile impurities and unreacted VCM
from the PVC resin. The vacuum system, which includes the Nash pump, is essential to
achieving these goals while lowering the risks involved in handling VCM.
• The unreacted VCM and other volatile impurities in the PVC resin vaporize when the
temperature is raised while under reduced pressure (vacuum conditions) during the
blowdown process. By creating a vacuum inside the vessel or chamber, the Nash pump
aids in removing these vapors from the resin.
• Lowering Boiling Point: The vacuum produced by the Nash pump reduces the boiling
point of VCM and other volatile substances, enabling them to vaporize at lower
temperatures. By doing this, the need for overheating—which might cause the PVC
resin to deteriorate—is avoided.
• Improved Efficiency: The liquid ring design of a Nash pump is particularly well suited
for handling vapor and gas streams in chemical processes. Effective gas-liquid
separation is provided, assisting in vacuum upkeep and preventing vapor carryover.
• Preventing Contamination: By effectively removing VCM and volatile impurities, the
Nash pump guards against environmental contamination ensures that environmental
laws are followed, and lowers the risk of VCM exposure for workers.
• Vacuum System: The Nash pump is a component of a vacuum system that also consists
of a variety of other parts, including condensers, receivers, and vacuum control devices.
While preserving the desired vacuum conditions, this system is made to remove VCM
and other volatile components as efficiently as possible.
• Safety Considerations: For the blowdown procedure to be safe, a Nash pump and
vacuum system must be used. VCM is flammable and toxic, so it must be removed and
handled carefully to protect workers and avoid environmental hazards.

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BLENDER
Combine different stabilizers, additives, and other parts with the PVC resin to produce a
homogeneous mixture with particular properties. PVC resin by itself might not have all the
qualities needed for a given application. To give the resin the desired properties, additives like
plasticizers (to increase flexibility), pigments (to add color), UV stabilizers (to improve
weather resistance), and heat stabilizers (to stop thermal degradation) are frequently added.
The blender makes sure that these additives are distributed uniformly throughout the PVC
resin, resulting in a steady and consistent mixture that can be further processed into the finished
good.

Devolatilization Unit or Stripper

To rid the PVC resin of any last-minute volatile impurities, unreacted VCM, and other gases, a
stripper is used. This process is essential for improving the PVC resin's quality and safety. It is
mainly used to remove the volatile impurities which are present. After VCM has been
polymerized into PVC resin, there may still be traces of VCM, byproducts, and other volatile
substances in the resin. These flammable impurities are vaporized and eliminated by the
stripper under vacuum and heat conditions.
Safety: Since unreacted VCM is toxic and flammable, removal is essential. The remaining
VCM must be removed to make sure the finished PVC product complies with safety
regulations.

Role of RVC plant

A facility that is engaged in the recovery and recycling of vinyl chloride monomer (VCM), a
vital raw material used in the production of polyvinyl chloride (PVC) resin, is referred to as a
recovery vinyl chloride (RVC) plant in PVC production. PVC is a versatile plastic used in a
variety of products, from consumer goods to building materials.

15
Any unreacted VCM that is left over after the polymerization process is captured, cleaned, and
recycled at an RVC plant to produce PVC. This accomplishes several things:
PVC is made from VCM, a pricey raw material. PVC producers can optimize resource use and
cut waste by recovering and recycling unreacted VCM. VCM is a volatile substance with
potential for harm to the environment. Any residual VCM must be properly captured and
processed to reduce environmental emissions and their effects on the air we breathe and
surrounding ecosystems. By lowering the need for additional VCM purchases and cutting
waste disposal costs, recycling VCM can be profitable for PVC manufacturers.
Usually, an RVC plant's process entails:
• Using a variety of separation and recovery techniques, any unreacted VCM is removed
from the polymerization process. This might entail techniques like distillation,
absorption, or others that separate the VCM from the other ingredients.
• Purification: Any impurities or contaminants are then taken out of the recovered VCM.
Making sure that the recycled VCM satisfies the necessary quality requirements for use
in PVC production is crucial.
• Recycling: The recovered VCM can be added again to the PVC manufacturing process
after being cleaned up. This lowers the overall demand for new VCM, which can help
save money and preserve resources.
• Safety precautions: Due to the potential risks involved with handling VCM, a toxic and
flammable substance, RVC plants place a high priority on safety. To protect both the
environment and the workforce, proper ventilation, monitoring, and safety procedures
are crucial.
Overall, by minimizing waste, preserving resources, and controlling the environmental impact
of the manufacturing process, an RVC plant is essential to the sustainability and effectiveness
of PVC production.

SLURRY TANK

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Following the stripper, the PVC resin is temporarily stored in the slurry tank. To guarantee a
constant supply of purified PVC resin for subsequent processing, it offers a buffer. Before going
through any additional processing or packaging, the purified PVC resin—which is now free of
volatile impurities—is placed in the slurry tank for short-term storage. To keep PVC resin
flowing continuously to downstream machinery and avoid production pauses, the slurry tank
is used.

Drying processes
In the drying stage of the production of PVC resin, the super decanter is a crucial piece of
machinery. It effectively removes extra liquid and water from the PVC resin, improving the
final product's quality, consistency, and suitability for a variety of applications. A super
decanter is essential to the drying process, especially in the separation and elimination of
surplus liquid from the PVC resin.
Water is frequently used as a medium to suspend PVC particles during the suspension
polymerization step of the PVC resin production process, particularly in this step. This water
can mix with the resin. Removal of Extra Water: To get the PVC resin's moisture content to the
desired level in the finished product, extra water must be removed after polymerization is
finished. Excessive moisture may have an impact on the PVC resins characteristics and quality.
A super decanter is a specialized centrifuge that uses fast rotation to separate the solid PVC
resin particles from the liquid parts of the slurry, primarily the water. The super decanter uses
a two-phase separation process in which the liquid components, such as water and any
remaining chemicals or impurities, are expelled to the center while the solid PVC particles
form a compact cake or layer at the outside of the rotating drum. Super Decanters are intended
for continuous operation. The PVC resin cake is continuously discharged from the drum as it
rotates, and the liquid that has been separated is gathered for disposal or further processing.

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Advantages of super decanters:
• Efficiency: Super decanters are very effective at separating the solid and liquid phases,
making it possible to quickly and significantly reduce the moisture content of PVC
resin.
• Utilizing super decanters makes it possible to maintain constant moisture levels in the
PVC resin, ensuring that the finished product satisfies quality standards.
• Super decanters are frequently made with energy efficiency in mind, which helps to
make drying processes more affordable.

Final drying procedures: Although the super decanter removes a significant amount of
moisture, additional drying procedures, such as hot air drying or fluidized bed drying, may be
used to bring the moisture content from 20 % to 0.3 % moisture. The PVC resin's quality and
suitability for various applications are ensured by these additional drying steps which include
the use of a screw conveyor, fluidized bed reactor, and cyclone separator.

Screw Conveyors
A screw conveyor is initially used to feed PVC resin into the process, which is typically in the
form of a wet cake or slurry. From a storage tank or another source, the screw conveyor is in
charge of moving the wet resin to the drying apparatus.

FLUIDIZED BED REACTOR

The wet PVC resin enters the fluidized bed reactor after being dried. A perforated plate or
distributor is located at the bottom of the reactor's chamber. To create a fluidized bed of resin
particles, heated air is forced up through the perforated plate. When air rises through the resin
bed, it gives the resin particles energy, which makes them become suspended and behave like
a fluid. This fluidization enables effective mass and heat transfer. The moisture within the PVC
resin particles evaporates due to the heat from the hot air in the fluidized bed reactor. The
evaporating moisture is carried away by the moisture-rich air as it rises through the fluidized
bed To ensure that the resin dries to the desired moisture content, the temperature and residence
time within the fluidized bed reactor are carefully regulated. Controlling the temperature is
essential to preventing the thermal degradation of PVC resin. The dried PVC resin particles
leave the fluidized bed reactor and enter a cyclone separator, where any remaining fines or dust
are separated from the resin. Released along with the cleaned gas or air are the fines that can
be gathered for recycling or disposal.

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CYCLONE SEPARATOR

▪ Separation of Particles: The centrifugal force of the cyclone separator is used to separate
fines or dust from the gas or air stream. These particles might be tiny resin fragments
or impurities that the fluidized bed drying process did not completely remove.
▪ Clean Gas Exit: Depending on the regulations, the cleaned gas or air can either be
released into the environment or subjected to additional treatment as it leaves the
cyclone separator through an upper outlet.
▪ Final Product: The PVC resin is expelled from the drying system after being dried to
the desired moisture content and free of solid contaminants. It can be gathered in storage
bins or transported to machinery for downstream processing, like extruders, mixers, or
pelletizers, where it will be turned into PVC products.

Packing methods
The packaging of PVC (Polyvinyl Chloride) powder is a crucial step in the production of PVC
because it guarantees the resin's secure handling, storage, and transportation. The quantity of

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PVC powder needed, logistics for transportation, available storage space at the customer's
location, and the sector or application for which the PVC resin will be used are all important
considerations when choosing a packaging system. Each packaging method has been created
to guarantee the consistency and high quality of the PVC powder while making it easy for
customers to handle and use the resin.

PVC powder can be packed using a variety of methods and systems, including:
Bags (valve, paper, or plastic): PVC powder is frequently packed in plastic or paper bags with
multiple layers. One-way valves on valve bags make it possible to fill and seal them effectively
without the use of additional tools. Depending on customer needs and the intended use of the
PVC resin, bags come in a variety of sizes, typically ranging from 25 kg to 1,000 kg.

Big Bags (Fixed Intermediate Bulk Containers, or FIBCs): Big bags are large, woven
polypropylene bags with a capacity ranging from 500 kg to 2,000 kg. They are also referred to
as bulk bags or super sacks. They are frequently utilized to deliver greater quantities of PVC
powder to clients who need bulk deliveries.
Bulk tanker vehicles: Bulk tanker trucks are used for customers who need even larger quantities
of PVC powder. At the manufacturing facility, the tanker truck is pneumatically loaded with
PVC resin before being driven to the customer's location, where it can be blown directly into
storage silos.
Bulk Storage Systems and Silos: Bulk storage silos or containers are on-site at some PVC resin
producers and large consumers. Using specialized machinery like bulk tanker trucks or silo
blowers, PVC powder can be delivered directly into these silos. For high-volume users who
require a constant supply of PVC resin, this method is practical.
custom packaging: PVC resin can be packaged in unique containers, like reusable plastic bins
or drums, depending on the needs of the customer. Custom packaging may be created for
particular uses, handling convenience, or particular client preferences.
Sensitive Applications Requiring Specialized Packaging: PVC resin may need to adhere to
strict cleanliness and hygiene standards in certain industries, including food packaging, medical
devices, and pharmaceuticals.

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BLOCK DIAGRAM

CONCLUSION
Role of chemical engineers in the manufacturing of PVC resins
Chemical engineers play a crucial role in the manufacturing process of polyvinyl chloride
(PVC), as they are responsible for polymerizing vinyl chloride (VCM) molecules into extensive
chains of PVC polymer. This process is essential for the production of PVC, as it results in a
highly versatile material that is widely used in various industries, such as construction,
healthcare, and consumer goods. The expertise and knowledge of chemical engineers ensure
that the PVC produced meets the highest standards of quality and safety, and is suitable for a
range of applications.
• In the field of chemical engineering, professionals utilize their knowledge of reaction
kinetics and thermodynamics to meticulously examine and optimize the polymerization
process of VCM molecules. This ensures that the resulting PVC polymer exhibits the
desired properties.
• The production process of Polyvinyl Chloride (PVC) is a task that falls under the
responsibility of chemical engineers. These professionals are responsible for designing

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 the process, which includes determining the appropriate reactor types, mixing methods,
temperature ranges, and catalyst systems for the polymerization of PVC.
• Chemical engineers engage in comprehensive research and development activities to
design and optimize catalyst formulations that facilitate the preferred reaction
pathways, enhance reaction kinetics, and ultimately result in the synthesis of polyvinyl
chloride (PVC) with targeted properties.
• Chemical engineers employ a meticulous approach in designing reactors for the VCM
polymerization process. This involves analyzing and optimizing various critical factors
such as heat and mass transfer, mixing efficiency, and reaction kinetics. The ultimate
aim of this process is to achieve the optimal conversion of VCM to PVC, thus ensuring
the production of high-quality polymer products.
• The diligent work of chemical engineers is instrumental in maintaining accurate and
effective oversight of the various components involved in production, including VCM,
initiators, catalysts, and raw materials. Through meticulous material balances, these
professionals ensure that all materials are tracked and utilized safely and efficiently.
• Chemical engineers play a crucial role in designing production processes that are both
safe and environmentally sound. Their responsibilities include conducting thorough
evaluations of the potential hazards associated with the handling, storage, and
polymerization of VCM, as well as implementing robust safety protocols and
containment measures to prevent accidents and minimize any negative impact on the
environment. By prioritizing safety and sustainability, chemical engineers help to
ensure that production processes are not only effective but also responsible and ethical.
• Chemical engineers employ analytical methodologies to track the advancement of
chemical reactions and guarantee that the resultant polyvinyl chloride (PVC) conforms
to the desired specifications.
• Chemical engineers are responsible for the challenging task of converting the
polymerization process from a laboratory scale to an industrial scale. This requires them
to address various complexities related to heat and mass transfer, mixing, and reaction
kinetics as they transition from small-scale experiments to large-scale production.
• The primary objective of chemical engineers is to achieve optimal energy utilization by
implementing heat recycling practices and minimizing energy wastage. This approach
results in enhanced energy efficiency, which ultimately leads to cost-effective
operations.
• The role of chemical engineers is to oversee the production process and ensure that it
adheres to all relevant safety, emission, and product quality regulations. Their expertise
is critical in maintaining compliance with industry standards and regulations, as well as
ensuring the safety of both personnel and the environment. Through their diligent
monitoring and management of production processes, chemical engineers play an
essential role in the success of any manufacturing operation.
• Within the realm of industrial production, chemical engineers play a crucial role in
maintaining quality production processes. By closely monitoring these processes,
analyzing relevant data, identifying areas of concern, and implementing strategic
solutions, they can improve efficiency, yield, and overall product quality.
In summary, chemical engineers leverage their specialized knowledge of reaction engineering,
process design, safety protocols, quality assurance, and optimization techniques to facilitate

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the efficient production of PVC from VCM. Their pivotal role is instrumental in ensuring the
successful conversion of VCM into PVC while upholding industry standards and delivering a
premium-grade end product.

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