SEETHI SAHIB MEMORIAL POLYTECHNIC

COLLEGE
TIRUR-5





DEPARTMENT OF MECHANICAL
ENGINEERING


SEMINAR REPORT ON
POLY VINYL CHLORIDE




SUBMITTED BY:

MUNAWAR. PM
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ROLL NO: 31
REG NO: 12021124
SSMPTC, TIRUR


SEETHI SAHIB MEMORIAL POLYTECHNIC COLLEGE
TIRUR-5



DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that this is the bona fide record of seminar on
POLY VINYL CHLORIDE has been presented by MUNAWAR.
PM 5
th
semester MECHANICAL ENGINNERING, S.S.M.P.T.C
TIRUR on . In partial fulfillment of requirement for
the award of the Diploma in MECHANICAL ENGINEERING.
Under directorate of Technical Education, Kerala state, during
the year 2014-2015.


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Staff in charge: Head of section:



External Examiner: Internal Examiner:


Place: Tirur
Date :



ACKNOWLEDGEMENT




First of all I would like to praise the God for blessing me to
complete this Seminar successfully.

I am deeply incepted to Mr. T.K Basheer (Head of
department in Mechanical Engineering: Seethi Sahib Memorial
Polytechnic College, Tirur) for providing me the opportunity to
present the seminar on this topic.

I extended my unexplainable gratitude towards all of my
Teachers & librarians who gave me a lot of information and
supports for this Seminar.
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I give my heart full thanks to my friends & Family, Whom
offered me all kind of supports for this.

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INTRODUCTION




Polyvinyl chloride (PVC) is a popular thermoplastic that
contains high levels of chlorine which can reach up to 57%. Carbon,
which is derived from oil or gas is also used in its fabrication. It is an
odorless and solid plastic that is white, brittle and can also be found
on the market in the form of pellets or white powder. PVC resin is
often supplied in the powder forms and its high resistance to oxidation
and degradation make it possible to store the material for long
periods. Some authors/activists that oppose the manufactures of PVC
often refer to it as the "Poison Plastic" due to the toxic pollutants it
might release. When plasticizers are added it becomes softer and more
flexible.
PVC is predominant in the construction industry due to its low
production cost, ease to mold and lightweight. It is used as a
replacement for metal in many applications where corrosion can
compromise functionality and escalate maintenance costs. Many of
the world's pipes are made from PVC and these are used in industrial
and municipal applications. It is also used to make pipe fitting and
pipe conduits. It does not have to be welded and can be connected
with the use of joints, solvent cements and special glues--key points
that highlight its installation flexibility. The material is also present in
the electrical components such as: electrical insulation, wires and
cable coatings.
In the health care industry it is used to make feeding tubes,
blood bags, intravenous (IV) bags, parts of dialysis devices and many
other items. This is only possible when phthalates are added to it.
Phthalates are used as plasticizers to produce flexible grades of PVC
(and other plastics), thus making it better suited for the
aforementioned applications due to improved performance
characteristics.
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HISTORY
THE HISTORY OF PVC
Man has worked hard from the earliest
times to develop synthetic materials which
would offer benefits not found in the natural
products around him. PVC is one of the oldest
synthetic materials with the longest history in
industrial production. Its early history is of
multiple and accidental discovery in different
places at different times as well as unsuccessful
quests for commercial application.
Early researchers accidentally discovered PVC on at least two
occasions in the 19th century. The first, in 1838, was by the French
physicist and chemist Henri Victor Regnault and the second in 1872
by the German Eugen Baumann. On both occasions, the polymer
appeared as a white solid inside flasks of the newly discovered vinyl
chloride gas that had been left exposed to sunlight. The material was
difficult to work with and no one mastered the challenge of
commercial applications.
In 1913, German inventor Friedrich Heinrich August Klatte took
out a patent on PVC. His method used polymerization of vinyl
chloride with sunlight.The most significant breakthrough occurred in
the United States when the company BFGoodrich hired the industrial
scientist Waldo Semon to develop a synthetic replacement for the
increasingly costly natural rubber. His experiments again produced
polyvinyl chloride. However, the material was threatened by the
recession in the 1920s and it was under threat of abandonment that
Semon conceived the idea of PVC as a water resistant coating for
fabrics. Sales took off quickly with a rapidly expanding product
range. Demand accelerated again during the Second World War,
when PVC quickly replaced traditional material to insulate wiring on
military ships.
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A PETROCHEMICAL PRODUCT

Although PVC can be produced from a range
of hydrocarbons including coal, and derivatives of
plants such as sugar cane, the bulk of world
production is currently manufactured using the
chemical compound ethylene. Ethylene (or ethene)
which has the chemical formula C2H4, is a product
of the oil & gas industry. PVC is therefore
considered to be a petrochemical product. At the
start of the ethylene-based PVC production process,
the ethylene is combined with chlorine to produce an intermediate
chemical known as EDC (ethylene dichloride or 1,2-dichloroethane).
Almost all EDC is used for PVC production in Europe, although
a small portion is used for manufacturing of ethylenediamine, organic
solvents and various pharmaceutical products.
Three major applications, polyethylene (PE), EDC and styrene
monomer (SM) account for about 78% of all ethylene consumption
(almost all styrene is used for PS).
The petroleum refining industry and the basic petrochemical
industry in Western Europe are
predominantly located in coastal
areas or where rivers or pipelines
provide easy access to imported
natural resources such as crude
oil. They form petrochemical
complexes, where refineries,
crackers and petrochemical
plants are connected by
pipelines. The chlor-alkali
(caustic soda) industry is often
located together with
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petrochemical complexes or near deposits or rock salt. VCM plants,
which use ethylene and chlorine as major raw materials, and PVC
plants, are generally located in petrochemical complexes due to this
background. Ethylene which is one of five types of products that are
yielded by cracking of naphtha, and downstream on to the production
of petrochemical products such as general purpose plastics.


PVC AND CHLORINE
Ethylene and chlorine are the major raw materials for VCM.
Therefore, VCM is affected by the supply-demand conditions of both
ethylene and chlorine, respectively. In Western Europe the share of
VCM amounts to 14% of all ethylene use (ethylene requirement). In
contrast, VCM amounts to 35% of all chlorine use. This is why the
demandsupply balance of chlorine has a greater impact on VCM than
that of ethylene.










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HOW IS PVC MADE ?
The chemical process for making PVC involves taking the
simplest unit, called the monomer, and
linking these monomer molecules together in
the polymerisation process. Long molecular
chains are formed called polymers (which
are also called macromolecules).
This is the case for PVC, which is made from vinyl chloride
monomer known usually by its initials VCM through polymerisation.
Some monomers exist in the form of reactive gaseous chemical
substances, and some of these may cause health hazards when in
direct contact with humans. In these cases they are manufactured and
processed under strict control for health, safety and environmental
protection. On the other hand, polymers such as PVC, which are
manufactured from monomers through polymerisation, are solid and
chemically stable substances, therefore do not affect human health.
VCM, which is the raw material for PVC, is a gas at ambient
temperature but is usually stored in liquid form under pressure.
Ethylene and chlorine are raw materials for PVC. Upstream industries
are those that provide these materials and include producers of basic
petrochemicals (sometimes known as feedstocks), which supply
ethylene, and the chlor-alkali (caustic soda) industry, which supplies
chlorine.
By thermal cracking of naphtha or natural gas, the basic
petrochemical industry manufactures ethylene and propylene, etc.
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Naphtha is mainly supplied from the petroleum refinery industry,
which uses crude oil as raw material. The chlor-alkali industry
produces caustic soda, chlorine and hydrogen via electrolysis using
industrial grade salt as main raw material.
At a first stage in the PVC production process ethylene and
chlorine are combined to produce an intermediate product called
ethylene dichloride; this is then transformed into vinyl chloride, the
basic building block of polyvinyl chloride or PVC. The process of
`polymerisation' links together the vinyl chloride molecules to form
chains of PVC. The PVC produced in this way is in the form of a
white powder. This is not used alone, but blended with other
ingredients to give formulations for a wide range of products.
Most commodity plastics have carbon and hydrogen as their
main component elements. PVC differs by containing chlorine
(around 57 per cent by weight) as well as carbon and hydrogen. The
presence of chlorine in the molecule makes PVC particularly versatile
because it makes it compatible with a wide range of other materials.
The chlorine content also helps to make PVC flame retardant. It can
also be used as a `marker' to distinguish PVC in automatic sorting
systems for plastics recycling. PVC formulations can be shaped by a
variety of techniques and, using very little energy, made into the final
product form. PVC polymer is chemically stable, neutral and non-
toxic. PVC formulations have a wide range of applications including
the most sensitive, such as medical equipment, plus construction,
automotive and electrical cabling.






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THE PVC PRODUCTION PROCESS

VINYL CHLORIDE MONOMER (VCM) PRODUCTION
Vinyl Chloride Monomer (VCM) is the key material from which
PVC is made.
VCM is a gas with a molecular weight of
62.5 and boiling point of -13.9C, and hence has a
high vapour pressure at ambient temperature. It is
therefore manufactured under strict quality and
safety control.There are two ways to manufacture
VCM from ethylene (obtained from thermal
cracking); the direct chlorination method and
oxychlorination method.
Under the direct chlorination method, ethylene and chlorine
(obtained from electrolysis of salt) react within a catalyst-containing
reactor to form the intermediate material EDC. EDC is then thermally
cracked to yield VCM at a few hundred C. When the hydrogen
chloride obtained as by-product from the above method reacts with
ethylene in the presence of catalyst and air (or oxygen), EDC is
obtained again. This is called the oxychlorination process. When EDC
from the oxychlorination process is dehydrated and then thermally
cracked (together with the EDC from the direct chlorination process),
VCM is obtained. These two methods are usually combined at the
major VCM plants in Western Europe.




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EDC (ethylene di chloride)
Making VCM is complicated.
First react the chemicals Ethylene & Chlorine.
And produce Ethylene Di Chloride(EDC).
This process is called chlorination.
It is the intermediate product to make poly vinyl chloride.
CRACKING
The EDC in the furnace the process is called cracking.
Using het the EDC is split into VCM and Hydrochloric acid.
The reaction is not quickly stopped because the VCM can
decomposed further.
QUENCHING
In order to the VCM the heat needs to removed very quickly.
This is called quenching.
The VCM coming out of the furnace through long tubes which
acts as heat exchanger.
After quenching the VCM is cooling with water &purify it in
distillation columns and back to storage.
CONTROL ROOM
The VCM process is continuous, non stop 24 x 7 controlled to
the polymerization to VCM which is done batches.
These process is completely monitored in the control rooms.
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The whole process is fully automated.

POLYMERIZATION
The actual polymerization of the VCM is in the reactor called
water clives.
Water clives are the closed container like pressure cooker.
A typical PVC plant have a number of water clives.
The size of water clives can be reachable 100 cubic meters in
volume.
Then the VCM reacts into the polymer in the reactor.
STRIPPING
After predetermining the period of time the reaction is stopped.
And the contents in the waterclives into stripper.
The no reacted VCM is separated from the polymer.
The recovered VCM is purified and later reused.
By this way the monomer in kept in the closed pipe avoid the
emission to atmosphere.
DRYING
In the process the PVC goes trough drier.
Approximately the process of drying produce 500 tones of
PVC/day
In this stage we can see the PVC in fine white powder.
SIEVING
In this process pass the dry PVC through the sieve.
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To removing lumps, to attaining the fine powder of consisting
quality.
In this stage the quality department checks the quality of PVC
resin.
PVC RECOVERY
The water used in water clives in the process stripping is also
threat them recovered.
The PVC looks like a white powder and the PVC recovered the
water being cleaned.
This is help to no wastage.













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PVC ADDITIVES
Without additives PVC would not be a
particularly useful substance, but its compatibility
with a wide range of additives to soften it, colour
it, make it more processable or longer lasting,
results in a broad range of potential applications
from car underbody seals and flexible roof
membranes to pipes and window profiles. PVC
products can be rigid or flexible, opaque or transparent, coloured
and insulating or conducting. There is not just one PVC but a whole
family of products tailor-made to suit the needs of each application.
Unlike most other thermoplastics, the majority of PVC applications
have a lifetime of between 10 and 100 years. This requires proven
durability and stabilisers play an important part in achieving such
performance. All polymers require stabilisers of one sort or another;
PVC is no different in this respect.
PTHALATE PLASTICIZERS- Plasticizers are compounds that
improve the performance characteristic quotient of PVC. They
must have less volatility and less toxicity. The following is Bis(2-
ethyl hexyl)pthalate.



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HEAT STABILIZERS - These are one of the most important
additives. These agents minimise loss of HCl which is a
degradation process that starts at 70 degree celsius.
Once dehydrochlorination starts the process is autocatalytic and
hence it must be minimised. Derivatives of heavy metals and Calcium
stearate are traditional heat stabilizers.















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PVC PROCESSES FOR VARIOUS PRODUCTS


EXTRUSION MOLDING
PVC resin is fed to the cylinder via the hopper.
The shaft (which is called "Screw") in the cylinder is rotated to
push resin forward.
Resin is melt by heat and kneaded, while it is pushed forward,
and then extruded from the outlet dies.
The technology is suitable for production of film, sheet, tube or
pipe by selecting a suitable die as the case may be.


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Extrusion Molder

CALENDARING
Resin is melt by heat and kneaded, while passed through
several pairs of roller in order to be stretched to the required
thickness.
This technology is best suitable for production of wide width
flat products such as film, sheet, artificial leather and board.
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Calendaring Process

INJECTION MOLDING
This is a technology to inject melt resin into the metal mold by
pressure, and is best suitable for production of PVC goods with
three-dimensional structure such as sealed containers, large-
sized receptacles including washing basin, bucket, and general
containers.




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THERMAL MOLDING
Sheet or film manufactured by the calendering technology or
the extrusion technology is heated to soften, and then air in the
metal mold is sucked out to press the melt material at an
ambient pressure.
This is called "Vacuum Molding", which is used for the
production of thin packaging material such as the egg package,
the food tray, the disposable cup, or the soybean cake package.
DIPPING
This technology enables to provide uniform coating by dipping
metal tool, fabric/ non-woven cloth into PVC resin solution
(called "Sol") and drying by heat.
Typical products include the hand-held section of pliers or
wrench (spanner), carrier basket for bicycle, canvas cloth for
warehouse tent, soil-reinforcement net and curing sheet for
civil work.


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PHYSICAL PROPERTIES

Glass Temperature - 82 degree celsius
Melting Temperature 100 to 260 degree celsius
Effective Heat of Combustion 17.95 MJ/Kg
Specific Heat 0.9 KJ/(kg.K)
Density 1.1 to 1.45 g/c.c

PROPERTIES
Mechanical- PVC has high hardness. These
properties increases with increasing molecular
weights and decreases with increasing
temperatures.
Thermal- As the heat stability of PVC is very poor
we are adding the heat stabilizers. It starts to
decompose at 140 degrees Celsius and melts at
160 degree Celsius.
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Electrical- PVC is a polymer with good insulation
properties and generally suitable for medium or
low voltage and low frequency insulations.

APPLICATIONS
PVC is relatively low cost, biological, chemical
resistance and workability of it resulted in it being used
in many applications.
PIPES- It is used for sewage pipes and other pipe
applications where cost or vulnerability to
corrosion limit the use of metal.
Electrical cables- PVC is an insulator and hence
used for insulation of electric cables. For this
purpose it must be plasticized
Other applications

It is used in
1. Construction
2. Clothing
3. Furniture
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4. Sports
5. Health care
6. Flooring


PVC Pipes

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Credit Cards




Car seats

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Electric wires

Flooring

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DISADVANTAGES

Recycling difficulty
It is not recommended for use above 70 degrees
Celsius.
Sensitive to UV and oxidative degradation.
Limited thermal capability.
Thermal decomposition evolves HCl.
Higher density than many plastics.








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CONCLUSION

PVC differs from many plastics in
that its production involves not only oil, but also
contains salt which we know is available in abundance.
Recycled PVC is broken down into small chips,
impurities removed and the product refined to make
pure white PVC. It can be recycled roughly 7 times and
has a life span of around 140 years. Around 400 tones
are recycled in the UK every month. Property owners
can recycle it through nationwide collection depots.