POLY VINYL CHLORIDE (PVC)

Petroleum Refining
Assignment

and

Petrochemical

Group Members:
Adil Gohar

CH-020

Shoaib Mumtaz Adhami

CH-024

Muhammad Haris

CH-012

Muhammad Juniad

CH-062

Submitted to: Sir Adeel-ur-Rehman

POLYVINYL CHLORIDE

Introduction:
Polyvinyl chloride, PVC commonly known as vinyl is 2nd most sought after thermoplastic
with a global consumption of approximately 22 tons per annum with annual growth of 6%. It is a
chlorinated hydrocarbon polymer - its basic building blocks are chlorine, carbon and hydrogen.
While most plastics are made mostly of petroleum, only 40 percent of the PVC molecule comes
from petroleum; 60 percent of it is chlorine, from salt, NaCl. PVC is a thermoplastic. This means
that it softens as it is heated, and hardens as it cools.

Brief History:
PVC is one of the oldest synthetic materials with the longest history in industrial production.
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. 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. Demand accelerated again
during the Second World War, when PVC quickly replaced traditional material to insulate wiring
on military ships.

Physical Properties of PVC:

Over view of Method to manufacture PVC:

The chemical process for making PVC involves taking the simplest unit, called the monomer,
and linking these monomer molecules together in the polymerization process. Long molecular
chains are formed called polymers.PVC is made from vinyl chloride monomer (VCM) through
polymerization. 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.
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 `polymerization' 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. . 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.

Process Description:
The suspension polymerization process is most widely used process to manufacture PVC. First,
the raw material VCM is pressurized and liquefied, and then fed into the polymerization reactor,
which contains water and suspending agents in advance. Through high-speed agitation within the
reactor, small droplets of VCM are obtained. Next, the initiator for polymerization is fed into the
reactor, and PVC is produced by reaction under a few bar at 40 - 60C. PVC obtained through
suspension polymerization is suspended in water as particles of 50~200 m diameter (in slurry
form). Thereafter the slurry discharged from the polymerization reactor is stripped of residual
monomer, dehydrated, dried and the particle size controlled by screening to yield PVC in the
form of a white powder. The un-reacted VCM is entirely recovered through the stripping
process, and after purification, recycled as raw material for reuse in this process. PVC resin
produced via this suspension process is referred to within the industry using the abbreviation SPVC.

PFD for PVC Production

Further Processing of PVC:

PVC can be supplied to factories either as a powder or, when additives are included, in pellet or
granular form. This raw PVC is then heated and shaped into a final product using a number of
different techniques. When softened by heating, the PVC powder or pellets can be molded or
extruded to achieve the desired shape. PVC can be fashioned into just about any shape or form. It
can be made into pipe, sheet, wire or tape. It can also be used as a coating for other materials,
like paper, cardboard or metal. Following steps are included to manufacture other products from
PVC:

Extrusion:
Hot, soft plastic is squeezed through a hole of the correct dimensions. It hardens as it
cools. Used for making continuous lengths like plastic sheets or pipes.

Injection molding:
Hot plastic is forced into a mould of the desired shape. The mould is then cooled and
opened up to remove the solid plastic object used to make more complicated shapes
like
pipe
fittings.

Blow molding:
Air is blown through a tube of hot plastic, pushing the PVC outwards to the sides of
the mould. Good for making hollow objects such as bottles.
Calendaring:
Squashing PVC is passed between heated rollers to make thin sheets.

World Wide Applications:

Piping Systems:
Pressure and non-pressure pipes, single and double walled corrugated pipes for drainage systems
and associated fittings. These pipes are used for water supply and drainage systems.

Indoor Applications:
PVC door & window profile, foam board, floor tile, wall panel, interior trim, office cubicles,
partitions, false ceiling, cabinets, racks, anti slip staircase covering, Floor matting, shower
curtains,
wall
paper,
table
mats,
upholstery,
louvers
and
blinds.
Electrical Applications:
Power cable insulation & sheath, conduit pipe & fitting, cable channel and insulation tape.
Housing:
Beach houses, mobile homes, site offices, security cabins etc.
Out of all the above, PVC pipes is by far the most widely used application throughout the world
and constitute between 30-50% of the global PVC consumption.

Technical Facilities:
We provide technical services with the intention to help improve our customers' businesses. We
achieve this by:

Prompt and efficient handling of all product complaints,

Providing technical information about various grades, new applications, formulations,
additives and more,
Suggesting improvements for greater efficiency in manufacturing processes,
Advising customers in improving the quality of PVC end products,
Delivering continuous updates on the latest technical developments in the field of PVC
processing.
Facilitate new plant setups and expansion plans of PVC customers.

Global Market of PVC:

In the global market PVC pipes and fittings constitute the largest volume application at 36% of
the marketplace. Worldwide demand for these pipes is forecasted to increase more than four
percent per year through 2007. In the European pipe market, plastic pipes rank first among other
materials and globally plastic pipes are used at about 54% of the total pipes used Polyvinyl
chloride (PVC) takes the lion's share at around 62% of the global market. Polyethylene (PE) has
33.5%, while polypropylene (PP) takes about 4.5%. In Europe, 1.5 million tons of PVC was used
in 2002 to make pipes. Similarly in case of USA pipe demand is projected to grow 2.5%
annually to 15.5 billion feet in 2007.

Major Importing Countries of PVC:

France, USA and Mexico have been the top importers of PVC over the past 5 years, contributing
to approximately 35% of world imports.
Major Exporting Countries of PVC:

USA, Germany and Canada are the top three exporters of PVC pipes in the last five years,
contributing to 32% of world exports.
PVC resins manufacturer in Pakistan:
Engro Asahi Polymer & Chemicals Limited Pakistan (EAPCL), in a Joint Venture with Asahi
Glass Company and Mitsubishi Corporation of Japan set up a PVC Plant in Karachi. The plant
went into full production in the year 1999 and since then it is producing about 100,000 metric
tons. Present domestic PVC requirement is about 70,000 metric tons annually. Its head office and
plant are located in Karachi.
Earlier on PVC demand was catered by importing resin directly from a number of countries. But
in recent years i.e. during 1996-2000, Pakistan imports of PVC resin have drastically shrunk
from a value of US$ 41 million to US$ 15 million. This imported PVC resin is used for injection
molding. The surplus resin (30,000 metric tons) is being exported to Australia, Dubai,
Bangladesh and other Middle East countries.
A new resin manufacturing plant in Faisalabad by Sitara chemicals will start operating in 2007
and will help in stabilizing the price level in domestic market. The said plant is said to be based
on Chinese technology which incorporates the wastage into account and is therefore more
efficient as a result its expected raw material price is anticipated to be cheaper.

Pakistan PVC pipes Manufacturing Industry:

The PVC pipe manufacturing industry has presence in all major industrial cities of
Pakistan (i.e. Karachi, Multan, Burewala, Lahore, Sialkot, Narrowal, Faisalabad,
Gujranwala, Gujrat, Jhelum, Rawalpindi & Peshawar) which consists of around 400
manufacturing units and manufactures 45,000 metric tons annually.
Major characteristics of this industry are:
There are in around 350-400 units in Pakistan scattered all over the country.
Major cluster of PVC Pipes manufacturing industry is in Lahore (250 units).
Second largest cluster is in Gujrat (around 25 units).
PVC pipes industry has an obsolete technology base having 75% units
Equipped with local single screw-extrusion machines. Rest 25% units are
using twin-screw type refurbished old machinery of 80s imported Western
Europe.
Few top line units are also using modern machines imported from China,
Korea and Germany.
Total number of people directly employed in this sector is 5,000.
The educational level of most of the workers is under matriculation.
Plastic pipes are the main products produced by this industry used for Water supply,
drainage, conduits and ventilation.
The installed capacity of these units is 75,000 metric tons per year.
Estimated production of these units is 45,000 metric tons per year.
Total production capacity of this industry is 89.11 million kilo grams per year.
The capacity being utilized by this industry is only 68%.
There still exists a huge potential of more than 41,000 Metric tons usage of
PVC pipes to serve as replacement of other products over the next five years.
Imports by Pakistan:
Over the past five years Pakistan has been importing PVC pipes from Korea, Dubai, Austria and
Germany on regular basis to fulfill local demand.
Exports by Pakistan:
Pakistan has exported pipes of other material but FBS does not show exports of
PVC pipes from Pakistan to any other country, prior to 2003. However, these exports were of
minimal nature. Only in recent years due to demand arising from different development schemes
in Afghanistan, the export figures are significant.

PVC growth potential in Pakistan:

At present only the most basic PVC applications are being made in Pakistan and that also
of low quality
Reason is due to lack of exposure in International markets and lack of information about
PVC processing and its versatility.
If Pakistans per capita consumption (presently around 0.5 kg/person) becomes at par
with world average PVC per capital consumption of around 4.5 kg/person, then Pakistan
would need 585,000 tons of PVC per annum at present population level.
The number of jobs created by setting up the integrated facilities to produce PVC and by
setting up PVC processing units will be more than 50,000.
The incremental impact of producing and processing PVC on GDP can amount to a
staggering figure of $ 1 billion.
Promoting the PVC in construction industry would help in reducing construction cost by
Rs. 32,000 per housing unit of 120 sq. yards.

Companies manufacturing products from PVC:

Dilpasand hosiery private limited:
Dilpasand Hosiery (Pvt) Ltd. was Established in 1918. Due to their vast manufacturing
experience they are proud to represent ourselves as world renowned supplier of Gloves and
safety products. Over the years, Dilpasand Hosiery (Pvt) Ltd has grown from a specialist in
Cotton Gloves to a provider of a full line of Work Gloves.
Products:
Their products include line of Cotton Gloves, string knit Gloves, Latex dipped Gloves, Nitrile
dipped Gloves, and PVC dipped Gloves and PVC Dotted Gloves.
Pakistan PVC limited:
Pakistan PVC Limited is a Chlor-Alkali/PVC Complex, producing PVC Resins and processing
these and other thermo-plastic compounds into finished and semi-finished products. The Plant is
situated at Shaffiabad , Gharo district Thatta , 66 KM from Karachi. Another production facility
for pipes and fittings has been put up at Islamabad Industrial Area. It was constructed in the
middle sixties in collaboration with M/s Shin-Etsu Chemical Industry Company Limited of
Japan, the largest producer of PVC Resin in the world and M/s Sekisui Chemical Company
Limited of Japan. The plant started producing PVC Pipes as early as in 1966 and we were the
pioneers to introduce this product in this country. The Plants have been upgraded from time to

time. The machinery , coming from the best extrusion machinery manufacturers in the world ,
M/s Toshiba of Japan , M/s Wavin Overseas of Holland , M/s Shekisui of Japan and M/s
Cincinnati of Austria. Besides the PVC Pipe Plant, the Company has various units for the
production of PVC Resin based Compounds and finished products for consumer and industrial
use. SHAVYL pipes and fittings are made according to the internationally established standard.
Our trained engineers are sent to foreign countries not only to acquire most modern technology
but also to render technical assistance to our various customers.
Products:
SPVC Resin
Variety of sPVC Resign is available ranging between K-55 to K-70
uPVC Pipes
Pressure Water Pipes from 1/2dia to 14 in B, C & D-Class
Soil, Waste & Vent Pipes (SWV Pipes) for Sanitary and Drainage from 32mm to 160mm
Electrical Conduits from diameter to 4 diameter
Special Sizes like 63 mm and 110 mm
PVC Welding rods
Most commonly used for industrial systems are the PVC welding rods. These are economical,
corrosion-resistant and self-extinguishing, as well as good thermal and electrical insulators.
Dimensions from 2 mm to 12 mm
Variety of Shapes
PVC Joining solution
250 gm tin is for joining pipes which are without Z-joints
Foamed Artificial leather
PVC Sheets (rigid and corrugated)
PVC Fittings (molded and fabricated)
Fittings including Elbow, Tee, Sockets, Bends, End Plug, Y-Tee, Half Set, Crosser, Plug Tee,
Plug Elbow are available in various sizes
PVC Pipe industry, Lahore cluster:
Lahore cluster has the largest number of PVC pipes manufacturing units making 62.5% of the
total manufacturers. Majority of the cluster exists along the line of Shahdrah, Brandreth road,
Band Road, Kana Kacha and Bhagwanpura.

Al-Munawwar PVC:
With headquarter in Lahore Pakistan, AL-MUNAWAR PVC INDUSTRIES is a distinguished
organization with state of the art production facilities engaged in manufacturing and supplying
optimum Polyethylene terephthalate (PET) container for mineral water, beverages, juice,
almost every size and quantity as required by the market today.

Siddiqui Sons:
Ever since its inception in the year 1990, SIDDIQI SONS has achieved great heights of success.
It is a growing organization in the plastic manufacturing industry. Siddiqi Sons Plastic offers its
customer a wide range of custom plastic injection molding components
Services:
1.
2.
3.
4.
5.

Plastic Injection Molding.

Thermo set - Bakelite Injection Molding for Automotive & Auto parts.
Hot Foil Stamping.
Product Assembly Facility.
Iron Flex Cord Assembly.

References:
1.
2.
3.
4.
5.

Plastics materials and processes (A concise Encyclopedia) by Charles A. Harper

www.pvc.org
www.smeda.org.pk
Dyna lab corporation
Engro Polymer