VCM PVC AN RevA
VCM PVC AN RevA
VCM PVC AN RevA
VCM Production
NaOH
and H2O
VCM
Quench
Column
Storage
Oxy-
Chlorination
C2H4 Air (O2)
(CuCl2)
Direct
Chlorination
Cl2 HCl Recycle
(FeCl3)
Crude EDC
Unconverted EDC
Purified VCM
NaOH
and H2O Crude
Cracking
HCl Stripper
Wash / Dryer
Distillation
Distillation
VCM
Column
Quench
Column
Column
Furnace
Column
Figure 1
Waste H2O Waste H2O Waste H2O Waste H2O
Application Note
VCM / PVC Process - pH
HCl more than outweigh the quality issues. EDC created Once all the batch components have been added to the
from the oxychlorination process is routed through the reactor it is heated to begin PVC formation. The actual
purification stages prior to cracking. reaction is exothermic thus, once started, large quantities
of cooling water are required to control the reactor
Thermal cracking is a pyrolysis reaction that produces temperature (typically 30 to 80C). Over the course of 3 to
VCM and HCl. Effluent gases are rapidly cooled in the 10 hours the PVC will precipitate out in the form in small,
quench tower. If the cooling is not done quickly then solid granules of plastic. An agitator is used to keep the
further decomposition occurs creating undesirable coke VCM and PVC in suspension. The reaction is run until 80 -
(tar) which can foul the reactor. HCl is stripped off in a 90% completion. The resulting PVC slurry is drained from
separate column for recycle in the oxychlorination process. the reactor. Any residual VCM will be stripped off for reuse
After a final distillation column the pure VCM is sent to back into the reactor. All water will be removed through
storage where it can be converted to PVC plastic. a centrifuge and cyclone dryer. The finished product is a
PVC powder with plastic granules ranging from 100 - 150
The PVC Process (suspension polymerization) m size.
While the VCM process is continuous, the PVC process is
based on a batch reaction. VCM and demineralized water pH Measurement Challenges
are pumped into a pressurized reactor vessel along with The VCM / PVC processes are highly water intensive thus
initiator chemicals, protective colloids, and a pH buffer. the need for reliable on-line pH and ORP measurements
The purpose of each is discussed below. is a primary requirement. pH control is used in the
oxychlorination quench tower to neutralize excess HCl
VCM - Vinyl chloride monomer is converted into polyvinyl to prevent corrosion. Downstream in the PVC process,
chloride when exposed to initiator chemicals in the reactor demineralized water is pH buffered to prevent corrosion in
the reactor. Throughout the plant cooling water is used.
Water - Demineralized water provides for the suspension ORP control of biocide addition is common in the cooling
of VCM droplets and PVC granules as well as acts as a water to prevent bacteria and algae growth. Wastewater
heat transfer fluid is generated by nearly all of the quench and distillation
processes throughout production. Considerable amounts
Intiators - The initiator reacts with VCM at a prescribed of water is also used for cleaning and maintenance
temperature to create long chain PVC molecules. purposes. VCM / PVC wastewater has a wide variety of
contaminants that must be dealt with:
Protective Colloids - Water soluble colloids influence the
size, surface texture, and porosity of the PVC as well as Residual EDC and VCM
prevent clumping of the granules Copper and iron catalyst
PVC granules
pH Buffers - Inorganic salts or bases designed to Chlorinated organic compounds
neutralize HCl acid created by the polymerization process Glycols
Coke from the EDC cracking process
Figure 2
Cooling Water
Cyclone Dryer
H2O VCM
VCM
Recovery
Recycle
Tank
VCM
Initiator
Colloid
PVC Centrifuge
Reactor PVC
Buffer
Storage
Stripper
VCM
Silo
PVC Slurry
Waste H2O
PVC Production
2
Application Note
VCM / PVC Process - pH
The wastewater chemical mixture is very effective in pH / ORP Electrode Examples
shortening the lifespan of conventional gel filled double
junction pH sensors. Over time, the sensor reference half
cell gets contaminated as the chloride and hydrocarbon The top electrode shows a CR
hemispherical glass pH electrode. The
compounds penetrate the junction and poison the dome shape provides a large surface
electrolyte and Ag/AgCl reference element. The solid area and high resistance to cracking
when process pressures and tem-
metallic catalyst and PVC particulates also are very peratures fluctuate. The notches on
effective at plugging the small porous reference junction each side provide added insurance to
protect the electrode against impact.
that is commonplace in many conventional pH sensors.
The end result of chemical contamination and plugging is a The bottom electrode is Barbens
shift in pH reading and eventual loss of sensor response to unique billet style ORP electrode.
Unlike most competitive designs, no
changes in pH. glass is used in the construction of the
sensor thus the design is highly resis-
tant to damage from impact as well as
pH and ORP Solutions chemical attack. The flush platinum
Barben Performance Series pH sensors are specifically electrode can be easily polished if hard
scale coatings occur.
designed for harsh chemical processes thus are well
suited for the measurement challenges in the VCM / PVC Figure 4
ION PATH
551
SENSOR
specified. The flat design provides a large surface area for 1/4 INSERTION DEPTH
3
Application Note
VCM / PVC Process - pH
Summary Contact Us
Barben Performance Series pH sensors offer many
advantages for VCM / PVC manufacturing facilities Barben Analytical is a leading supplier of analytical mea-
including the following: surement technology targeting the industrial
marketplace. It is a wholly owned subsidiary of Ametek.
Less frequent calibration intervals
High pH / ORP measurement accuracy Ametek has nearly 14,000 colleagues at over 120 manu-
Increased pH / ORP sensor lifespan facturing locations around the world. Supporting those
Simplified sensor specification operations are more than 80 sales and service locations
across the United States and in more than 30 other coun-
In process control applications higher accuracy and tries around the world.
reliable pH / ORP measurement leads to savings by
reducing chemical usage. Maintenance expenses are Barben Analytical
also decreased as spares inventory is reduced and fewer 5200 Convair Drive
calibration hours are required to keep measurements Carson City, NV 89706 USA
accurate.
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Phone: +1 (775) 883-2500
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Email: [email protected]
Web: www.BarbenAnalytical.com
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