Report No. 57A Supplement AND. September A private report by the PROCESS ECONOMICS PROGRAM PARK, CALIFORNIA STANFORD RESEARCH INSTITUTE I
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1 Report No. 57A Supplement POLYVINYL POLYVINYL ACETATE AND ALCOHOL by YU-REN CHIN September 1976 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I MENLO PARK, CALIFORNIA
2 CONTENTS 1 INTRODUCTION , SUMMARY INDUSTRY STATUS.... Polyvinyl Acetate Polyvinyl Alcohol 20 Polyvinyl Butyral an: Poiy$iyi Fokal', POLYVINYL ACETATE BY EMULSION POLYMERIZATION... Chemistry... Review of Pa;eiti... Process Description... Raw Material Storage and Purification... Polymerization and Product Storage... Process Discussion... Cost Estimates... Capital Costs... Production Costs... 5 POLYVINYL ACETATE BY OTHER POLYMERIZATION PROCESSES... Review of Processes... Solution Polymerizat;o;l... Suspension Polymerization... Bulk Polymerization... Process Descriptions... Solution Polymerization... Raw Material Storage and Purification... Polymerization... Monomer and Solvent Recovery... Finishing and Bulk Handling... Suspension Polymerization... Raw Material Storage and Purification... Polymerization... Product Dewatering and Drying... Bulk Handling... Process Discussion... Cost Estimates... Solution Polymerization... Capital Costs... Production Costs... Suspension Polymerization... Capital Costs... Production Costs i:: Vii
3 CONTENTS 6 POLYVINYL ALCOHOL : 95 General Chemistry Review of Processes Polymerization of Vinyl Acetate Hydrolysis of Polyvinyl Acetate Process Description Raw Material Storage and Purification Polymerization and Hydrolysis Solvent Separation and Product Drying Bulk Handling Solvent and By-Product Recovery Process Discussion Cost Estimates Capital Costs Production Costs POLYVINYL BUTYRAL AND POLYVINYL FORMAL Chemistry Review of Processes Acetalization Processes Work-up Processes Process Description Raw Material Storage and Purification Polymerization, Hydrolysis, and Condensation Product Washing and Drying Bulk Handling Solvent and By-Product Recovery Process Discussion Cost Estimates Capital Costs Production Costs ETHYLENE-VINYL ACETATE AND ETHYLENE-VINYL ALCOHOL COPOLYMERS Review of Patents Ethylene-Vinyl Acetate Copolymer Ethylene-Vinyl Alcohol Copolymer Process Description Baw Material Storage and Purification Polymerization and Product Storage Process Discussion Costs Estimates Capital Costs Production Costs Viii
4 CONTENTS APPENDIX A DESIGN AND COSTS BASIS APPENDIX B COMMERCIAL POLYVINYL ACETATE, POLYVINYL ALCOHOL, POLYVINYL BUTYRAL, POLYVINYL FORMAL, AND ETHYLENE- VINYLACETATE COPOLYMER...., APPENDIX C MODIFIED POLYVINYL ACETATE, POLYVINYL ALCOHOL, AND ETHYLENE-VINYL ACETATE COPOLYMERS APPENDIX D TREATMENT AND APPLICATION OF POLYVINYL ALCOHOL AND POLYVINYL BUTYRAL CITED REFERENCES PATENT REFERENCES BY COMPANY ix
5 ILLUSTRATIONS Polyvinyl Acetate by Emulsion Polymerization Flowsheet Polyvinyl Acetate by Emulsion Polymerization Effect of Plant Capacity on Total Fixed Capital Polyvinyl Acetate by Emulsion Polymerization Effect of VAM Price on Production Cost Polyvinyl Acetate by Emulsion Polymerization Effect of Operating Level and Plant Capacity on Production Cost Polyvinyl Acetate by Solution Polymerization Flowsheet Polyvinyl Acetate by Suspension Polymerization Flowsheet Polyvinyl Acetate by Solution Polymerization Effect of Plant Capacity on Total Fixed Capital Polyvinyl Acetate by Solution Polymerization Effect of VAM Price on Production Cost Polyvinyl Acetate by Solution Polymerization Effect of Operating Level and Plant Capacity on Production Cost Polyvinyl Acetate by Suspension Polymerization Effect of Plant Capacity on Total Fixed Capital Polyvinyl Acetate by Suspension Polymerization Effect of VAM Price on Production Cost Polyvinyl Acetate by Suspension Polymerization Effect of Operating Level and Plant Capacity on Production Cost Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Flowsheet Xi
6 ILLUSTRATIONS 4.2 Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Effect of Plant Capacity on Total Fixed Capital Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Effect of VAM Price on Production Cost Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Effect of Operating Level and Plant Capacity on Production Cost Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Effect of Acetic Acid Credit on Total Capital Investment and NetProductionCost Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Butyraldehyde Flowsheet Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Butyraldehyde Effect of Plant Capacity on Total Fixed Capital Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Butyraldehyde Effect of VAM Price on Production Cost Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Butyraldehyde Effect of Operating Level and Plant Capacity on Production Cost Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Butyraldehyde Effect of Acetic Acid Credit on Total Capital Investment and Net Production Cost Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Flowsheet Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Effect of Plant Capacity on Total Fixed Capital Xii
7 ILLUSTRATIONS 8.3 Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Effect of VAM Price on Production Cost Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Effect of Operating Level and Plant Capacity on Production Cost Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Effect of Ethylene Content on Production Cost Xiii
8 TABLES 2.1 Manufacture of Polyvinyl Acetate Summary of Process Conditions Manufacture of Polyvinyl Acetate Summary of Process Economics Manufacture of Polyvinyl Alcohol, Pdlyvinyl Butyral, and Ethylene-Vinyl Acetate Sunmary of Process Conditions Manufacture of Polyvinyl Alcohol, Polyvinyl Butyral, and Ethylene-Vinyl Acetate Summary of Process Economics Polyvinyl Acetate Plants United States Polyvinyl Acetate Plants Western Europe Polyvinyl Acetate Plants Other Americas, Africa, Asia, Oceania, and Eastern Europe Polyvinyl Alcohol Plants Asia and Europe Polyvinyl Alcohol Plants The Americas Polyvinyl Acetate by Emulsion Polymerization Patent Summary, Polyvinyl Acetate by Emulsion Polymerization Major Equipment and Utilities Summary....,.., Polyvinyl Acetate by Emulsion Polymerization Stream Flows Polyvinyl Acetate by Emulsion Polymerization Waste Streams Summary...., Polyvinyl Acetate by Emulsion Polymerization. 43 xv
9 TABLES, 4.6 Polyvinyl Acetate by Emulsion Polymerization 5.1 Polyvinyl Acetate by Solution Polymerization PatentSurrPnary Polyvinyl Acetate by Solution Polymerization Major Equipment and Utilities Sunxnary Polyvinyl Acetate by Solution Polymerization Stream Flows Polyvinyl Acetate by Solution Polymerization Waste Streams Sunznary Polyvinyl Acetate by Suspension Polymerization Major Equipment and Utilities Summary Polyvinyl Acetate by Suspension Polymerization Stream Flows Polyvinyl Acetate by Suspension Polymerization Waste Streams Suuxnary Polyvinyl Acetate by Solution Polymerization 5.9 Polyvinyl Acetate by Solution Polymerization 5.10 Polyvinyl Acetate by Suspension Polymerization 5.11 Polyvinyl Acetate by Suspension Polymerization 6.1 Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate PatentSunznary Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Major Equipment and Utilities Summary Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Stream Flows xvi
10 TABLES 6.4 Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Waste Streams Sunnnary Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate 6.6 Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Using WAC as Starting Material 6.7 Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate 6.8 Polyvinyl Alcohol by Hydrolysis of Polyvinyl Acetate Using PVAc as Starting Material 7.1 Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Bu tyra ldehyde PatentSummary Polyvinyl Formal by Condensation of Polyvinyl Alcohol with Formaldehyde Patent Summary Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Bu tyra ldehyde Major Equipment and Utilities Surwnary Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Bu tyra ldehyde Stream Flows Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Bu tyra ldehyde Waste Streams Sutrnnary Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Bu tyra ldehyde 7.7 Polyvinyl Butyral by Condensation of Polyvinyl Alcohol with Bu tyra ldehyde xvii
11 TABLES B-1 B.2 B.3 B.4 B-5 B-6 B.7 c-1 Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization PatentSummary Ethylene-Vinyl Alcohol Copolymer by Hydrolysis of Ethylene- Vinyl Acetate Copolymer PatentSummary Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Major Equipment and Utilities Sunznary Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Stream Flows Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Sumry of Waste Streams Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Ethylene-Vinyl Acetate Resin by Emulsion Polymerization Ethylene-Vinyl Acetate Copolymer by Emulsion Polymerization Ethylene-Vinyl Acetate Resin by Emulsion Polymerization Commercial Polyvinyl Acetate Properties of Polyvinyl Acetate Cocznercial Polyvinyl Alcohol Classification of Polyvinyl Alcohol Cozznercial Polyvinyl Butyral and Polyvinyl Formal.... Properties of Polyvinyl Butyrals Properties of Polyvinyl Formals Modified Polyvinyl Acetate PatentSumna7.y I xviii
12 TABLES c.2 Modified Polyvinyl Alcohol PatentSurrrnary c.3 Modified Ethylene-Vinyl Acetate Copolymer PatentSummary D.1 Treatment of Polyvinyl Alcohol Fiber PatentSusunary D.2 Treatment of Polyvinyl Alcohol Film PatentSutmnary D.3 Applications of Polyvinyl Alcohol PatentSummary D.4 Applications of Polyvinyl Butyral PatentSummary XIX
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