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Influence of Water Regeneration on Chemical and Process Indices in an Energy-Integrated PVC Production Process
Arelmys Bustamante-Miranda1, Eduardo Aguilar-Vásquez1, Miguel Ramos-Olmos2
1Chemical Engineering Department, Nanomaterials and Computer Aided Process Engineering Research Group (NIPAC), Universidad de Cartagena, Cartagena 130015, Colombia.
Polymers
|June 27, 2025
Summary
This study assesses the inherent safety of poly(vinyl chloride) (PVC) production using a zero-liquid-discharge approach. While improving sustainability, the process retains significant chemical and operational risks requiring careful management.
Area of Science:
- Chemical Engineering
- Process Safety
- Environmental Sustainability
Background:
- Poly(vinyl chloride) (PVC) production is water-intensive, necessitating sustainable solutions.
- Zero-liquid-discharge (ZLD) approaches and water regeneration are crucial for environmental compliance and resource conservation in chemical manufacturing.
- Assessing inherent safety is vital when implementing new sustainable technologies in established industrial processes.
Purpose of the Study:
- To evaluate the inherent safety of PVC production integrated with water regeneration and ZLD strategies.
- To identify and quantify safety risks associated with hazardous materials and critical operations in a sustainable PVC manufacturing context.
- To apply the Inherent Safety Index (ISI) methodology to a PVC plant adopting circular economy principles for water management.
Main Methods:
- Utilized the Inherent Safety Index (ISI) methodology to quantify process hazards.
- Employed simulation software and computer-aided process engineering (CAPE) for risk assessment.
- Analyzed safety data from repositories and expert publications, focusing on toxicity, flammability, and chemical interactions.
Main Results:
- The Chemical Safety Index scored 22 points, with flammability and toxicity (vinyl chloride monomer - VCM, and PVC) posing the highest risks.
- The Process Safety Index scored 15 points, primarily due to the inventory of hazardous substances and the presence of critical equipment like boilers and reactors.
- High heat of reaction for the main polymerization reaction and secondary reactions from PVA biodegradation contributed significantly to the overall risk profile.
Conclusions:
- Implementing water regeneration and ZLD in PVC production presents inherent safety challenges, particularly concerning hazardous material handling and process conditions.
- Despite sustainability gains, significant chemical and operational risks persist, necessitating robust control strategies.
- Optimizing safety measures is essential to balance environmental sustainability with operational viability in PVC manufacturing.
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