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This study introduces a regeneration approach for polyvinyl chloride (PVC) production, significantly cutting freshwater use by 61% and wastewater by 83% through advanced water management strategies.

Keywords:
PVCWEP analysismass integrationprocess system engineeringregenerationsustainability

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Area of Science:

  • Chemical Engineering
  • Environmental Engineering
  • Process Systems Engineering

Background:

  • Polyvinyl chloride (PVC) suspension polymerization generates substantial freshwater demand and wastewater.
  • Existing mass integration strategies for PVC production primarily focus on direct recycling.
  • Improved water management is crucial for sustainable PVC manufacturing.

Purpose of the Study:

  • To implement and evaluate a regeneration approach for integrating a PVC suspension process to enhance water management.
  • To assess the water-energy-product (WEP) performance of the integrated PVC process.
  • To analyze the impact of regeneration on freshwater consumption, wastewater generation, and overall process efficiency.

Main Methods:

  • Simulation of the PVC suspension process using AspenPlus software (v.14).
  • Application of mass integration with a focus on a regeneration approach for wastewater reuse.
  • Evaluation of the integrated system using Water-Energy-Product (WEP) technical analysis.

Main Results:

  • Achieved a 61% reduction in freshwater consumption and an 83% reduction in wastewater generation.
  • Despite reductions, 258.6 t/day of residual wastewater remained.
  • Significant improvements in water usage indicators, reducing annual freshwater costs by $426,858.
  • Energy performance showed high consumption with limited energy savings (11 MJ/h) from heat integration.

Conclusions:

  • The regeneration approach offers substantial benefits for water conservation in PVC production, aligning with circular economy principles.
  • Emerging effluent regeneration technologies present significant advantages and trade-offs for plastic plants.
  • While water management is improved, further optimization is needed for energy efficiency in the integrated process.