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Computational Environmental Impact Assessment of an Enhanced PVC Production Process.

Arelmys Bustamante Miranda1, Segundo Rojas-Flores2, Ángel Darío González-Delgado1

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Summary

This study assessed the environmental impacts of improved poly(vinyl chloride) (PVC) production using mass/energy integration and zero-liquid-discharge (ZLD) systems. While reducing water use, the process intensified acidification and global warming impacts, primarily from natural gas consumption.

Keywords:
computer-aided process engineeringenvironmental analysissuspension polymerizationzero discharge

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Area of Science:

  • Environmental Science and Engineering
  • Chemical Engineering
  • Polymer Science

Background:

  • Poly(vinyl chloride) (PVC) is a widely used polymer produced via suspension polymerization.
  • Current PVC production is resource-intensive, consuming significant water and energy, and generating hazardous byproducts like vinyl chloride monomer (VCM).
  • There is a need for sustainable PVC production methods to mitigate environmental impacts.

Purpose of the Study:

  • To quantify and compare the potential environmental impacts (PEIs) of an improved PVC production process.
  • To evaluate the combined effects of mass/energy integration and a zero-liquid-discharge (ZLD) water-regeneration system.
  • To identify key stages and flows contributing to the environmental burden in different operating scenarios.

Main Methods:

  • Implemented mass and energy integration strategies coupled with a ZLD system using sequential aerobic and anaerobic reactors.
  • Conducted a scenario-based assessment using the Waste Reduction Algorithm (WAR) software (v 1.0.17).
  • Compared four scenarios: Case 1 (no product/energy), Case 2 (product only), Case 3 (energy only), and Case 4 (product and energy).

Main Results:

  • The total PEI increased significantly from 2.46 PEI/day (Case 1) to 6230 PEI/day (Case 4), driven by acidification and global warming from natural gas consumption.
  • Cases 1 and 2 demonstrated negative PEI values, suggesting environmental benefits from converting toxic VCM to PVC.
  • The ZLD system effectively maintained low aquatic toxicity in Case 4 (90.70 PEI/day).

Conclusions:

  • Integrating mass/energy savings with ZLD in PVC production presents a trade-off between resource conservation and intensified impacts like acidification and global warming.
  • Natural gas consumption is a major contributor to the environmental burden in the optimized PVC process.
  • The study provides valuable insights for industrial design, highlighting the need for comprehensive environmental assessments of sustainable chemical processes.