Document EeGwNBBrLZKzZRqg8vNKYVD0

<Ph Marstcller n si.: Splenomegalic Li*Sf Disease 129 602450 fk/23. 3r.0hl, W. 1966. Zwischenfalie und Komplikationen bei der Laparoskopie and " , . gezielten Leberpunktion (Ergebnij einer Umfrage). Deut. Med. Wochschr. 91: J&W- 2297. bj*yiA. Canada, Department-of National Health and Weltare, Industrial Health DivisiQ)f'$949^2k guide to- the diagnosis of occupational diseases.' King's Prjgt^CvtawaTOntario, Canada. r. M. Burgison, 1. F. Vitcha & J. C. Krantz, Jr. 1949. Anesthesia. Chemical constitution of hydrocarbons and cardiac automatidty. J. 97: Sftj%ffl6.awwLtJ m Nud. 48:277. M'd' '27. Chemical Economics Handbook. September 1973. Vinyl Chloride and PolyyinyT* - "* Chloride Resins. Stanford Research Institute. Me"'" Park Calif Ed. L^i^fcKNOWETH^R^^^CTCTHAKE. iy62. The smaller halogenated aliphatic by- NHfcpcarbons. Ann. Rev. Pharmacol. 2: 363. 7 30. OBctJnspector of Factories. 1953. Annual Report for the Year 1951. Cmd. SnBaH.M.S.O. London, England. LX^3l. C00K/*w5b^., P. M. Giever, B. D. Dinman A H. J. Macnuson. 1971. Oecupa- tionanffi^Mteolysis. II. An industrial hygiene study. Arch. Environ. Health 22: QCL-32. Coxoier, J. nK!C. Fievez, M. J. LefEvre A A. Sevrin. 1966. Acro-ost6olyse et Idsions cutaRMhassociecs chez deux ouvriers affeetis au nettoyagc d'autoclavcs. Cahiers de Mwedne du Travail (Association Professionnelle beige des M6de- dns du Travail Ifipavier 1966). , 33. Creech, J. L., Jr. dim. N. Johnson. 1974. Angiosarcoma of liver in thqbnanu- - facture of poIyvinyfBKoride. J. Occupational Med. 16: 150. %d^iA. Croll, M. N., L. W. Bady. I. Brodsxy & L. Stanton. 1965. A new agent for ~ splenic scanning: BMfS&Jladiology 84:492. ii Dahlcren, S. 1961. ThorS&Ut tumour}. A review of the literature and report of , two cases. Acta Pathol. MStrobiol. Scand. 53: 147. 36. Danishevsioi, S. L. A N. M>fepQROV. 1961. Voprosyi toksikologii v khimii vysov komolekulyarnykh soedinertRsfiigiena Truda Prof. 21abolevaniya $ (9): 26. 1^37. Danzioer, H. 1960. AccidemaPwisoning by vinyl chloride: report of two cases. Can. Med. Assoc. J. 82: 828. 38. Deese, D. E. A R. E. Joyner. 19fffcyinyl acetate: a study of chronic human ex posure. Am. Jnd. Hyg. Assoc. J. 3S8449. ?oo 16--39, Deichmann, W. B. A H. W. Gerardk^1969. Toxicology of drugs and chemicals. Academic Press. New York, N,Y. C'CZ.C- 40. Devignevielle, Dr. A A. M. Flucher. >E953. Etude toxicologique expdrimentale des rdsines polyvinyliques. Service MidSnl des Manufactures de Saint-Marcel, Vernon, avnl 1953. As cited inTruffert, W69. i Dimov, D. A T. Beritic. 1971. Profesiondft* akroosteoliza. Arhiv. Hig. Rada Toksikol. 22: 53. 42. Dinman, B. D., W. A. Cook, W. M. WKnEHOtgig, H. J. Macnuson A Th. Drr- check. 1971. Occupational acroosteolysis. I. epidemiological study. Arbh. . Environ. Health 22:61. 43. Dodson, V. N., B. D. Dinman, W. M. Whitehi A. N. M. Nasr A H. J. Macnuson. 1971. Occupational acroosteolysis. clinical study. Arch. En- viron. Health 22: 83. OCX.6- 44. Domininohaus, H. 1972. Kunststoffe I. Aufbau tenschaften-Kunststoff- sorten-Anwendungen. 2nd edit. VDI-Verlag. DOsseldoi est Germany. QflrC- 45. DoMtNtNOHAUS, H. 1973. Kunststoffe IL Aufbereiten-OI nveredeln- Uny formen. 2nd edit. VDI-Verlag. DOsseldorf, West German! 46. Dublin_L. I. A R. J. Vane. 1933. Occupational hazards diagnostic signs. U. S. Department of Labor, Bureau of Labor Statistics. BunKn No. 582. U.S. ' -. . -- ---- r\r> _ AO A. WLt in Danziaer. \/ 47 1 1: ^035616 B "B.g.JS Thank you for choosing Cfcinltb Advanced Information Consultants Vender for your document delivery needs MI Mail frmTypa GEO02 vntHiiwi $ Coot $ 19 $ CM Chare* $ December 1979 Plastics and Resins 580.1881 A CEH Marketing Research Report POLYVINYL CHLORIDE RESINS By H. E. Frey with Robert L. Maffly v 1 ;V~ 0^ bG356V1 CEH Marketing Research Reports are comprehensive studies prepared from information in the CEH Data Center and from extensive personal interviews with sources in the chemical industry. A distinctive feature of these reports is the analysis of future supply/demand relationships. Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1881 B TABLE OF CONTENTS SUMMARY............................................................................................................................... Current Supply/Demand................................................................................................ Projected Demand............................................................................................................. Supply and Availability.................................................................................................... 580.1881 D 580.1881 D 580.1881 E 580.1881 G DESCRIPTION........................................................................................................................... Vinyl Chloride................................................................................................................. Polyvinyl Chloride Resins.................................................................... ........................... 580.1882 A 580.1882 A 580.1882 A MANUFACTURING PROCESSES...................................................................................... Vinyl Chloride...................................................................................................................... Polyvinyl Chloride Resins................................................................................................ Polymerization Processes...................................................................................... Suspension Polymerization.............................................................................. Emulsion Polymerization.................................................................................. Bulk Polymerization........................................................................................... Solution Polymerization....................................................................................... Compounding of PVC Resins.................................................................................. Processing of Compounded PVC Resins into End Products....................... 580.1882 B 580.1882 B 580.1882 B 580.1882 B 580.1882 C 580.1882 D 580.1882 D 580.1882 D 580.1882 E 580.1882 E PRODUCING COMPANIES, PLANT LOCATIONS, AND CAPACITIES .... Vinyl Chloride...................................................................................................................... Polyvinyl Chloride Resins........................................................................................... 580.1882 F 580.1882 F 580.1882 H PRODUCTION AND SALES................................................................................................ Vinyl Chloride....................................................................................................................... Polyvinyl Chloride Resins........................................................................................... 580.1882 L 580.1882 L 580.1882 M CONSUMPTION...................................................................................................................... Vinyl Chloride.................................................................................................................. Polyvinyl Chloride Resins........................................................................................... PVC Resin Consumption by Process of Conversion..................................... Extrusion.................................................................................................................. Calendering......................................................................................................... Dispersion.............................................................................................................. Molding.................................................................................................................. Coatings and Adhesives.................................................................................. AUOther Uses........................................................... ......................................... Consumption by End Use....................................................................................... Construction......................................................................................................... Consumer Goods................................................................................................ Electrical Uses........................................................................................... Packaging.............................................................................................................. Transportation..................................................................................................... Home Furnishings................................................................................................ Miscellaneous Uses........................................................................................... 580.1882 R 580.1882 R 580.1882 R 580.1882 S 580.1882 V 580.1882 Y 580.1883 C 580.1883 G 580.1883 J 580.1883 L 580.1883 M 580.1883 N 580.1883 Q 580.1883 R 580.1883 S 580.1883 T 580.1883 U 580.1883 U PRICE AND UNIT SALES VALUE - ..................................................................... Vinyl Chloride.................................................................................................................. Polyvinyl Chloride Resins................................................................................................ 580.1883 V 580.1883 V 580.1883 W BFG35618 Chemical Economics Handbook - SRI International 24855003 in t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1881 C U.S. TRADE.............................................................................................................................. Vinyl Chloride................................................................................................................. Polyvinyl Chloride Resins.......................................................................................... INTERNATIONAL....................... ................................................................................. Producers and Capacities.......................................................................................... Production and Demand............................................................................................... Trade.................................................................................................................................. BIBLIOGRAPHY..................................................................................................................... 580.1883 Y 580.1883 Y 580.1884 A 580.1884 E 580.1884 E 580.1884 J 580.1884 M 580.1884 N BFG35619 Chemical Economics Handbook - SRI International T December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1881 D f SUMMARY Current Supply/D emand A. Vinyl Chloride Monomer (VCM) Key data describing supply and demand for vinyl chloride in 1978 are given below. VINYL CHLORIDE MONOMER SPPPLY/DEMAND - 1978 Millions of Thousands of Pounds Metric Tons Production Annual Production Capacity (year-end, nameplate) Domestic Consumption Exports 6,955 8,695a 6,065 899 3,155 3,944a 2,751 408 a. Includes 500 million pounds (227 thousand metric tons) of capacity that was operated by PPG in Puerto Rico until the end of 1978. SOURCE: U.S. government publications, trade literature, and CEH estimates. In 1979, total VCM demand for domestic use is estimated to be 6.4 billion pounds (2.9 million metric tons); U.S. exports are expected to be about 1 billion pounds (454 thousand metric tons). Capacity to meet this demand level is sufficient in spite of the loss of PPG's Puerto Rican capacity. B. Polyvinyl Chloride (PVC) Resins The 1978 PVC supply/demand balance is characterized by the following figures. PVC RESIN SUPPLY/DEMAND - 1978 Millions of Pounds Thousands of Metric Tons Production Annual Production Capacity (mid-1978, nameplate) Domestic Consumption Exports 5,724 6,890 5,570 252 2,596 3,125 2,527 114 SOURCE: U.S. government publications, trade literature, and CEH estimates. Effective U.S. PVC capacity in 1978 was, overall, 12-15% less than nameplate because of operating deficiencies and also as a result of regulatory compliance with VCM control standards. On that basis, U.S. production capacity, overall, operated at nearly full utilization in 1978. The incremental capacity increases that became operational in the second half of 1978 and the first half of 1979 were comparatively minor; total mid-1979 U.S. PVC production BFG35620 Chemical Economics Handbook - SRI International 24855004 irr i December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1881 E capacity (nameplate) amounted to 7,115 million pounds (3,227 thousand metric tons). Since more stringent EPA control requirements took effect in October 1978, however, copolymer and dispersion resin capacities were further reduced in their effectiveness. The overall (predominantly suspension homopolymer) capacity effectiveness is believed to have im proved to about 90% of nameplate, however. With domestic PVC demand for 1979 estimated at 5,890 million pounds (2,672 thousand metric tons) and PVC exports at 260 million pounds (118 thousand metric tons), capacity utilization again was about 96%, overall, but copolymers and dispersion resins were actually in short supply. Projected Demand A. Vinyl Chloride Monomer (VCM) Monomer demand for domestic use will parallel PVC demand growth, and on that basis is estimated to increase an average of 6% annually between 1979 and 1983, leading to a projected domestic monomer demand of 8.07 billion pounds (3.66 million metric tons) by 1983 (non-PVC uses are projected to grow at about the same rate). Monomer exports are expected to run at the 800 million pound-per-year (363 thousand metric tons) level through 1981 and then drop to about 600 million pounds (272 thousand metric tons) per year. Thus, total VCM requirements are estimated to be 8.6-8.7 billion pounds (3.9 million metric tons) in 1983. B. Polyvinyl Chloride (PVC) Resins Long-term demand for PVC in its major markets is expected to remain stable, since PVC plastics uses are firmly established and there is no competitive material that can readily replace PVC. The following table summarizes demand projections for major PVC end-use markets. ESTIMATED CONSUMPTION OF PVC RESINS1 - 1978 AND 1983 1978 1983* Average Annual Millions Thousands Millions Thousands Growth Rate, of of Metric of of Metric 1978-1983 Pounds* Tons Pounds* Tons (Percent)' Construction Consumer Goods Electrical Uses Packaging Transportation Home Furnishings Miscellaneous Exports 3,000 710 510 460 280 220 390 250 Total 5,820 1,361 322 231 209 127 100 177 113 2,640 4,410 840 610 550 330 260 460 300 7,760 2,000 381 ) 277 249 150 > 118 209 136 3,520 8% 3.5% ----- 6% a. Data have been rounded to the nearest 10 million pounds. SOURCE: CEH estimates. BFG35621 Chemical Economics Handbook - SRI International 1 iDecember 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1881 F The above projections assume an average annual GNP growth of 3.5-3.7%. Construction is by far the largest market for PVC; in fact, one sector of this market, pipe and conduit, accounts for the bulk. PVC resin consumption for pipe has become the decisive factor in the determination of overall PVC demand. In 1978, 2.3 billion pounds (1.0 million metric tons), about 40% of the total consumption, were used in this market, which is expected to consume 33-3.4 billion pounds (1.5 million metric tons) by 1983. Any major deviation of PVC consumption for pipe from the projected figures would, therefore, cause significant change in the projected overall PVC consumption. PVC pipe and conduit markets will continue to grow primarily as a result of the ongoing replacement of conventional pipe and tubing. The remaining potential for this growth is particularly large for sewer pipe (10-13% annually), although in terms of PVC requirements, municipal water pipe for urban areas continues to be an important growth market. By contrast, almost no growth is seen in the rural water pipe market in general, although this varies somewhat among geographic regions. In the conduit field, growth is expected to continue and will be the strongest for electrical conduit. Comparatively low growth rates are expected for drain, waste, and vent (DWV) pipe, and for irrigation pipe. Demand for other rigid PVC building products is generally expected to increase at a combined average annual rate of at least 8% between 1978 and 1983, with siding as the leading product. Flooring, however, is not expected to grow at that high a rate. The other PVC market categories represent generally mature or highly penetrated markets; some segments are not expected to grow at all and might even decline (e.g., shower curtains, garden hose, baby pants), while others will increase (e.g., wall coverings) resulting in modest overall growth. Electrical uses represent a market that is expected to parallel construction activity, resulting in somewhat better gains for PVC than more consumerrelated markets. PVC resin prices are firm as of mid-1979; they reflect added costs for controlling vinyl chloride monomer as well as the industry's need to continue expanding. 24855005 BFG35622 Chemical Economics Handbook - SRI International irr t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1881 G Supply and Availability The near-term supply of VCM and PVC compared to projected demand is tabulated below. ______________ NEAR-TERM SUPPLY/DEMAND BALANCE FOR VCM AND PVC 1980 1981 Millions Thousands Millions Thousands of of Metric of of Metric Pounds Tans Percent Pounds Tons Percent Estimated Mean Annual Effective VCM Capacity Estimated Domestic VCM Demand0 Estimated VCM Exports Capacity Utilization 7,826 6,575 800 3,550 2,982 363 94% 8,546b 6,905 800 3,876b 3,132 363 90% Estimated Mean Annual Effective PVC Capacity Estimated PJ/C Demand0 Capacity Utilization 6,850 6,310 3,107 2,862 92% 7,435 6,610 3,372 2,998 89% a. Estimated capacity is nameplate capacity reduced by 10%. b. Includes 630 million pounds (286 thousand metric tons) as the estimated capacity of Georgia-Pacific, which will be effective in 1981. c. Includes 100 million pounds (45 thousand metric tons) for non-PVC uses. Reduction (from total PVC demand) to allow for comonomer used in copolymers and increase to allow for VCM monomer losses were assumed to be equal. d. Includes 260 million pounds (113 thousand metric tons) for exports. SOURCE: CEH estimates. BFG35623 According to these estimates, domestic VCM supply will be barely adequate in 1980 if domestic demand continues to increase as projected and exports stay up. Relief will come in 1981 when new capacity by Georgia-Pacific and by PPG comes on stream. PVC supply will be sufficient, overall, through 1980, but in early 1981 supply could become tight until new capacity by Tenneco and by Shintec becomes operational. (Late in 1981, additional new capacity by BFGoodrich and Conoco is expected to come on stream). Of the eleven U.S. producers of vinyl chloride monomer, Dow Chemical is the largest, followed by Shell, Diamond Shamrock, BFGoodrich, and Conoco (78% of the total U.S. capacity). Georgia-Pacific is scheduled to start up a one billion pound-per-year VCM plant in late 1980. Of the 21 PVC resin producers, BFGoodrich remains the largest by far, followed by Tenneco, Firestone, Diamond Shamrock, Conoco, Borden, and Stauffer (67% of total U.S. capacity). Georgia-Pacific will have sufficient capacity in early 1980 to become one of the four largest U.S. PVC producers. December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 A DESCRIPTION Vinyl Chloride Vinyl chloride, the monomer for polyvinyl chloride homopolymer and copolymer resins, is a gaseous, reactive intermediate derived from ethylene or acetylene. Generally, 1.025 pounds of vinyl chloride are needed to manufacture 1.0 pound of PVC homopolymer. (A factor of 1.03 is sometimes used). Polyvinyl Chloride Resins The term polyvinyl chloride (PVC) resins includes vinyl chloride homopolymers with the repeating unit-CH^CHCl-, and copolymers of vinyl chloride with varying amounts of vinyl acetate, ethylene, propylene, vinylidene chloride, or acrylates. Generally, these resins are in the form of white powders or granules that, after compounding with auxiliary ingredients, are converted into a large variety of plastic end products through several types of processes. Because PVC resins are thermoplastic, these processes employ heat (except in the case of coating resins, which are processed by dissolving them and applying them from solution). The general performance characteristics of PVC plastics include mechanical toughness, fairly good weather resistance, resistance to water and to many chemicals (including strong mineral acids), fairly good electrical insulating properties, and a pronounced thermoplastic character, i.e., the manufactured articles tend to be soft in a warm environment and increasingly stiff in colder surroundings. PVC plastics that contain little or no plasticizer, therefore, tend to be sensitive to impact at low temperatures. All of these properties depend entirely on the exact composition of the compounds used. The processing and performance characteristics of PVC resins can be varied with the molecular weight, which for most commercial PVC resins lies between 50,000 and 120,000. Molecular weight distribution, particle size, and particle surface characteristics are other variables that are controlled in resin production and that vary among the different grades of PVC resins. Of particular importance to the characteristics of PVC plastics is the presence or absence of plasticizer. Most PVC plastics produced in past decades have been flexible types containing plasticizer. The processing of plasticized PVC is relatively easy to carry out, compared to that for PVC compounds containing essentially no plasticizer. Processing of the latter, which are used for the production of rigid PVC plastics, is technically more demanding. The properties of plasticized PVC plastics depend greatly on the exact amounts and chemical types of plasticizers used; it is common to employ mixtures to achieve the desired properties. Although the great majority of PVC resins used to manufacture PVC plastics are homopoly mers of vinyl chloride, copolymers are still essential in some processes where they are used alone or in admixture with homopolymers. The most important commercial copolymers of vinyl chloride are those used for phonograph records and those for vinyl asbestos floor tile; these have an average vinyl acetate content of about 13%. Other PVC-vinyl acetate copolymers are used in calendering and extrusion formulations; these have an average vinyl acetate content of 4%. Special, soluble PVC-acetate copolymers with an average vinyl acetate content of 12%, as well as some dispersion and blending resins with a lower vinyl acetate content, are used for coatings and adhesives. BFG35624 Chemical Economics Handbook - SRI International O nnC C D W in i December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 B Other vinyl chloride copolymers are specialty resins of comparatively small commercial volume. Copolymers with vinylidene chloride are used in coating applications because of their enhanced solubility, and as extender resins in plastisols where rapid fusion is required. Copolymers with maleate and fumarate esters are used for special applications in coatings and adhesives. Specialty terpolymers that are used in the form of emulsions are based on vinyl acetate, ethylene, and vinyl chloride. Post-chlorinated PVC homopolymer resins are also a small-volume specialty. Products made from them have better heat resistance than products made from ordinary PVC resins. The main application is in residential hot water pipe. Minor amounts of PVC are produced and consumed in latex form (usually containing 50% solids and characterized by small particle size and low viscosity in the uncompounded state); most are homopolymers, but some are copolymers, e.g., with acrylates. MANUFACTURING PROCESSES Vinyl Chloride The bulk of the vinyl chloride produced in the United States is made from ethylene - about half by oxychlorination and half by chlorination. In both processes, ethylene dichloride is first obtained, then cracked to vinyl chloride monomer and hydrogen chloride (HC1). (In the oxychlorination process, HC1 is recycled to the oxychlorination reactor). Polyvinyl Chloride Resins Vinyl chloride, a gas at room temperature, is used in liquid form under pressure when it is polymerized by one of the four basic processes - suspension, emulsion, bulk, and solution polymerization - described in the following paragraphs. A. Polymerization Processes* In all processes, the polymerization is initiated by free radicals (produced by the thermal decomposition of such initiators as peroxides or persulfates) and proceeds at temperatures of 40-70C with the evolution of heat. The rate of polymerization is particularly sensitive to the reaction temperature and the concentration and type of initiators used. The molecular weight distribution of the final product, which is of key importance to the processing characteristics of the resin, is also influenced substantially by these parameters. The trend in these batch processes has been toward larger and larger reactors that typically have a capacity in the range of 2,000 to 7,500 gallons, although recently reactors with capacities of 26,000 and even 35,000 gallons have been installed. In the Federal Republic of Germany, the polymerization of vinyl chloride is carried out continuously in tall reaction towers by some producers. Comprehensive descriptions and analyses of PVC manufacturing processes are provided by the Process Economics Program, SRI International. For a useful summary of PVC resin manufacturing processes and related aspects, see "Chemistry and Technology of Polyvinyl Chloride," by Roy T. Gottesman, a paper presented at the symposium of The American Chemical Society, Division of Organic Coatings and Plastics Chemistry, Atlantic City, NJ, September 11, 1974. Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 C The control of vinyl chloride monomer escaping into the atmosphere during its handling in the production of PVC resins and the protection of workers from exposure to vinyl chloride, e.g., during the cleaning of reactors, became an issue of great impact when, in early 1974, cases of angiosarcoma, a rare type of cancer of the liver, were first reported to have occurred among workers exposed to the monomer. Since that time, manufacturing processes have been modified to comply with stringent standards set by various government agencies to ensure uniform controls on vinyl chloride monomer, e.g., its emission, the exposure of workers, and residual content in PVC resins. 1. Suspension Polymerization. The majority of all PVC resins (both homopolymers and copolymers) produced in the United States in recent years have been made by suspension polymerization. The polymerization is carried out in an aqueous system in which monomer droplets are maintained in suspension by means of a protective colloid in conjunction with brisk agitation. Typical protective colloids are polyvinyl alcohol, gelatin, and substituted celluloses (e.g., hydroxypropyl methylcellulose). Generally, suspension polymerization is operated as a batch process employing glasslined or stainless steel reactors. The reactor is first charged with deionized water; then a protective colloid (0.05-2% of the weight of the monomer), a buffer (e.g., sodium acetate), and an initiator (e.g., lauryl peroxide, azobisisobutyronitrile, or diisopropyl peroxydicarbonate) are added. The vinyl chloride and, in the case of copolymer production, the second monomer (e.g., vinyl acetate, propylene, or vinylidene chloride) are then intermittently introduced in controlled ratios. The mixture is brought to the polymerization temperature (about 50C), and after variable induction periods depending on the initiator used, the polymerization starts. The heat of polymerization is removed from the system to maintain the desired reaction temperature. When lauryl peroxide is used as the initiator, polymerization is substantially complete after a period of about 16 hours; with diisopropyl peroxydicarbonate, typical reaction periods are on the order of 8 hours. In the last several years the use of so-called co-initiator systems, which permit better control of the molecular weight distribution and faster reaction rates resulting in higher output, has come into prominence in PVC resin production by the suspension process. Residence times of about six hours are achieved with such systems (e.g., diisopropyl peroxydicarbonate combined with acetyl cyclohexyl sulfonylperoxide). A dispersion of relatively large polymer particles in water is obtained by the suspension polymerization process. After unreacted monomer is driven out of the' slurry and recovered^ the slurry is centrifuged and the polymer is flash dried in an air stream at about 80 C. The dry polymer is screened, generally through a 40-mesh screen, and shipped in bulk or packed in multiwall paper bags. A typical cost breakdown for suspension-polymerized PVC is as follows. CENTS PER POUND Vinyl Chloride Monomer (1.025 pounds per 1.0 pound of resin) Conversion and Overhead Depreciation D istribution Corporate Overhead 17.6a 4.7 2.7 1.5 2.9 Total Cost 29.4 a. At a vinyl chloride monomer cost of 17.2 cents per pound. SOURCE: CEH estimates. Chemical Economics Handbook - SRI International irr t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 D 2. Emulsion Polymerization. Roughly 10% of the PVC resins produced in the United States in recent years was made by emulsion polymerization; this process is basically similar to the suspension process except that relatively large amounts of emulsifying agents are used, usually in pairs; one of the pair is soluble in the monomer and the other in water. Such systems effectively prevent the coalescence of polymer particles and result in resins of a very small particle size. The initiator systems used are also different from those described for suspension polymerization; typically they are redox-type systems employing persulfates. The drying methods are also designed to maintain a small particle size; spray dryers are frequently used. Because complete removal of emulsifiers is never achieved, articles of high clarity (as needed in packaging film) or of very low water absorption (as needed in wire insulation) cannot be produced from these resins. The generally higher price of emulsion-polymerized resins compared to that of suspen sion-polymerized resins is, nevertheless, accepted by users who need compounds in liquid form (fluid dispersions of PVC resins in plasticizers, called plastisols). In the United States, most resins produced by emulsion polymerization are used for plastisols (and are to a minor extent in latex form). In Europe, general-purpose resins (useful for calendering and extrusion) are also produced by variations of the emulsion process. /" S 3. Bulk Polymerization. In this process, used to a small extent in the United States, vinyl chloride is polymerized without the addition of other liquids. A two-stage version of the process, which was developed by Pechiney-Saint-Gobain of France, has been widely licensed. U.S. licensees are Occidental Petroleum Corporation, Hooker Chemical Corporation, subsidiary; The Goodyear Tire & Rubber Company, Chemical Division; The BFGoodrich Company, BFGoodrich Chemical Division; and Certain-Teed Corporation. In the two-stage bulk polymerization process, a suitably shaped reactor is provided for the initial liquid phase of the reaction. A differently designed autoclave is used for the second phase to agitate the then-dry powdery mass effectively until the conversion from monomer to polymer reaches a level of about 80%. Heat exchange is provided by the distillation of monomer and its recondensation within the reactor and in external condensers. The rate of output in two-stage bulk polymerization plants is said to be considerably higher than that in typical suspension process plants of comparable size (i.e., with a comparable number and size of reactors). | | Bulk polymerized PVC resins resemble suspension resins in appearance and are charac terized by high particle uniformity and purity. These properties result in end products of unusually good optical clarity (important for packaging uses). These resins also have very good heat stability and improved fusion properties, i.e., they can be processed with the ease of conventional vinyl chloride-vinyl acetate copolymers. 4. Solution Polymerization. In this process the monomers are first dissolved in an organic solvent (such as n-butane or cyclohexane) in an autoclave. After the addition of a peroxide initiator and heating of the stirred solution to 40 C, polymerization begins and the polymer precipitates as the reaction proceeds. Solution polymerization is used exclusively for the production of specialty copolymers of vinyl chloride with vinyl acetate (usually those containing 10-25% acetate). These solution-polymerized copolymers are very pure and uniform, and their chief value lies in their unique solubility and film-forming characteristics. BFG35627 Chemical Economics Handbook - SRI International ITT December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 E B. Compounding of PVC Resins PVC resins are compounded with a number of auxiliary materials before they are converted to end products. In the case of flexible or plasticized PVC products, the chemical types and exact amounts of plasticizers used are most important - the amount may range from about 10% (for semirigid sheet) to 100% (for very soft film) of the weight of the resin. The plasticizers are chiefly higher alcohol esters of phthalic acid (e.g., dioctyl phthalate). Polyester plasticizers (e.g., adipic acid-glycol polyesters) and epoxy plasticizers (e.g., epoxidized soybean oil) are resistant to leaching and are therefore used in biomedical products. (See the CEH Marketing Research Report on Plasticizers for detailed information). Other important compounding ingredients are light stabilizers and heat stabilizers. Among the most frequently used are heavy metal salts (e.g., of lead, tin, barium-zinc) or organotin compounds; about 0.1% to 2% (depending on the type and the fabricating process used) is added.* Pigments and fillers are incorporated, depending on the end use. When flexibility and toughness are needed in an end product, vinyl compounds tolerate only relatively light filler loadings. PVC compounding in general begins with premixing followed by very intense mixing, because uniform distribution (especially of stabilizers) is mandatory for trouble-free processing and uniform product quality. Of the many types of PVC compounds in use, most (plasticized as well as unplasticized) are relatively dry in the premix stage and have a free-flowing, sandy consistency. To achieve intimate mixing, they are subjected to a hot mixing step at fusing temperature, usually in a Banbury mixer. Modem twin-screw extruders perform these steps successively. In the case of plastisols, compounding is strictly a stir-in process (except that pigments are predispersed with plasticizer over a three-roll paint mill). Organosols (which are PVC resin dispersions in plasticizers and a balanced mixture of solvents and diluents) are usually prepared in enclosed ball mills. C. Processing of Compounded PVC Resins into End Products PVC compounds are converted to end products by several processes. Extrusion is used to produce both rigid items (e.g., pipe and conduit, siding, window sash) and flexible items (e.g., electrical wire insulation, garden hose, packaging film). Extruder trains naturally vary greatly in their particular engineering features and are designed for the production of one particular type of extrusion. Typically, extruders are continuously fed with compound, which is either purchased or prepared in an on-site compounding plant. Calendering is used for the manufacture of some types of vinyl flooring and for most of the great variety of PVC film and sheeting produced - flexible and rigid. The sheet may be combined with a fabric as it leaves the calender, or this may be done subsequently in a separate laminating step. The following book is recommended for supplemental reading an vinyl stabilizers, in particular, and vinyl compounding, in general: Harold A. Sarvetnick, Polyvinyl Chloride, Van Nostrand Reinhold Co., New York, 1969. BFG35628 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 F Modern PVC calenders run widths usually to 72 inches and some as broad as 92 inches. They produce film and sheet at rates averaging more them 8 million pounds per year of compound (equivalent to 5.5-6 million pounds of resin), depending on thickness (e.g., 2.5 million pounds per year for light gauge rigid film, 4.5 million pounds per year for heavier flexible film, and higher rates for flexible sheeting). Dispersions or plastisols are used mostly for fabric coating (either an knife machines, roll coaters, or casting machines) and in the production of coated types of vinyl flooring where plastisol is cast on a felt base. Plastisols are also used in rotational molding, and in dipping and hot-spraying. Compression molding of PVC resins is restricted to the production of phonograph records, although modified compression molding is used in the production of certain plasticized PVC products, e.g., automobile floor mats. Injection molding of rigid (as well as plasticized) PVC compounds was developed largely in the 1960s and is mostly employed in the production of pipe fittings. Other uses include the production of parts for automobiles, communications equipment, business machines, and toys. Blow molding requires special equipment and is used in the production of PVC bottles. PRODUCING COMPANIES, PLANT LOCATIONS, AND CAPACITIES Vinyl Chloride U.S producers of vinyl chloride monomer and the annual capacities of their plants are listed in the following table. U.S. PRODUCERS OF VINYL CHLORIDE MONOMER Annual Vinyl Chloride Capacity ________ As of October 1979 Millions of Thousands of ______ Company and Plant Location_______ Pounds Metric Tons Borden Inc. Borden Chemical Division Geismar, LA 380 172 Conoco Inc. Conoco Chemicals Co. Division Lake Charles, LA 700 318 Diamond Shamrock Corporation Industrial Chemicals and Plastics Unit La Porte, TX 1,000 454 Dow Chemical U.S.A. Freeport, TX Oyster Creek, TX Plaquemine, LA 150 ) 750 } 1,250 J 2,150 68 340 975 567 b?g35629 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 G U.S. PRODUCERS OF VINYL CHLORIDE MONOMER (continued) Annual Vinyl Chloride Ca ______ As of October 1979' Millions of Thousands of Company and Plant Location Pounds Metric Tans Ethyl Corporation Industrial Chemicals Division Baton Rouge, LA 300 136 The BFGoodrich Company BFGoodrich Chemical Division Calvert City, KY 1,000 454 ICI Americas Inc. Petrochemicals Division Baton Rouge, LA 300 136 Monochem, Inc. (jointly owned by Borden Inc. and Uniroyal, Inc.) ^ Geismar, LA 300 136 PPG Industries, Inc.C Chemical Group Chemical Division-U.S. Lake Charles, LA 400 181 Shell Chemical Company Deer Park, TX Norco, LA 840 1 700 | 1 540 3811 - 699 318) Stauffer Chemical Company Long Beach, CA 175 79 Total 8,245 3,740 a. Actual operating capacities are usually somewhat lower than these nameplate capacities. The new emission standards for vinyl chloride have caused some reduction of these operating capacities according to industry sources. b. Vinyl chloride production based on acetylene. c. Company discontinued production of VCM at Guayanilla, Puerto Rico at the end of 1978. SOURCE: CEH estimates based on trade announcements and communication with industry. The following companies plan to add vinyl chloride capacity: Dow, 400 million pounds (181 thousand metric tons) at Plaquemine (already in place; start-up date will depend on demand); Georgia-Pacific, one billion pounds (454 thousand metric tons) at Plaquemine (late 1980); BFG35630 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 H PPG, 500 million pounds (227 thousand metric tons) at Lake Charles (late 1980); Shell, 800 million pounds (363 thousand metric tons) at Edgard, Louisiana (construction not expected to begin until 1981). Polyvinyl Chloride Resins U.S. producers of PVC resins and their annual plant capacities are listed in the following table. U.S. PRODUCERS OF PVC RESINS Estimated Annual Polyvinyl Chloride Resins Capacity ________ As of October 1979 Millions of Thousands of Company and Plant Location______ Pounds Metric Tons Air Products and Chemicals, Inc. Plastics Division Calvert City, KY Pensacola, FL (220)a 200 300a (100)a 136a 91 , Borden Inc. Borden Chemical Division Illiopolis, IL Leominster, MA 340 \ 185 ) 525 154 84 238 Certain-Teed Corporation Lake Charles, LA 190 86 Conoco Inc. Conoco Chemicals Co. Division Aberdeen, MS Oklahoma City, OK 335 1 215 ) 550c 152 98 c Diamond Shamrock Corporation Industrial Chemicals and Plastics Unit Plastics Division Deer Park, TX Delaware City, DE |470 \ 120 590 213 55 268 Ethyl Corporation Industrial Chemicals Division Baton Rouge, LA The Firestone Tire 8c Rubber Company Firestone Plastics Company, division Baton Rouge, LA Perryville, MD Pottstown, PA (continued) 200 260 240 180 82 91 700 118 318 109 Chemical Economics Handbook - SRI International BFG35631 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 I U.S. PRODUCERS OF PVC RESINS (continued) Estimated Annual Polyvinyl Chloride Resins Capacity _______ As of October 1979 Millions of Thousands of ______ Company and Plant Location Pounds Metric Tans The General Tire & Rubber Company Chemical/Plastics Division GTR Chemical Company Ashtabula, OH Point Pleasant, WV 125 60 185 57 27 84 Georgia-Pacific Corporation Plaquemine, LA 350 The BFGoodrich Company BFGoodrich Chemical Division Avon Lake, OH Henry, IL Long Beach, CA Louisville, KY Pedricktown, NJ Plaquemine, LA 300 \ 200 I 150 l 375 ( 150 I 190 ) 1,365* The Goodyear Tire & Rubber Company Chemical Division Niagara Falls, NY 70 Great American Chemical Corporation Fitchburg, MA 75 International Materials Corporation IMEX Polymers, Inc., subsidiary New Bedford, MA 50 Keysor Corporation Saugus, CA 50 Occidental Petroleum Corporation Hooker Chemical Corporation, subsidiary RUCO, subsidiary Burlington, NJ 190 (continued) 159 136 \ 91 68 ( 619* 170 { 68 86 / 32 34 23 23 86 BFG35632 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 J U.S. PRODUCERS OF FVC RESINS (continued) Estimated Annual Polyvinyl Chloride Resins Capacity _______ As of October, 1979 Company and Plant Location Millions of Pounds Thousands of Metric Tons Pantasote Inc. Eleonora Chemical Division Passaic, NJ Point Pleasant, WV 55 1 85 ) 140 25 j 39 1 64 Rico Chemicals Corporation Guayanilla, Puerto Rico Shintech Incorporated (owned by Shin-Etsu Chemical Industry Company Ltd. (Tokyo)) Freeport, TX Stauffer Chemical Company Plastics Division Delaware City, DE Long Beach, CA ....... 160 330h 280 \ 140 J 420 73 150h 127 ) 64 j 191 Tenneco Inc. Tenneco Chemicals, Inc. Organic and Polymers Division Burlington, NJ Flemington, NJ Pasadena, TX Union Carbide Corporation Chemicals and Plastics, division South Charleston, WV Texas City, TX Total 160 ) 80. } 4801 j 720 s,| ' 327 218 J 50 } 125 1 175 7,315j 23 1 57 j 80 3,318i,k a. The capacity at the Calvert City plant represents designed output; the effective capacity of this plant in most of 1979 is believed to have been in the 100 million pound (45 thousand metric ton) per year range. Company's total PVC capacity during 1979 is estimated to have been about 300 million pounds (136 thousand metric tons) per year, nameplate. b. Company has announced plans to build a new 240 million pound (109 thousand metric ton) per year PVC plant at Geismar, LA. The first production from the plant is scheduled to come an stream in early 1982. c. Company plans to expand total PVC capacity of these two plants to 700 million pounds (318 thousand metric tons) per year by late 1981. Chemical Economics Handbook - SRI International gpG35633 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.188Z K (continued) d. Came on stream during October 1979. e. Company is expanding PVC capacity to 700 million pounds (318 thousand metric tons) per year, to be complete by late 1979. f. Company has announced plans to approximately double its PVC production in North America by year-end 1985. Specific plant expansions or new plant constructions have not been announced. g. Company plans to expand PVC capacity at this location by 200 million pounds (91 thousand metric tons) per year by late 1981. h. Company plans to expand capacity to 660 million pounds (299 thousand metric tons) per year by mid-1981. i. Company has announced plans to expand plant capacity to a total of 750 million pounds (340 thousand metric tons) per year by mid-1981. j. The capacity distribution for PVC dispersion resins as of mid-1979 was approximately as follows. Millions of Pounds per Year Thousands of Metric Tans per Year Firestone BFGoodrich Stauffer Diamond Shamrock Goodyear Tenneco Borden Ethyl 170 160 100 80 52 45 30 20 77 73 45 36 24 20 14 9 Total 657 298 As a result of operating procedures designed to meet EPA requirements, actual effective U.S. dispersion resin capacity was only 70-75% of nameplate, i.e., 460-490 million pounds (209-222 thousand metric tons) per year, for much of 1979. k. Total does not equal the sum of the categories due to rounding. SOURCE: CEH estimates based on communication with industry. Most large resin manufacturers also produce PVC compounds for sale or for feeding their own manufacturing operations of fabricated end-products. For example, Conoco Chemicals has a PVC compound production capacity of 135 million pounds (61 thousand metric tons) per year at Aberdeen, MS. The Plastics Division of Diamond Shamrock has two compound plants with a combined capacity of 175 million pounds (79 thousand metric tons) per year. BFGoodrich Chemical has long operated several large compound facilities. Other large BFG35634 Chemical Economics Handbook - SRI International 248S50U ITT 1 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 L producers o compounded resins are Tenneco Chemicals, Inc., Firestone Plastics Company, and the Pantasote Company. PRODUCTION AND SALES Vinyl Chloride The following table provides data an U.S. vinyl chloride production. U.S. PRODUCTION OF VINYL CHLORIDE Millions of Thousands of Pounds Metric T< 1955 1956 1957 1958 1959 529 597 627 691 977 240 271 284 313 443 1960 1961 1962 1963 1964 1,037 1,044 1,312 1,435 1,615 470 474 595 651 733 1965 1966 1967 1968 1969 2,000 2,500 2,424 2,969 3,736 907 1,134 1,100 1,347 1,695 1970 1971 1972 1973 1974 4,040 4,336 5,089 5,351 5,621 . 1,833 1,967 2,308 2,427 2,550 1975 1976 1977 1978p 4,196 5,677 5,986 6,955 1,903 2,575 2,715 3,155 See MANUAL OF CURRENT INDICATORS - SUPPLEMENTAL DATA for additional information. SOURCES: (A) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. International Trade Commission (formerly U.S. Tariff Commission) (data for 1955-1977). (B) Preliminary Report on U.S. Production of Selected Synthetic Organic Chemicals, SOC Series C/P-79-1, U.S. International Trade Commission (preliminary data for 1978). Chemical Economics Handbook - SRI International BFG35635 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 M Polyvinyl Chloride Resins The following table presents data on U.S. production of polyvinyl chloride resins as reported by the U.S. International Trade Commission (formerly the U.S. Tariff Commission) and, in recent years, by The Society of the Plastics Industry, Inc. U.S. PRODUCTION OF FVC RESINS (millions of pounds) Suspension Homopolymers" Suspension^ Copolymers Dispersion R,,ersi.nsc Total 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 527 637 690 657 905 936 977 e 1,215 1,386 1,637 1965 - -- -- 1,838 1966 1,224 658 282 2,164 1967 1,303 550 289 2,142 1968 1,713 578 344 2,635 1969 2,052 592 388 3,032 1970 2,232 519 364 3,115 1971 2,475 504 458 3,437 1972 3,149 559 550 4,259 1973 3,433 540 589 4,562 1974 3,772 608 471 4,850 1975 2,861 402 385 3,648 1976 3,738 489 489 4,716 1977 4,200 559 494 5,253 1978 4,690 578 456 5,723 (continued) BFG35636 Chemical Economics Handbook - SRI International in i December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 N U.S. PRODUCTION OF FVC RESINS (continued) ______________ (thousands of metric tons)____________ Suspension Suspenam^ Dbpara. Homopolymersa Copolymers Resins Totald 1955 1956 1957 1958 1959 239 289 313 298 411 1960 1961 1962 1963 1964 444234 e 551 629 743 1965 -- -- -- 834 1966 555 298 128 982 1967 591 249 131 972 1968 777 262 156 1,195 1969 931 269 176 1,375 1970 1,012 235 165 1,413 1971 1,123 229 208 1,559 1972 1,428 254 249 1,932 1973 1,557 245 267 2,069 1974 1,711 276 213 2,200 1975 1,298 182 175 1,655 1976 1,696 222 222 2,139 1977 1,905 254 224 2,383 1978 2,127 262 207 2,596 See MANUAL OF CURRENT INDICATORS - SUPPLEMENTAL DATA for additional information. a. Included in recent years are an estimated 400-500 million pounds (181-227 thousand metric tans) per year of homopolymers produced by bulk polymeri zation. Beginning in 1974, blending resins and latexes are included in this category. b. Included are copolymers produced by solution polymerization. c. According to the source, latexes and suspension homopolymers used as blending resins are included up to 1973. Not all blending resin produced is believed included due to erroneous reporting. d. Totals may not equal sums of categories due to rounding. Chemical Economics Handbook - SRI International BFG35637 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 O e. Includes 678 million pounds (308 thousand metric tons) of PVC homopolymer, 283 million pounds (128 thousand metric tons) of vinyl chloride-acetate copolymer, and 16 million pounds (7 thousand metric tons) of other PVC copolymers. SOURCES: (A) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (data for 1955-1971 in the table, and data in footnote e). (B) Year-end Monthly or Annual Statistical Reports, Plastic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (all other data in the table). (C) CEH estimates (estimate in footnote a). Data in the table on pp. 580.1882 M-N indicate that, historically, growth in PVC resin production has been cyclic. The years 1962, 1968, and 1977 were years of peak production, or catch-up years. Captive PVC resin consumption by producers, e.g., Borden, Diamond Shamrock, Firestone, BFGoodrich, Stauffer, and Tenneco, is estimated to be close to 2 billion pounds per year. Producers typically manufacture a line of resin grades for various markets. Most producers manufacture general-purpose type suspension resins for the calendering and/or extrusion of plasticized PVC products. There is some specialization in the production of other resin grades. The following table gives a breakdown of estimated 1978 PVC resin production by resin type. BFG35638 Chemical Economics Handbook - PT 00 cn o CJ in i December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 P D.S. PRODUCTION OF PVC HOMOPOLYMER AND COPOLYMER RESINS BY TYPE OF RESIN AND MAJOR PRODUCERS - 1978 Millions of Thousands of Type of Resin Pounds Metric Tans Major Producers Pipe Extrusion 2,300 1,043 Conoco Georgia-Pacific Diamond Shamrock BFGoodrich Shintech Tenneco General-Purpose 1,900 862 BFGoodrich Firestone Diamond Shamrock Borden Tenneco Dispersion 490 222 Firestone BFGoodrich Stauffer Diamond Shamrock Tenneco Goodyear Copolymer 430 195 Tenneco Borden Air Products Stauffer Solution (copolymer) 150 68 Union Carbide Other 480 218 (various) Total 5,750 2,608 a. Increased capacity due on stream by late 1979 or early 1980 will make Georgia-Pacific the largest domestic producer of PVC pipe extrusion resin. SOURCE: CEH estimates based on communication with industry. BFG35639 Chemical Economics Handbook - SRI International 0 05 CO N (0 in I i ! December 1979 * POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 Q 4.000 3.000 2.000 1,000 900 800 700 600 500 400 300 200 100 90 80 70 60 50 40 30 20 10 1955 1960 1965 1970 1975 1980 BFG35640 CO 07 07 2 ITT T December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 R CONSUMPTION Vinyl Chloride Vinyl chloride monomer is used almost entirely for the production of polyvinyl chloride homopolymer and copolymer resins. Industry sources variously apply a factor of 1.025 or 1.03 to pounds of PVC homopolymer resin produced to determine pounds of vinyl chloride monomer consumed. Using a factor of 1.025, the 1978 consumption of VCM breaks down as follows. Millions of Pounds Thousands of Metric Tans PVC Resins Exports Other Uses 5,965 899 100 2,706 408 45 Total 6,964 3,159 SOURCE: CEH estimates. The 100 million pounds for "Other Uses" represent a rough estimate of VCM used for vinylidene chloride copolymer containing less than 50% vinyl chloride, and other uses as a comonomer. Polyvinyl Chloride Resins Total consumption of PVC resins (exports included) in 1978 was 5.8 billion pounds, and it is expected to reach 6.1-6.2 billion pounds in 1979. All PVC resins are used in the production of plastic products and, to a relatively minor extent, in coatings. These PVC products are produced by a large number of fabricators, either from purchased PVC compounds (most merchant compounds are produced by PVC resin manufacturers in large, automated plants) or from compounds that the fabricators prepare themselves. In most cases, processing of the PVC compounds to the end products requires specially designed and capital-intensive operations.* This fact, and the very competitive nature of the PVC plastics business in most of its segments, explain the specialization by process of most PVC plastic producers. Rigid and semirigid (substantially unplasticized) PVC resin consumption is estimated to have totaled 3,050 million pounds (55%) in 1978, versus 2,520 million pounds (45%) for flexible (plasticized) products. Resin consumption for rigid applications has increased steadily over the last decade, primarily as a result of the continuous rise in PVC pipe production, the predominant rigid Detailed information on PVC compounding and processing may be found in the following sources: C. A. Brighton, "Vinyl Chloride Polymers, Compounding and Fabricating," Encyclopedia of Polymer Science and Technology, Volume 14, Intersci ence Publishers, New York, 1971, pp. 394-452; and J. M. McKelvey, Polymer Processing, John Wiley & Sons, Inc., New York, 1962. Chemical Economics Handbook - SRI International BFG35641 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 S PVC product. Other rigid extrusion has consumed much smaller, although increasing, amounts of PVC. Rigid calendering, the rigid portion of injection molding, compressionmolded sound records, blow molding, and solution coatings are the remaining rigid PVC categories. Flexible (plasticized) PVC consumption is mostly for calendered as well as dispersion coated fabrics, film and sheeting, and for extruded and injection-molded products. Per capita PVC consumption in some Western European countries, particularly in the Federal Republic of Germany, is considerably greater than in the United States. A major portion of this higher PVC usage is in rigid building products. European PVC consumption in transportation is also proportionately greater than in the United States. Total PVC consumption in Western Europe in 1978 is estimated to have been approximately 3.5 million metric tons (7.7 billion pounds), and Japanese PVC consumption was approximately one-third as large. For additional information on world PVC supply and demand and a breakdown of PVC production capacities by country, see the INTERNATIONAL section of this report. In the following subsections of this report, domestic PVC consumption is first analyzed by conversion process, and then is discussed by major end-use market. A. PVC Resin Consumption by Process of Conversion Estimated domestic PVC resin consumption by process of conversion is shown in the following table. ESTIMATED DOMESTIC CONSUMPTION OF PVC RESINS BY PROCESS OF CONVERSION - 1978 Millions of Pounds Thousands of Metric Tans Rigid Extrusion Flexible Extrusion Calendered Film and Sheet (flexible) Rigid Calendering Dispersion Processes Injection Molding Compression Molding Blow Molding Solution Coatings and Latex 2,390 850 805 85 615 330 210 90 195 1,084 386 365 39 279 150 95 41 88 Total 5,570 2,527 SOURCE: CEH estimates. Resin producers reporting sales cannot always determine the ultimate application of the resin in advance, however. Therefore, published statistics on PVC resin consumption by process of conversion always include the use of resin under such headings as "All Other Uses," although no conversion processes other than those listed in the preceding table exist. Nevertheless, the reported data are listed in the following paragraphs because they are useful for tracing historical trends in PVC resin consumption. BFG35642 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 T Published historical data on PVC resin consumption by major process of conversion are given below. DOMESTIC CONSUMPTION OF PVC RESINS BY PROCESS (millions of pounds) All Other Extrusion Calendering Dispersions2 Molding2 Solutions*5 Uses Total0 I960 230 392 89 70 39 83 903 1961 238 424 100 72 36 95 965 1962 272 490 105 78 45 121 1,111 1963 317 559 144 97 -- 206 1,323 1964 399 652 178 99 -- 249 1,577 1965 1966 1967 1968 1969 483 574 596 739 1,000 686 736 660 650 793 203 121 ___ 295 1,788 287 179 54 228 2,058 231 177 72 305 2,041 272 200 83 491 2,435 279 248 84 350 2,754 1970 1971 1972 1973 1974 1975 1976 1977 1978 1,095 1,295 2,052 2,298 2,214 1,777 2,380 2,883 3,254 705 835 963 913 809 591 700 664 667 281 415d 457d 459074dd 4Ud 453d 449,4ldd 254 309 410e 51 le 454e 334e 416e 468e 535e 85 90 118 142 150 123 171 177 209 376 2,796 281 3,225 180 4,181 224 4,586 283 4,414 216 3,452 247 4,366 327 4,993 411 5,567 (continued) Chemical Economics Handbook - SRI International BFG35643 in t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 U DOMESTIC CONSUMPTION OF PVC RESINS BY PROCESS (continued) _________________________ (thousands of metric tons)________________________ AllOther Extrusion Calendering Dispersions2 Molding2 Solutions** Uses Total I960 1961 1962 1963 1964 104 108 123 144 181 178 192 222 254 296 40 32 18 38 410 45 33 16 43 438 48 35 20 55 504 65 44 -- 93 600 81 45 -- 113 715 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 219 260 270 335 454 497 587 930 1,042 1,004 806 1,080 1,308 1,476 311 334 299 295 360 320 379 437 414 367 268 318 301 303 92 55 130 81 105 80 123 91 127 .112 -- 134 811 24 103 934 33 138 926 38 223 1,105 38 159 1,249 127 115 39 171 1,268 i88 140 41 127 1,463 207* 186 54 82 1,896 225 j 23 2e 64 102 2,080 229d 206e 68 128 2,002 2108S6dJ 152e 189 56 78 98 1,566 112 1,980 212e 80 148 2,265 223d 2436 95 186 2,525 See MANUAL OF CURRENT INDICATORS - SUPPLEMENTAL DATA for additional information. a. Terminology used by the U.S. International Trade Commission for these categories and their subcategories has been inconsistent over the years. Reported data were regrouped to permit this comparative organization. b. Reported as "Protective Coatings" and "Adhesives and All Other Coating Uses." Believed to include mostly resins for solutions but also some for dispersion coatings and powder coatings. c. Totals may not equal the sums of the categories due to rounding. d. Components: Coating - Flooring, and Textile and Paper Coating; Paste Processes Plastisol Formulation, and All Other. e. Components: Bottles (blow molding), Sound Records (compression molding), Fittings (for rigid pipe and tubing), and All Other Molding. SOURCES: (A) CEH estimates (components of some data for I960, 1961, and 1962 as detailed in subsequent tables). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (data for I960 through 1971). riVlPrniral PmTtnmi/r U BFG35644 CT>T T_ * - -a. ' m t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 V (continued) (C) Year-End Monthly or Annual Statistical Reports, Plastic and Resin Materials. The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst 8t Ernst (data for 1972-1978). Further breakdowns of these major process categories are given in the following paragraphs. 1. Extrusion. Domestic PVC resin consumption in extrusion is shown in the following table. U.S. CONSUMPTION OF PVC RESINS IN EXTRUSION (millions of pounds) Total as a Percent Rigid Pipe Wire and Film and All . of All and Tubing Cable Sheet Other* Total" PVC Consumption 1960 1961 1962 1963 1964 ---- -- 230 ---- -- 238 170 102 272 184 133 317 195 204 399 26% 25 24 24 25 1965 1966 1967 1968 1969 217 266 483 226 66 282 574 196 103 297 596 289 134 316 739 376 161 463 1,000 1970 409 194 492 1,095 1971 497 343 179 276 1,295 1972 1,008 439 220 384 2,052 1973 1,255 414 204 425 2,298 1974 1,245 348 220 401 2,214 1975 1,016 273 175 312 1,777 1976 1,418 330 254 378 2,380 1977 1,818 384 238 442 2,883 1978 2,099 400 255 500 3,254 27 28 29 30 36 36 40 49 50 50 52 55 58 58 (continued) BFG35645 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 W U.S. CONSUMPTION OF PVC RESINS IN EXTRUSION (continued) ______________________(thousands of metric tons)______________________ Total as a Percent Rigid Pipe Wire and Film and All of All and Tubing Cable Sheet Other Total0 PVC Consumption 1960 1961 1962 1963 1964 __ 104 ---- -- 108 77 46 123 83 60 144 88 93 181 26% 25 24 24 25 1965 1966 1967 1968 1969 98 121 219 103 30 128 260 89 47 135 270 131 61 143 335 171 73 210 454 27 28 29 30 36 1970 186 88 223 497 1971 225 156 81 125 587 1972 457 199 100 174 930 1973 569 188 93 193 1,042 1974 565 158 100 182 1,004 36 40 49 50 50 1975 461 124 79 142 806 1976 643 150 115 171 1,080 1977 825 174 108 200 1,308 1978 952 181 116 227 1,476 52 55 58 58 a. Includes all PVC resins consumed for pipe, conduit, tubing, and rod from 1966 to 1970, and all other rigid, semirigid, and flexible profile extrusions in all years. b. Totals may not equal the sums of the categories due to rounding. SOURCES: (A) CEH estimates (data for I960 and 1961). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (data for 1962-1971). (C) Year-End Monthly or Annual Statistical Reports, Plastic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (data for 19721978). The data show that the principal factor that drove PVC resin consumption in extrusion to current levels was pipe extrusion. a. Rigid Extrusions. The PVC resins most commonly used in rigid extrusions are suspension homopolymers of high bulk density, compounded in the form of so-called powder blends. (Postchlorinated homopolymers are also used in relatively small BFG35646 Chemical Economics Handbook - SRI International GO C/7 Co/I >1 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 X quantities). The resins and additives are blended to balance the required physical properties of the end product with ease and speed of processing. Aside from heat stabilizers, light stabilizers (for such products as siding), lubricants, and relatively small amounts of pigments,* impact modifiers (special acrylic and ABS polymers) are important. The bulk of PVC resin consumption in rigid extrusion is for pipe. Leading suppliers of PVC resins for pipe extrusion are listed in the table on p. 580.1882 Q. Most of these suppliers also offer powder blend compounds for pipe production. Extruded rigid PVC film and sheet** (using an estimated 35 million pounds of resin in 1978) were mostly for packaging (shrink and blister), for signs and display uses, and stationery supplies. Other rigid extrusions (using about 200 million pounds of resin in 1978) include mostly siding and window hardware. More information about each of these markets can be found in the appropriate end-use sections of this report. b. Flexible Extrusions. Approximately one-half of an estimated 850 million pounds of PVC resins consumed in flexible extrusions in 1978 (almost all general-purpose homopolymer resins) was used for wire and cable insulation (420 million pounds). The largest single product after wire and cable is clear film for meat packaging and stretch film (using about 240 million pounds of resin in 1978); other flexible extrusions include biomedical products, garden hose and other tubing, gaskets, some products used in construction, e.g., cove base, and a variety of specialty products that consume comparatively small amounts of resin. (See the Consumption By End Use section of this report for more information.) * See the CEH Marketing Research Report on TITANIUM DIOXIDE PIGMENTS for the consumption of that major pigment in rigid PVC extrusions. ** The term "film" is usually used for thicknesses under 6 mils (0.006 inch), whereas the term "sheet" applies to thicknesses greater than 6 mils. A good portion of so-called rigid PVC film and sheet is not strictly plasticizer-free but may contain up to 10% plasticizer, depending on the exact physical requirements in the end application. Chemical Economics Handbook - SRI International BFG35647 | December 1979 ! POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 2 U.S. CONSUMPTION OF FVC RESINS IN CALENDERING (continued) ______ (thousands of metric tons)______ Total as a Percent Film and of All Sheeting2 Flooring Textile^ Total PVC Consumption I960 1961 1962 1963 1964 105 108 111 129 149 6565dd 18 178 19 192 84 27 222 93 32 254 111 36 296 43% 44 44 42 41 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 152 163 145 146 196 173 215 252 249 244 171 201 155 167 119 135 120 111 122 112 124 151 132 84 67 75 78 69 41 311 36 334 34 299 39 295 41 360 34 320 39 379 34 437 33 414 39 367 29 268 41 318 69 301 66 302 39 36 32 27 29 25 26 23 20 18 17 16 13 12 a. Designated by the sources as "All Other Calendering." b. Data or 1960-1965 are estimates of the calender-coated portion of the total reported consumption for all paper and textile coating uses. Data for 1966-1970 are estimates of the calender-coated textiles portion of the reported con sumption in all calendering except flooring. c. Totals may not equal the sums of the categories due to rounding. d. Data for I960 and 1961 are estimates of the calendered portion of the total reported consumption for flooring, which was 156 million pounds (71 thousand metric tons) in I960 and 185 million pounds (84 thousand metric tons) in 1961. e. Data for 1966-1970 are estimates of the calendered film and sheeting portion of the reported consumption in all calendering except flooring. BFG35648 Chemical Economics Handbook - SRI International S T o e e s tz trr t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1882 Y 2. Calendering. Domestic PVC resin consumption in calendering is given in the following table. D.S. CONSUMPTION OF PVC RESINS IN CALENDERING (millions of pounds) Total as a Percent Film and of All Sheeting3 Flooring Textile Total PVC Consumption I960 1961 1962 1963 1964 .231 237 244 284 328 12lJ 145 d 186 205 244 40 392 42 424 60 490 70 559 80 652 43% 44 44 42 41 1965 1966 1967 1968 1969 334 359 320 321 433 262 297 265 244 270 90 686 80 736 75 660 85 650 90 793 1970 1971 1972 1973 1974 382 474 556 548 537 247 274 333 292 186 76 705 87 835 74 963 73 913 86 809 39 36 32 27 29 25 26 23 20 18 1975 378 148 65 591 17 K* 1976 444 165 91 700 16 1977 341 171 152 664 13 1978 367 153 146 667 12 (continued) Chemical Economics Handbook - SRI International BFG35649 -rT December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 A SOURCES: (A) Synthetic Organic Chemicals, U.S. Pro duction and Sales, U.S. Tariff Commission (FILM AND SHEETING data for 19601965 and 1971, FLOORING data for 19621971, TEXTILE datum for 1971, TOTAL data for 1960-1971, and data in footnote d). (B) Year-End Monthly or Annual Statistical Reports, Plastic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (data for 19721978). (C) CEH estimates (all other data in the table). Most PVC calendering (using an estimated total of 890 million pounds of resin in 1978) involves flexible film and sheeting of a great variety but substantially all based on generalpurpose homopolymers. The use of general-purpose copolymers (with relatively high molecular weight and low vinyl acetate content) has declined since less expensive homopoly mers with comparable ease of processing have been available for a number of years. Flexible calendered film and sheeting is used in many applications; the major markets are seating for furniture and for motor vehicles; in this use, the film is combined with a backing textile, either directly at the calender or in a separate laminating step. Most of the flexible calendered film and sheeting produced is combined with textiles to produce vinyl coated fabrics; the rest is used as so-called unsupported film and sheeting. PVC coated fabrics and film and sheeting are used in many other markets, mostly for home furnishings and consumer goods. Production of calendered film, sheet, and coated fabrics recovered in 1978 after a decline in 1977 when a flood of imported calendered goods from the Far East appeared on the U.S. market (for such uses as outerwear, footwear, handbags, inflatable toys, and other consumer goods). PVC resin consumption in calendered flooring in 1978 was about 170 million pounds. Of this amount, an estimated 70 million pounds were for vinyl-asbestos floor tile, and the balance was for plasticized roll goods. Rigid calendering consumed an estimated 90 million pounds of specialty resins, some of them copolymers. The principal end uses for calendered rigid PVC sheet are in packaging. There are probably about 130 PVC calenders in operation in the United States, most of them producing flexible film and sheeting, and flooring. The largest calender operators for general PVC film and sheet production include the following companies (listed in order of estimated production capacity and output). BFG35650 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 B The General Tire & Rubber Company Kalex Chemical Products, Inc. Uniroyal, Inc. Tenneco Chemicals, Inc. Borden Inc. Stauffer Chemical Company The Goodyear Tire & Rubber Company Diamond Shamrock Corporation The Pantasote Company of New York, Inc. Ford Motor Company Chrysler Corporation Intex Corporation Atlantic Tubing & Rubber Company Plymouth Rubber Company Firestone Plastics Company Hooker Chemical Corporation These companies account for about 100 calenders. General Tire is by far the largest, with at least 16 calenders. On the order of ten calenders are believed to be used for rigid products. Major producers of calendered rigid sheet include American Hoechst, Tenneco, Reneer (Division of Goodyear), Firestone, Pantasote, and Plicoflex. BFq3565 J Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 C 3. Dispersion. Dispersions of PVC resins in plasticizer, are fluid compounds called plastisols. (In a solvent-modified version, used infrequently, they are called organosols.) Dispersion resin consumption in the reported use categories is presented in the following table. U.S. CONSUMPTION OF PVC DISPERSION RESINS4 __________________ (millions of pounds)__________________ Plastisol Textile Total as a Percent Formulating and Molding and Paper Coating Flooring H of All Total0 PVC Consumption I960 1961 1962 1963 1964 30 30c 28 34C 39C 24 35 89 30 40 100 30 47 105 58 52 144 76 63 178 10% 10 9 11 11 1965 1966 1967 1968 1969 43 C 92 78 107 112 19313dd 101 108 101 69 203 62 287 52 231 57 272 66 279 11 14 11 11 10 1970 1971 1972 1973 1974 113 156 150 155 157 93 75 281 142 117 415 173 134 457 191 150 497 200 147 504 10 13 11 11 11 1975 1976 1977 1978 117 147 164 169 162 132 411 150 155 453 153 158 474 141 181 491 12 10 " 10 9 (continued) 24855020 BFG35652 Chemical Economics Handbook - SRI International December 1979 POLYVINYL. CHLORIDE RESINS Plastics and Resins 580.1883 D U.S. CONSUMPTION OF PVC DISPERSION RESINS2 (continued) _____________________(tlmnsands of metric tons)_____________________ Plastisol Textile Total as a Percent Formulating and Molding and Paper Coating Flooring of All Totalb PVC Consumption I960 1961 1962 1963 1964 14 14 13 C 15C 18C 11 14 14 26 34 16 40 18 45 21 48 24 65 29 81 10% 10 9 11 11 1965 1966 1967 1968 1969 Z0C 42 35 49 51 4610dd 31 92 28 130 11 14 46 26 123 11 49 26 123 11 46 30 127 10 1970 51 42 34 127 10 1971 71 64 53 188 13 1972 68 78 61 207 11 1973 70 87 68 225 11 1974 71 91 67 228 11 1975 53 73 60 186 12 1976 67 68 70 205 10 1977 74 69 72 215 10 1978 77 64 82 223 9 a. Includes predominantly the PVC dispersion resin content of plastisols, and also that of organosols (solvent-modified plastisols). To obtain estimates for the total PVC resin consumption in dispersions that include the use of blending resins, a factor of 1.15 should be applied. Latexes have not been included since 1974. An estimated 70 million pounds (32 thousand metric tons) of latexes, resin content, were consumed annually in recent years. b. Totals may not equal the sums of the categories due to rounding. c. Reported as used in slush molding (rotational molding or rotocasting). d. Includes 117 million pounds (53 thousand metric tons) of PVC resins reported for "Coating" and 16 million pounds (7 thousand metric tons) for unspecified "Other" textile and paper applications. e. Includes resins reported as used in "Plastisol Formulation," and those reported as used in "All Other Paste Processes." BFG35653 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 E SOURCES: (A) CEH estimates (all data for I960 and 1961; TEXTILE AND PAPER COATING data for 1962-1965). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (FLOORING and PLASHSOL FORMULATING AND MOLDING data for 19621971; TEXTILE AND PAPER COATING data for 19661971). (C) Year-End Monthly or Annual Statistical Reports, Plas tic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (all data for 1972-1978). An additional amount of so-called blending resin is consumed in these dispersions; typically, 80 parts of dispersion resin are blended with 20 parts of the (less expensive) blending resin. However, blending resins are not used in all applications of dispersion resins. Overall, a factor of 1.15 applied to dispersion resin consumption provides a useful approximation for the total resin consumption that includes blending resins. A luge part of the growth of dispersion resin consumption in the 1970s is attributable to the commercial success of coated types of vinyl flooring. -(Major producers are listed on p. 580.1883 P). Also, the production of plastisol-coated fabrics* for use in automobiles, furniture, garments, luggage, wall coverings, and a multitude of other items has shown consistent growth despite competition from calender-coated textiles. Most large coaters operate both calender and dispersion processes because technical factors usually dictate the use of one process or the other for a particular product. Processes include knife coating, reverse roll coating, casting (used for coated fabrics), rotational or slush molding (to make hollow objects such as beach balls), dipping (for gloves and tool handles), and hot spraying (thick protective coatings on metal objects such as tool housings). Casting ovens came into widespread use in the 1960s. Typically, a PVC dispersion is cast on release paper that may be embossed; it is fused, separated from the substrate, and in most cases, combined with a textile. Sometimes chemical blowing agents are employed to produce a cellular structure. Major producers of dispersion-coated fabrics include Borden Inc., The General Tire & Rubber Company, Pervel Industries (division of Bemis Company, Inc.), the BandelBradford Company, and Uniroyal, Inc. Most PVC dispersion resins are homopolymers, but some copolymers are used (most are prepared by the emulsion process). Blending resins (used in conjunction with dispersion resins to lower the cost and to adjust flow properties) are also mostly homopolymers, but they are produced by the suspension process. * Nonwoven webs, papers, and saturated felts are used as a substrate for specialty products. BFG35654 Chemical Economics Handbook - SRI International 720SS8frg in T December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 F In 1978, approximately 530 million pounds of dispersion resins are estimated to have been used in conjunction with about 85 million pounds of blending resins. In addition, a major portion of an estimated 70 million pounds of PVC latexes (resin content) consumed were used in conjunction with dispersion coating operations. This total consumption can be broken down as follows. CONSUMPTION OF PVC IN DISPERSIONS ____________AND LATEX - 1978____________ Millions of Thousands of Pounds, Metric Tons, Application PVC Resin PVC Resin Coated Fabrics Coated Flooring Molding, Dipping, and Other Carpet Backing, Synthetic Turf Backing, Gymnasium Floors Closures Protective Coatings 220 210 160 25 30 25 100 95 73 11 14 11 Total 670 304 SOURCE: CEH estimates. A major portion of the resin used for molding, dipping, for protective coatings, and smaller portions of some of the other categories went through formulator/compounders. Included in the coated fabrics category is the use of plastisols as tie-coats for laminating film to fabrics or other substrates; also included axe nonwoven fabrics, in which some latex may be involved. Some of this consumption may be reported by the SPI under *Adhesives and All Other Coating Uses." (See p. 580.1883 T of this report). Molding is mostly rotational molding and slush molding of hollow articles that include toys and novelties, recreational articles (such as beach balls, bicycle saddles, basket balls), a few automotive interior trim items (some headrests, armrests, and crash pad skins), and other specialty products. BfG35655 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 G 4. Molding. Reported domestic PVC resin consumption in the various molding processes is shown in the following table. U.S. CONSUMPTION OF PVC RESINS IN MOLDING __________________(millions of pounds)___________________ Total Sound Records Injection as a Percent (compression and Other Blow of All PVC molding) Molding Molding Total0 Consumption I960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 58 58 61 78 75 90 114 105 122 138 141 138 148 144 153 12 0 70 14 0 72 17 0 78 19 0 97 24 0 99 26 5 121 50 15 179 52 20 177 55 23 200 64 46 248 66 47 c 254 135 36C 309 185 77 410 280 87 511 227 74 454 8% 7 7 7 6 7 9 9 8 9 9 10 10 11 11 1975 1976 1977 1978 129 150 175 211 145 60 334 187 78 416 219 75 468 230 94 535 10 10 9 10 (continued) BFG35656 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 H U.S. CONSUMPTION OF PVC RESINS IN MOLDING (continued) (thousands of metric tons)_______________________________________ Total Sound Records Injection as a Percent (compression and Other Blow . of All PVC molding) Molding Molding Total Consumption 1960 1961 1962 1963 1964 26 26 28 35 34 5 0 32 8% 6 0 33 7 8 0 35 7 9 0 44 7 11 0 45 6 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 41 52 48 55 63 64 63 67 65 69 12 2 55 23 7 81 24 9 80 25 10 91 29 21 112 7 9 9 8 9 30 21C 115 9 61 16c 140 10 84 35 186 10 127 39 232 11 103 34 206 11 1975 1976 1977 1978 59 68 79 96 66 27 152 10 85 35 189 10 99 34 212 9 104 43 243 10 a. Includes injection-molded fittings for rigid pipe and tubing, reported to have consumed 117 million pounds (53 thousand metric tons) of resin in 1978, and "All Other Moldings," 113 million pounds (51 thousand metric tons) in 1978. b. Totals may not equal the sums of the categories due to rounding. c. It is widely believed that actual consumption in blow molding in 1970 and 1971 was considerably higher. Estimates for PVC resin consump tion in blow molded bottles are on the order of 70 million pounds (32 thousand metric tons) in both years. SOURCES: (A) CEH estimates (all data for I960 and 1961; data for INJECTION AND OTHER MOLDING, 1962-1970; data for BLOW MOLDING, 1965-1970; and estimate in footnote c). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S Tariff Commission (all other data for 1962-1971). bG35^ Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 I (C) Year-End Monthly or Annual Statistical Reports, Plastic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (data for 19721978 and data in footnote a). a. Compression Molding. The principal component is the reported consumption of resins for phonograph records, which require special acetate copolymer resins. This resin consumption for phonograph records has always been a separate reporting category, but other compression molding is believed reported together with other consumption under "All Other Molding." Strictly speaking, there is no compression molding of PVC other than sound records, but there is resin consumption for some press-molded articles that are plasticized. Although very low pressure is involved in the molding of, for example, automobile vinyl floor mats, or kitchen drainboards (in most cases the compound is injected into the mold), some of this production can be called compression molding. b. Injection Molding. The principal component is consumption for pipe fittings. Injection molding of PVC resin for rigid and plasticized products other than pipe fittings is estimated to have consumed 210 million pounds of resin in 1978. Typical products (in addition to those mentioned under Compression Molding) include electri cal outlet boxes (rigid), electrical outlet plugs, filler strips and other parts for automobile bumpers, automobile rearview mirror housings, window winder knobs, bicycle grips, toys, shoe soles and heels (unit soles), and a variety of parts for business machines and electrical and electronic uses. Typically, injection molders buy pelletized compound. PVC compounds for injection molding are made and sold by such companies as BFGoodrich, Schulman Manufactur ing, and Firestone Plastics. c. Blow Molding. This sophisticated technology was developed in the 1960s and is used for the production of containers. The bulk of the polymer used is high-density polyethylene; PVC consumption is relatively small and is mostly for bottles of chemicals and pharmaceuticals. BFG35658 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 J 5. Coatings and Adhesives. Data on PVC resin consumption in coatings and adhesives in recent years are given in the following table. U.S. CONSUMPTION OF PVC RESINS IN COATINGS AND ADHESIVES*_________ Total as a Percent Millions of Thousands of of All PVC Pounds Metric Tans Consumption I960 1961 1962 1963 1964 39 36 45 50 50 18 16 20 23 23 4% 4 4 4 3 1965 1966 1967 1968 1969 50 54 72 83 84 23 24 33 38 38 3 3 4 3 3 1970 1971 1972 1973 1974 85 90 118 142 150 39 41 54 64 68 3 3 3 3 3 1975 1976 1977 1978 123 171 177 209 56 78 80 95 4 4 4 4 a. Reported by the sources as "Protective Coatings and Adhesives" in 1960-1962 and 1966-1971 and as "Protective Coatings" (123 million pounds (58 thousand metric tons) in 1978) and "Adhesives and All Other Coating Uses" (86 million pounds (39 thousand metric tons) in 1978) since 1972. SOURCES: (A) Synthetic Organic Chemicals, U.S. Production and Sales. U.S. Tariff Commission (data for 1960-1962 and 1966-1971). (B) CEH estimates (data for 1963-1965). (C) Year-End Monthly or Annual Statistical Reports, Plastic and Resin Materials. The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (data for 19721978). Chemical Economics Handbook - SRI International BFG35659 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 K This consumption has been reported as "Protective Coatings and Adhesives" and recently was in a category called "Adhesives and All Other Coating Uses." A major portion of this consumption has been in applications in which the resin is dissolved (about 90 million pounds in 1978); dispersion resins, powder coating resins, and latex probably account for most of the balance: Solution-grade resins are produced mostly by solution polymerization (Union Carbide), and most are vinyl chloride-vinyl acetate copolymers with vinyl acetate content of 812%. One type often used in adhesives is modified to contain a certain amount of free carboxyl groups, and another type frequently used in protective coatings contains free hydroxyl groups. Other acetate copolymers are used, often in admixture with acrylic resins, for rotogravure printing inks and topcoatings on vinyl film and sheeting. Can coatings and other packaging applications are also important markets. Adhesives based on or containing PVC copolymer resins are used in a variety of specialized industrial applications. Typical solvents used in the solutions are cyclohexa none, tetrahydrofuran, methyl ethyl ketone, and diisobutyl ketone; however, some of the resins tolerate the presence of minor quantities of aromatic hydrocarbon diluents. (For more information on the use of PVC resins in coatings, see the CEH Marketing Research Report on VINYL SURFACE COATINGS). Resin consumption for PVC powder coatings does not amount to more than 5 million pounds per year. 24855024 BFG35660 Chemical Economics Handbook - SRI International in' t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 L 6. All Other Uses. This category accounts mostly for resins sold to distributors and to compounders with an end use undetermined when the resin is sold. The category serves largely to balance statistics (i.e., the bulk reported under this heading actually belongs in the individual process category previously discussed). The following table presents the reported data with pertinent commentary in the footnotes. U.S. CONSUMPTION OF FVC RESINS IN ALL OTHER USES Millions of Thousands of Pounds Metric Tans I960 1961 1962 1963 1964 1965 1966 1967 1968 1969 83a 19251bb 206 C 249C 295 C 228 305 491 350 38a 43b 55b 931 113 134C 103 138 223 159 1970 1971 1972 1973 1974 376 281 180 224 283 171 127 82 102 128 1975 1976 1977 1978 216 247 327 411d 98 112 114886dd a. The actual figures reported for I960 and 1961 were 113 million pounds (51 thousand metric tons) and 125 million pounds (57 thousand metric tons), respectively. An estimated 30 million pounds (14 thousand metric tons) of resins used in commercial plastisols were subtracted in each year and added to the table an U.S. consumption of PVC dispersion resins (pp. 580.1883 C-D). b. The 161 million pounds (73 thousand metric tons) reported by the source include an estimated 40 million pounds (18 thousand metric tons) of exports (included in the U.S. TRADE section of this report). c. Believed to include about 50 million pounds (23 thousand metric tons) per year used in protective coatings and adhesives in 1963, 1964, and 1965). d. Consists of 89 million pounds (40 thousand metric tons) reported under "Resellers" and 322 million pounds (146 thousand metric tons) reported as "All Other Uses." BFG356o Chemical Economics Handbook - SRI International in t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 M SOURCES: (A) CEH estimates (data for 1960-1962 and estimates in the footnotes). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (data for 1963-1971). (C) Year-End Monthly or Annual Statistical Reports, Plastic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (data for 19721978). PVC resin consumption in some specialty uses may not have been covered by the main process categories. ` B. Consumption by End Use A breakdown of domestic PVC resin consumption by major market category is given in the following table. ESTIMATED DOMESTIC CONSUMPTION OF PVC RESINS - 1978 Millions of Thousands of Pounds Metric Tons Construction Consumer Goods Electrical Uses Packaging Transportation Home Furnishings Miscellaneous Uses 3,000 710 510 460 280 220 390 1,361 322 231 209 127 100 177 Total 5,570 2,527 SOURCE: CEH estimates. The individual categories are discussed in the following paragraphs. BFG35662 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 N 1. Construction. Estimated PVC resin consumption in construction is listed below. ESTIMATED CONSUMPTION OF PVC IN CONSTRUCTION - 1978 Millions of Thousands of Pounds Metric Tans Pipe and Conduit Pipe Fittings Siding, Window Hardware, and Other Rigid Profiles Flooring Wall Coverings and Paneling Pool and Pond Lining Other 2,160 120 200 375 80 30 35 980 54 91 170 36 14 16 Total 3,000 1,361 SOURCE: CEH estimates. a. Pipe, Conduit, and Pipe Fittings. The data in the preceding table indicate that 39% of the total PVC resin consumption is for pipe, conduit, and pipe fittings. The data represent PVC resin shipped to pipe producers, not actual pipe shipped or installed. Massive federal funding of rural water projects and HUD support of plastic pipe use in the early 1970s were principal factors in the phenomenal growth of PVC pipe markets in the last decade. is# It is estimated that PVC has 70-80% of the current total plastic pipe and conduit business on a poundage basis. A breakdown of the PVC pipe and conduit market is as follows. ESTIMATED PVC CONSUMPTION IN PIPE AND CONDUIT - 1978 Millions qf Thousands of Pounds Metric Tans Water-Supply Pipe Sewer and Drain Pipe Electrical and Telephone Conduit Drain, Waste, and Vent Pipe Agricultural and Turf Irrigation Other Pipe 740 350 310 250 200 120 336 159 141 113 91 54 Total 1,970 894 SOURCE: CEH estimates. >e data represent the PVC content of (salable) pipe shipped. The content of pipe and conduit varies from about 80% for some types of conduit to 95% or more for most pressure pipe, overall, the resin content can be considered to be about 90% by weight. Chemical Economics Handbook - SRI International b?G35663 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 O The penetration of pipe markets by plastic pipe (on the basis of economics and performance properties) varies greatly. For water-supply pipe the penetration is estimated to be less than 50% overall, and considerable growth potential for PVC is seen in the municipal water pipe market. However, the fastest growing segment for PVC pipe in the last three years has been sewer pipe, which is expected to lead future demand growth for PVC pipe. Resin consumption for conduit (which includes conduit for power cables and electrical wiring, and for communication wiring) also has increased markedly in the last few years. The drain, waste, and vent (DWV) segment, which PVC shares with ABS at a roughly 50:50 ratio, is more than 50% penetrated and has shown relatively little demand increase for PVC in the recent past. Similarly, at least 50% of the agricultural and turf irrigation pipe is believed to be plastic (with PVC the predominant plastic pipe used). Other pipe markets of commercial significance include natural gas distribution pipe (predominantly polyethylene), with an estimated penetration by plastic of 40-50%, water distribution (inside the house, with minimal penetration by plastic), oil production pipe, and chemical process pipe (for which plastics are heavily used). The leading multiplant producers of PVC pipe and conduit include the following companies (listed by estimated pipe extrusion capacity and output). Robintech Incorporated Johns-Manville Corporation Certain-Teed Corporation Indian Head, Inc., CarIon Division Harsco Corporation, Cantex Division Robintech is believed to process 300-400 million pounds of PVC pipe resin annually. Other smaller extruders of PVC pipe include Gifford-Hill & Company, Inc., Western Plastics Corporation (Tacoma), Celanese Piping Systems Division of Celanese Corpo ration, and Clow Corporation. There is also a large number of smaller single-plant producers.* R. & G. Sloane Manufacturing Company, Inc., is the leading producer of fittings for PVC pipe and conduit. b. Siding, Window Hardware, and Other Rigid Profiles. The major portion of this consumption, an estimated 150 million pounds in 1978, is for siding. PVC siding is now cost-competitive with aluminum siding. That, as well as quality improvements, have resulted in strong demand for PVC siding in 1978 and 1979* Distributors of aluminum siding now typically carry a complete line of PVC siding as well; Alcoa has become a producer of PVC siding (major producers of PVC siding are Bird & Son, Inc., Certain-Teed Corporation, and Mastic Corporation). In the past, most PVC siding was sold in the replacement (remodeling) market and for mobile homes, but recently its use in new residential construction has become more widespread. An estimated 45 million pounds of PVC were used for windows and window hardware in 1978. PVC consumption in window frames is still mostly for vinyl-clad wood; vinyl is extruded directly over a wood core of the sash, while corner joints are given a welded Listings of all producers of approved PVC and other pipe are in the directory of the National Sanitation Foundation Testing Laboratory, Inc., Ann Arbor, Michigan. Chemical Economics Handbook - SRI International BFG35664 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 P seal af ter assembly. In another method, rigid PVC extrusions are attached to wooden ' frames with adhesives. All-vinyl windows are still at the infancy stage. Rigid profiles other than window frames are spline for storm windows and doors, rigid weather stripping, and molding. Some gutter and rigid profile sheet are also included in this market segment, as are shutters thermoformed from extruded sheet. c. Flooring. Coated PVC flooring (typically with a saturated felt base and intermediate layers that are sometimes cellular in structure) is still the leading product category and is estimated to have consumed 210 million pounds of dispersion and blending resins in 1978. Calendered vinyl flooring has been holding its position (these products are typically calendered with copolymer resins that are highly filled); the 1978 resin use is estimated at about 170 million pounds. Leading producers of vinyl flooring include the following companies. Armstrong Cork Company Congoleum Industries Inc. GAF Corporation Kentile Floors Inc. Mannington Mills Inc. National Floor Products Company, Inc. Vinyl Plastics Inc. In contrast to the declining vinyl flooring market of the 1960s, the industry has been characterized by growth since that time as a result of attractive new products. The large replacement market is believed to be growing more than the new construction market as the remolding of older homes gains importance in the face of soaring building costs. I ' d. Other Uses in Building and Construction. PVC wall coverings (actually a consumer product in the sense that they are in the replacement market as much as in new construction) are mostly coated fabrics (predominantly sheetings and sateens) with film thickness of 5-20 mils; some constructions use nonwoven webs as a substrate. An estimated 55 million pounds of PVC were used for these products in 1978. About two-thirds are calendered, the balance dispersion coated. In addition, there is paneling, consisting of particle board or gypsum board to which a rigid or flexible vinyl film (typically painted with a wood-grain pattern) is laminated. In 1978, an estimated 25 million pounds of PVC went into these products, which are not all used for wall paneling but are also used for furniture and other case goods such as speaker cabinets and for the interiors of recreational vehicles. Also included in this category is PVC sheet for swimming pool liners and for the lining of water settling ponds and reservoirs. Other inclusions are resins used for some extruded products such as cove base and for some rigid PVC products used in industrial ducting and fan impellers and housings. Chemical Economics Handbook - SRI International BFG35665 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 Q 2. Consumer Goods. This large market is highly diversified. An attempted breakdown is given in the table below. ESTIMATED CONSUMPTION OF PVC RESIN IN CONSUMER GOODS - 1978 Millions of Thousands of Pounds Metric Tans Sound Records Footwear, Handbags, Purses, and Similar Articles; Bookbinding; Toys and Recreational Articles; Kitchenware and Appliances; Consumer Electronics; Luggage; Garden Hose Other (e.g., beauty supplies, novelties, stationery articles, window shades, waterbeds, tool handles, bicycle grips, wigs, plastic Christmas trees) 210 400 100 95 181 45 Total 710 322* a. Total does not equal sum of categories due to rounding. SOURCES: CEH estimates. The largest single segment, sound records, requires special polyvinyl chloride-acetate copolymers for compression molding. This market was rather static for a long time, but it surged in 1978 as a result of several events (among them the death of singer Elvis Presley and also as a result of several highly successful new releases). While the level of resin use for records dropped in 1979, industry observers expect a pattern of fluctuating demand around the 200 million pound-per-year level in the next few years. In spite of skyrocketing costs for recordings, new pressing facilities are in the installation and planning stage. The next largest single market of this category is probably footwear, which includes coated fabrics (for uppers and linings), calendered or extruded soling, and injectionmolded soles and heels for sneakers and other shoewear. Also included are injectionmolded boots. PVC resin use for this market is believed to total somewhat over 100 million pounds, but it fluctuates from year to year depending on fashion trends. Also included are coated fabrics and film and sheeting for such diverse uses as handbags and purses, toys and recreational articles (mostly cases or bags, e.g., for golf clubs, rifles, backpacks, and camping gear), for luggage, kitchenware and appliances (gaskets), and garden hose. BFG35666 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 R 3. Electrical Uses. Total PVC consumption in 1978 for electrical uses is estimated to have been 510 million pounds. Wire and cable insulation, the predominant use, consumed 420 million pounds. This market can be subdivided roughly as follows. ESTIMATED BREAKDOWN OF PVC CONSUMPTION IN WIRE AND CABLE - 1978 Building Wire and Power Cables Communication and Signal Wire Flexible Cord (for household lamps, extension cords) Automotive Electrical Wire and Other Auto Uses Appliance Wire Total 50% 20 12 10 8 100% SOURCE: Communication with industry. PVC shares the wire and cable market with several other plastics and elastomers. Polyolefins are better electrical insulators, but PVC is a better jacketing material when resistance to flexing is required in a wire or cable. The largest Use of PVC in wire and cable is in the low-voltage field (500V and below), in which building wire accounts for a large portion. PVC jacketing, usually black, is common on 1-5 kV unshielded distribution cable for industrial use and in low-voltage city networks, as well as on cables for the 10-35 kV range that are used by utilities in underground power distribution. PVC resins used for wire and cable are of slightly higher molecular weight than calender-grade resins but are sold as general-purpose resins. Wire and cable extruders use large amounts of compound (pelletized) as well as resin (for their own compound ing). The largest suppliers of PVC compounds for wire and cable are BFGoodrich, Firestone, and Tenneco. The largest wire and cable extruders are listed below. COMPANY PLANT LOCATION Aluminum Company of America Marshall, Texas Massena, New York The Anaconda Company Anaconda Wire & Cable Co., subsidiary Marian, Indiana Orange, California Sycamore, Illinois Watkinsville, Georgia Belden Corporation Richmond, Indiana Essex International Inc. (subsidiary of United Technologies Corporation) Marion, Indiana Paducah, Kentucky Chemical Economics Handbook - SRI International BFG35667 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 S (continued) General Cable Corporation Elkton, Maryland Pownal, Virginia Kaiser Aluminum & Chemical Corporation Electrical Products Division Pawtucket, Rhode Island San Leandro, California Reynolds Metals Company Chester, Pennsylvania Western Electric Company Atlanta, Georgia Baltimore, Maryland Buffalo, New York Omaha, Nebraska Phoenix, Arizona Of these, Essex International and Western Electric alone are believed to consume as much as half of all PVC resins used for wire and cable extrusion. Other large consumers in this field include Packard Electric Division of General Motors Corporation (Warren, Ohio) and Prestolite Division of Eltra Corporation (Port Huron, Michigan, and Hazelton, Pennsylvania), both producers of automotive wire and cable products. Outside of wire and cable insulation, about 20 million pounds of PVC were used in rigid injection molding for electical outlet boxes and, to a minor extent, for some other items in the electronics field. An estimated 70 million pounds were used for outlet plugs and for wire connectors. PVC consumption for electrical tape is not included here. 4. Packaging. A breakdown of PVC resin consumption in packaging is given in the following table. ESTIMATED PVC RESIN CONSUMPTION IN PACKAGING - 1978 Millions of Thousands of Pounds Metric Tans Plasticized Clear Film Bottles Rigid Sheet (blister and trays) Coatings Closures Total 235 90 90 15 30 460 107 41 41 7 14 209* a. Total does not equal sum of categories due to rounding. SOURCE: CEH estimates. Of the extrusion-blown plasticized clear film, about 150 million pounds were for meat wrap, and the balance was mostly for stretch film. The Resinite Division of Borden Inc. BFG35668 Chemical Economics Handbook - SRI International 24855028 ; December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 T is the largest producer, followed by The Goodyear Tire & Rubber Company. Rigid sheet (of which about 60 million pounds were calendered and the balance extruded) is mostly for blister-packaging and shrink-packaging of hardware; lesser quantities are used for processed meats and for pharmaceuticals, for trays or boxes for candy, and for greeting cards. An example of a food packaging film composite employing PVC is a laminate of Sairan-coated polyethylene film and PVC. Also, laminates of PVC and Saran films are used. Such combinations provide both the barrier properties and processing characteris tics (e.g., for heat sealing) needed. Closures involve plasticized bottle cap and jar lid linings based on dispersion resins. Resin consumption for coatings is for can coatings. 5. Transportation. An estimated breakdown for 1978 consumption in the transportation market is given below. ESTIMATED PVC RESIN CONSUMPTION IN TRANSPORTATION - 1978 Millions of Thousands of Pounds Metric Tans Passenger Car Seating and Interior Trim (including trunk lining) Seating and Accessories for Trucks, Buses, and Other Vehicles (e.g., campers, mass transit, snowmobiles) Auto Floormats Auto Tops and Exterior Trim Bumper Strips, Bumper Guards, Window Winder Knobs, and Other Items Other Total 135 30 25 25 20 45 280 61 14 11 11 '9 20 127a a. Total does not equal sum of categories due to rounding. SOURCE: CEH estimates. Most of this consumption is in the form of coated fabrics (about three-fourths of these are calender-coated, and the balance is dispersion coated). Floor mats are molded from extruded sheet or injection molded; such items as bumper guards, window winder knobs, and rearview mirror housings are typically injection molded. The resin consumption listed under "Other" is for such items as air filter incaps, battery separators, and other items. This market has not grown for PVC, overall, in the last two years. Principal factors are the trend toward smaller cars, the increasing use of fabrics instead of vinyl for seating, and the loss of the vinyl headliner to the rigid molded snap-in headliner on most GM cars. Chemical Economics Handbook - SRI International BFG3566* urt December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 U 6. Home Furnishings. An estimated breakdown of this market is given in the following table. ESTIMATED CONSUMPTION OF PVC IN HOME FURNISHINGS - 1978 Millions of Thousands of Pounds Metric Tons Furniture Upholstery Shower Curtains Adhesive-Backed Film Tablecloths and Placemats 150 10 10 50 68 5 5 23 Total 220 iooa a. Total does not equal sum of categories due to rounding. SOURCE: CEH estimates. Most of the products listed are made from calender-coated fabrics and, to a lesser extent, dispersion-coated fabrics and unsupported film. Vinyl furniture upholstery, the largest single end use of this category, has declined somewhat in the last two years as upholstery fabrics have become less expensive relative to vinyl. Also, polypropylene upholstery fabrics have taken an increasing share of this market. 7. Miscellaneous Uses. A total of 390 million pounds of PVC is estimated to have been used in miscellaneous applications in 1978. About 180 million pounds of this were for coatings and adhesives. Included are an estimated 75 million pounds of resin for highperformance protective coatings (based on special copolymers) for ships, and for industrial, military, and farm equipment; and topcoatings and inks (often in admixture with acrylic resins) for coated fabrics and sheeting. Solvent-based adhesives containing these PVC copolymers in conjunction with other resins are used in the manufacture of leather goods and simulated leather goods including luggage, shoes, handbags, and purses; and in the assembly of toys, novelties, and swimming pool liners. About 35 million pounds of noncoating specialty applications of these same types of soluble resins are also included, as are resins for powder coatings (less than 5 million pounds). Some plastisols and an estimated 70 million pounds (dry basis) of latex are also included, the main use of which is for coated fabrics; some dipped products are also included. Other uses for PVC in this category are for medical tubing, blood bags, and for other hospital and health care uses; credit card stock (rigid sheet); and flooring applications such as carpet and synthetic turf backing. 24855029 BFG35670 Chemical Economics Handbook - SRI International trr t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 V PRICE AND UNIT SALES VALUE Vinyl Chloride A history of vinyl chloride prices and unit sales values is given in the following table. U.S VINYL CHLORIDE MONOMER PRICE AND UNIT SALES VALUE Price* Unit Sales Value Cents per Cents per Cents per Cents per Pound Kilogram Pound Kilogram 1955 10.5 23 10 22 1956 11 24 11 24 1957 11 24 11 24 1958 11 24 11 24 1959 12.5 28 11 24 I960 12.5 28 10 22 1961 7.5 17 8 18 1962 8 18 7 15 1963 8 18 7 15 1964 8 18 6 13 1965 1966 1967 1968 1969 8 8 8 8 4.75 18 18 18 18 11 6 13 6 13 5 11 5 11 49 1970 1971 1972 1973 1974 4.75 4.75 4.75 5 7-10 11 11 11 11 15-22 4 4 4 4 8 9 9 9 9 18 1975 1976 1977 1978 1979 9-12 12-13 14.5-15 13.4-14.5 15.2 20-26 26-29 32-33 30-32 34 10 10 12 -- -- 22 22 26 -- -- a. Midyear list prices. Price bases are: 1955 1956-1960 1961-1968 1969-1972 1973-1979 Tanks, freight equalized Tanks, works Tanks, works, minimum freight allowed East Polymer grade, tanks, works, freightequalized East Polymer grade, tanks, f.o.b. works. SOURCES: (A) Chemical Marketing Reporter (PRICE data). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. International Trade Commission (formerly U.S. Tariff Commission) (UNIT SALES VALUE data). Chemical Economics Handbook - SRI International BFG356'7^ December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 W Vinyl chloride monomer prices do not fluctuate nearly as much as do polyvinyl chloride resin prices because most of the monomer is sold on long-term contracts. As of September 14, 1979, the list price for vinyl chloride was 17.2 cents per pound (tanks, f.o.b. works). Polyvinyl Chloride Resins As of October 1, 1979, PVC resin prices were generally as follows. RESIN TYPE PRICE Cents per Cents per Pound Kilogram General-Purpose Suspension Homopolymer: Calender and Extrusion Grades Pipe Resin Specialty Homopolymers Suspension Copolymers (flooring and record grades) Dispersion Resins Blending Resins 35a 34a 41a 39-40a 50 41b 77a 75a 90a 86-8a 110 90 a. Bulk price (bulk hopper rail cars), f.o.b. producing location, freight allowed. b. Bagged, truckload, carload, f.o.b. producing location, freight allowed. SOURCE: Communication with industry. BFG35672 Chemical Economics Handbook - SRI International C>q( U\ c. t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 X A history of domestic PVC resin prices and reported unit sales value is given in the following table. U.S. POLYVINYL CHLORIDE RESINS PRICE AND UNIT SALES VALUE Price General Purpose _______ Dispersion_______ Unit Sales Value Cents per Cents per Cents per Cents per Cents per Cents per Pound Kilogram Pound Kilogram Pound Kilogram 1955 1956 1957 1958 1959 31 27 27 23.5 23.5 68 60 60 52 52 34 30 30 26.5 26.5 75 66 66 58 58 34 75 31 68 29 64 ---- 25 55 I960 18.5 41 24 53 23 51 1961 16 35 24 53 19 42 1962 16 35 24 53 18 40 1963 16 35 24 53 18 40 1964 16 35 24 53 17 37 1965 16 35 24 53 17 37 1966 14 31 20-22 44-49 17 37 1967 13.5 30 20-22 44-49 16 35 1968 10 22 18-19 40-42 14 31 1969 11 24 18-19 40-42 14 31 1970 1971 1972 1973 1974 11.5 14.5 14 15.5 20 25 18-19 40-42 13 32 19-20 42-44 13 31 19-20 42-44 13 34 24-26 53-57 15 44 34 75 23 29 29 29 33 51 1975 24 53 35 77 24 53 1976 27.5 61 39 86 26 57 1977 28.5 63 39 86 26 57 1978 29 64 41 95 ---- a. Prices are those in effect at the end of each year and are for truckload quantities of material packed in 50-pound bags, minimum transportation allowed or prepaid. SOURCES: (A) Communication with industry (PRICE data). (B) Synthetic Organic Chemicals. U.S. Production and Sales, U.S. Interna tional Trade Commission (formerly U.S. Tariff Commission) (UNIT SALES VALUE data). Chemical Economics Handbook - SRI International BFG3567 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 Y U.S. TRADE Vinyl Chloride A. Imports Data on U.S. imports of vinyl chloride are reported by the U.S. Department of Commerce, Bureau of the Census under import code # 429.4400. U.S. imports of vinyl chloride were negligible from 1964 through 1967. Since 1968, they have been less than 5 million pounds per year. The import rate of duty an vinyl chloride prior to 1968 was 2.5 cents per pound (5.5 cents per kilogram) plus 12.5% ad valorem. As a result of the Kennedy Round Agreements, the duty was decreased in stages to 1.25 cents per pound (2.8 cents per kilogram) plus 6% ad valorem as of January 1, 1972 (Tariff Schedules of the United States Annotated (1976), USITC Publication 749, U.S. International Trade Commission). B. Exports Data an U.S. exports of vinyl chloride as reported by the U.S. Depatment of Commerce are presented in the following table. U.S. EXPORTS OF VINYL CHLORIDE* Millions of Thousands of Pounds Metric Tons 1970 1971 1972 1973 1974 664 620 621 420 412 301 281 282 191 187 1975 1976 1977 1978 415 188 641 291 423 192 899 408 See MANUAL OF CURRENT INDICATORS SUPPLEMENTAL DATA for additional information. a. Data were reported in the source under export code # 512.0978 though 1977, and under export code # 511.3100 in 1978. SOURCE: U.S. Exports, FT 410, U.S. Department of Commerce, Bureau of the Census. According to industry sources, VCM exports in 1977 actually are believed to have been 466 million pounds. Exports of VCM through July 31, 1979, were 633 million pounds (287 thousand metric tons). TC0SS8f-Z BFG35674 Chemical Economics Handbook - SRI International in t t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1883 Z Data an U.S. exports by country of destination in 1978 are shown in the following table. Country of Destination Taiwan Yugoslavia Mexico Canada Brazil Korea Australia Colombia Nicaragua Other Totalb U.S. EXPORTS OF VINYL CHLORIDE - 1978a Quantity___________ Value _______ Unit Value Millions of Pounds Thousands of Metric Tons (millions of of dollars) Cents per Pound Cents per Kilogram 153.8 121.9 110.9 104.4 99.7 97.6 68.7 59.5 39.1 43.3 898.9 69.8 55.3 50.3 47.4 45.2 44.3 31.2 27.0 17.7 19.6 407.7 16.0 13.6 15.5 14.2 13.6 11.1 7.7 7.6 5.1 5.8 110.2 10.4 11.2 14.0 13.6 13.7 11.4 11.2 12.8 13.1 13.4 12.3 23.0 24.6 30.8 29.9 30.2 25.0 24.7 28.2 28.9 29.5 27.0 a. Data are reported in the source under export code # 511.3100. b. Totals may not equal sums of categories due to rounding. SOURCE: U.S. Exports, FT 410, U.S. Department of Commerce, Bureau of the Census. Chemical Economics Handbook - BFG35675 -- ITT T December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 A Polyvinyl Chloride Resins A. Imports Data on U.S. imports of polyvinyl chloride resins as reported by the U.S. Department of Commerce are presented in the following table. U.S. IMPORTS OF POLYVINYL CHLORIDE RESINSa Millions of Thousands of Pounds Metric Tons 1964 5 2 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 7 9 14 17 6 6 4 4 65 124 3 4 6 8 3 3 2 2 29 56 1975 1976 1977 1978p 27 52 37 45 12 24 17 20 See MANUAL OF CURRENT INDICATORS - SUPPLEMENTAL DATA for additional information. a. Data are reported in the source under import code # 445.4520. SOURCES: (A) U.S. Imports, FT 246, U.S. Department of Commerce, Bureau of the Census (data for 1964-1977). (B) U.S. Imports for Consumption, IM 146, U.S. Department of Commerce, Bu reau of the Census (data for 1978). Polyvinyl chloride imports for the first seven months of 1979 totaled just over 25 million pounds (11 thousand metric tons). BFG35676 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 B Data on U.S. imports by country of origin in 1978 are given in the following table. Country of Origin U.S. IMPORTS OF POLYVINYL CHLORIDE RESINS - 1978a Quantity Millions of Thousands of Pounds Metric Tans Value (millions of dollars) Unit Value Cents per Cents per Pound Kilogram Canada Mexico Federal Republic of Germany Japan Italy Other Total*1 1Z.7 9.2 5.6 5.3 5.Z 6.7 44.7 5.8 4.2 Z.5 Z.4 Z.4 3.0 Z0.3 3.6 Z.O 1.4 Z.2 1.2 1.6 12.1 28.6 21.6 25.8 40.7 23.8 Z4.0 27.0 63.1 47.5 56.9 89.7 52.6 52.9 59.5 a. Data are reported in the source under import code # 445.45Z0. b. Totals may not equal sums of categories due to rounding. SOURCE: U.S. Imports for Consumption, IM 146, U.S. Department of Commerce, Bureau of the Census. The import rate of duty on polyvinyl chloride resins prior to 1968 was 2.5 cents per pound (5.5 cents per kilogram) plus 12.5% ad valorem. As a result of the Kennedy Round Agreements, the duty was decreased in stages to 1.Z5 cents per pound (2.8 cents per kilogram) plus 6% ad valorem as of January 1, 197Z (Tariff Schedules of the United States Annotated (1976), USITC Publication 749, U.S. International Trade Commission). Chemical Economics Handbook - SRI International I ! - v | December 1979 _____ POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 C B. Exports Data on U.S. exports of polyvinyl chloride resins as reported by the U.S. Department of Commerce (exports by ail shippers) and The Society of the Plastics Industry, Inc. (SPI) (exports by resin producers only) are presented in the following table. U.S. EXPORTS OF POLYVINYL CHLORIDE RESINS __________________ (millions of pounds)_______________ _ _______________ Department of Commerce_____________ Uncompoundeda Reported Estimated Resin Content Estimated Total SPI 1965 48 31 25 73 1966 50 37 30 80 1967 42 34 27 69 1968 74 38 30 104 1969 129 38 30 159 1970 1971 1972 1973 1974 1975 1976 1977 1978 132 118 119 110 212 121 225 187 177 35 28 160 34 27 145 165 40 32 151 156 54 43 153 146 105 84 296 297 55 44 165 164 141 113 338 272 127 102 289 239 94 75 252 243 See MANUAL OF CURRENT INDICATORS - SUPPLEMENTAL DATA for additional information. a. Data reported in the source under export code # 581.2022 through 1977, and under export code # 588.1350 in 1978. b. Data reported in the source under export code # 581.2024 through 1977, and under export code 588.1355 in 1978. c. Based on an estimated average PVC resin content of 80%. SOURCES: (A) U.S. Exports, FT 410, U.S. Department of Commerce, Bureau of the Census (UNCOMPOUNDED and REPORTED COMPOUNDED data). (B) Year-End Monthly or Annual Statistical Reports. Plastic and Resin Materials, The Committee on Resin Statistics of The Society of the Plastics Industry, Inc., as compiled by Ernst & Ernst (SPI data). (C) CEH estimates (all other data, and estimate in footnote c). Exports of uncompounded PVC resins totaled 136 million pounds (62 thousand metric tons) through July 1979. Reported exports of compounded PVC resins totaled 51 million pounds (23 thousand metric tons) for the same period. BFG35678 Chemical Economics Handbook - SRI International in December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 D Data on U.S. exports by country of destination in 1978 are given in the following tables. U.S. EXPORTS OF PNCOMPOUNDED POLYVINYL CHLORIDE RESINS - 1978a Quantity Value Unit Value Country of Millions of Thousands of - (millions of Cents per Cents per Destination Pounds Metric Tons dollars) Pound Kilogram Canada Belgium New Zealand Brazil Venezuela Australia Japan Republic of South Africa Other Totalb 39.1 22.6 18.5 17.7 14.7 7.5 6.4 5.6 44.7 176.8 . 17.7 10.3 8.4 8.0 6.7 3.4 2.9 2.5 20.3 80.2 11.8 7.2 5.2 4.5 4.1 2.9 4.2 2.3 17.3 59.5 30.2 31.8 28.3 25.5 27.7 38.6 66.3 40.5 38.6 33.6 66.6 70.1 62.4 56.3 61.0 85.0 146.1 89.4 85.1 74.2 a. Data are reported in the source under export code # 558.1350. b. Totals may not equal the sums of the categories due to rounding. SOURCE: U.S. Exports, FT 410, U.S. Department of Commerce, Bureau of the Census. U.S. EXPORTS OF COMPOUNDED POLYVINYL CHLORIDE RESINS - 1978a Quantity Value Unit Value Country of Millions of Thousands of (millions of Cents per Cents per Destination Pounds Metric Tons dollars) Pound Kilogram Canada Brazil Venezuela Dominican Republic Peru Jamaica Other Totalb 28.9 10.9 8.4 7.6 5.7 3.8 29.2 94.4 13.1 5.0 3.8 3.5 2.6 1.7 13.2 42.8 9.9 2.1 2.2 2.3 1.1 1.3 11.7 30.7 34.2 19.5 26.9 30.7 19.3 35.1 40.0 32.5 75.5 43.0 59.3 67.6 42.3 77.3 88.3 71.7 a. Data are reported in the source under export code # 588.1355. b. Totals may not equal the sums of the categories due to rounding. SOURCE: U.S. Exports, FT 410, U.S. Department of Commerce, Bureau of the Census. BFG35679 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 E INTERNATIONAL* Producers and Capacities A. Vinyl Chloride The following table summarizes world vinyl chloride monomer capacity by region and country. Data are obtained from the PRODUCING COMPANIES, PLANT LOCATIONS, AND CAPACITIES section of this report and from the World Petrochemicals (WP) Program. Detailed information by company is contained in the WP study. ANNUAL WORLD VINYL CHLORIDE CAPACITY ____________ (thousands of metric tons)____________ As of August 1, 1979 Future' North America Canada Mexico United States and Puerto Rico South America Argentina Brazil Chile Colombia Peru Venezuela 3,900 90 70 3,740 456 55 296 18 29 8 50 5,305 408 270 4,627 760 155 496 18 29 12 50 Western Europe Belgium Finland France Germany, Federal Republic of Greece Italy The Netherlands Norway Portugal Spain Sweden Switzerland United Kingdom 6,234 820 57 930 1,255 30 1,018 500 300 32 497 100 35 660 7,144 820 57 1,130 1,275 30 1,058 500 300 182 847 100 35 810 (continued) Data and information in this section were developed by the World Petrochemicals Program, SRI International. BFG35680 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 F ANNUAL WORLD VINYL CHLORIDE CAPACITY (continued) __________________ (thousands of metric tons)___________________ As of August 1, 1979 Future* Eastern Europe Bulgaria C zechoslovakia German Democratic Republic Hungary Poland Rumania U.S.S.R. Yugoslavia 1,231 35 220 0 223 188 233 332 0 2,356 185 220 200 223 393 233 602 300 Middle East Iran Iraq Israel Turkey 216 549 62 212 0 66 100 100 54 171 Asia China India Japan Korea, Republic of (South) Pakistan Philippines Taiwan 3,059 80 100 2,394 60 5 10 410 4,026 680 147 2,244 410 5 10 530 Oceania Australia 81 81 81 81 Africa Algeria Libya Morocco Nigeria Senegal South Africa, Republic of 223 409 40 40 0 65 0 27 0 42 0 52 183 183 World Total 15,400 20,630 a. Includes capacity already on stream and announced expansions, closures, and new plant construction scheduled for year-end 1984. SOURCE: World Petrochemicals Program, SRI International. BFG35681 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 G Vinyl chloride monomer producers outside the United States with annual capacities of 250 thousand metric tons or more in any one country are listed below. For information about producers in the United States and Puerto Rico, see the PRODUCING COMPANIES, PLANT LOCATIONS, AND CAPACITIES section of this report. MAJOR VINYL CHLORIDE PRODUCERS OUTSIDE THE UNITED STATES, ANNUAL CAPACITY AS OF JANUARY 1979 (thousands of metric tons) Western Europe Montedison SpA (Italy) 580 Akzo Zout Chemie Nederland BV (owned 100% by Akzo NV) (The Netherlands) 500 Limburgse Vinyl Maatschappij NV (owned 50% by DSM, by Tessenderlo Chemie sa, and 5% by Compagnie Financiere de Tessenderlo) (Belgium) 450 Chemische Werke Huels AG (owned 50% by VEBA AG and 50% by Chemie-Verwaltungs-AG) (Federal Republic of Germany) 415 Imperial Chemical Industries Limited (United Kingdom) 400 Rhone-Poulenc Industries SA (owned by Rhone-Poulenc SA) (France) 400 Norsk Hydro a.s (owned 51% by the Norwegian government) (Norway) 300 BP Chemicals Ltd. (unit of BP Chemicals International Limited) (United Kingdom) 260 Hoechst AG (Federal Republic of Germany) 260 Japan Toyo Soda Manufacturing Co., Ltd. 319 Kashima Vinyl Chloride Monomer Company Ltd. (owned 50% by Shin-Etsu Chemical Co., Ltd.; 25% by Mitsubishi Petrochemical Co., Ltd; 10% by Asahi Glass Company, Ltd.; 10% by Kanegafuchi Chemical Industry Company Limited; and 5% by Asahi Denka Kogyo K.K.) 270 SOURCE: World Petrochemicals Program, SRI International BFG35682 December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 H B. Polyvinyl Chloride Resins The following table summarizes world polyvinyl chloride resin capacity by region and country. Data are obtained from the PRODUCING COMANIES, PLANT LOCATIONS, AND CAPACITIES section of this report and from the World Petrochemicals (WP) Program. Detailed information by company is contained in the WP study. ANNUAL WORLD POLYVINYL CHLORIDE RESINS CAPACITY (thousands of metric tons) As of August 1, 1979 Future* North America Canada Mexico United States 3,527 166 134 3,227 4,310 266 208 3,836 Central America Nicaragua 30 30 30 30 South America Argentina Brazil Chile Colombia Peru Venezuela 462 783 53 152 297 497 15 15 43 43 8 30 46 46 Western Europe Austria Belgium Finland France Germany, Federal Republic of Greece Italy The Netherlands Norway Portugal Spain Sweden Switzerland United Kingdom 5,187 60 240 55 975 1,325 45 1,012 330 75 35 260 135 30 610 5,955 60 240 55 1,145 1,385 88 1,032 330 75 85 490 135 30 805 ,o Vo s $ Eastern Europe Bulgaria Czechoslovakia German Democratic Republic Hungary Poland Rumania U.S.S.R. Yugoslavia 1,162 35 205 -- 207 180 225 238 72 2,068 155 205 100 207 380 225 488 308 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.18841 ANNUAL WORLD POLYVINYL CHLORIDE RESINS CAPACITY (continued) (thousands of metric tons) As of August 1, 1979 Future* Middle East Iran Iraq Israel Turkey 212 372 60 60 -- 60 100 100 52 152 Asia China India Indonesia Japan Korea, Democratic People's Republic of (North) Korea, Republic of (South) Malaysia Pakistan Philippines Singapore Taiwan Thailand 2^06 100 56 1,863 24 184 24 5 47 15 470 18 4,024 600 200 66 1,863 24 384 24 5 47 15 754 42 Oceania Australia 116 166 116 166 Africa Algeria Egypt Libya Morocco Nigeria Senegal South Africa, Republic of 177 35 -- -- -- -- -- 142 432 35 80 60 25 40 50 142 World Total 13,679 18,140 a. Includes capacity already on stream and announced expansions, closures, and new plant construction scheduled for year-end 1984. SOURCE: World Petrochemicals Program, SRI International. Polyvinyl chloride resin producers outside the United States with annual capacities of 200 thousand metric tons or more in any one country are listed below. For information about producers in the United States and Puerto Rico, see the PRODUCING COMPANIES, PLANT LOCATIONS, AND CAPACITIES section of this report. BFG35684 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 J MAJOR POLYVINYL CHLORIDE RESIN PRODUCERS OUTSIDE THE UNITED STATES, ANNUAL CAPACITY AS OF JANUARY 1979 (thousands of metric tons) Western Europe Montedison SpA (Italy) Chemische Werke Huels AG (owned 50% by VEBA AG and 50% by ChemieVerwaltungs-AG) (Federal Republic of Germany) 510 410 Rhone-Poulenc Industries SA (owned by Rhone-Poulenc SA)(France) 375 Wacker-Chemie GmbH (Federal Republic of Germany) 310 Imperial Chemical Industries Limited (United Kingdom) 280 Solvic SA (owned 75% by Solvay & Cie SA and 25% by Imperial Chemical Industries Limited) (France) 250 Hoechst AG (Federal Republic of Germany) 240 BP Chemicals Ltd. (unit of BP Chemicals International Limited) (United Kingdom) 230 Asia, Far East Formosa Plastics Corporation (Taiwan) 342 Shin-Etsu Chemical Co., Ltd. (Japan) 218 Kanegafuchi Chemical Industry Company Limited (Japan) 216 SOURCE: World Petrochemicals Program, SRI International. Production and Demand A. Vinyl Chloride Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 K The following table shows world production of vinyl chloride monomer in 1977 by geographic region. WORLD PRODUCnON OF VINYL CHLORIDE - 1977 Thousands of Percent of Region Metric Tons Total United States Canada Mexico South America Western Europe Japan Other 2,715 90 56 170 3,899 1,338 468 31% 1 1 2 45 15 5 Total SOURCE: 8,736 100% World Petrochemicals Program, SRI International. The table below shows world consumption of vinyl chloride monomer in 1977 by geographic region, with a forecast for 1983. Region WORLD CONSUMPTION OF VINYL CHLORIDE - 1977 AND 1983 1977 1983 Thousands of Percent of Thousands of Metric Tons Total Metric Tans Percent of Total United States Canada Mexico South America Western Europe Japan Other 2,492 109 79 257 3,875 1,191 697 29% 1 1 3 44 14 8 3,600 290 170 659 5,051 1,422 1,486 Total 8,700 100% 12,678 SOURCE: World Petrochemicals Program, SRI International. 29% 2 1 5 40 11 12 100% B. Polyvinyl Chloride Resins The following table shows world production of polyvinyl chloride resins in 1977 by geographic region. BFG35686 AgaffiSStZ Chemical Kmunmirs HsmHHnnlr - PT ITT T December 1979 POLYVINYL CHLORIDE RESINS r * Plastics and Resins 580.1884 L WORLD PRODUCTION OF POLYVINYL CHLORIDE RESINS - 1977 Thousands of Percent of Region Metric Tans Total United States Canada Mexico South America Western Europe Japan Other 2,383 100 71 250 3,754 1,031 677 29% 1 1 3 46 12 8 Total 8,266 100% SOURCE: World Petrochemicals Program, SRI International. The table below shows world consumption of polyvinyl chloride resins in 1977 by geographic region, with a forecast for 1983. WORLD CONSUMPTION OF POLYVINYL CHLORIDE RESINS - 1977 and 1983 1977_____________ _____________ 1983 Thousands of Percent of Thousands of Percent of Region Metric Tans Total Metric Tons Total United States Canada Mexico South America Western Europe Japan Other Total 2,265 137 70 336 3,396 1,030 691 7,925 28% 2 1 4 43 13 9 100% 3,360 250 160 640 4,469 1,270 1.392 11,541 29% 2 1 6 39 11 12 100% SOURCE: World Petrochemicals Program, SRI InternationaL In 1977, consumption of polyvinyl chloride resins by major category in Western Europe was as follows: rigid PVC, 60%, and flexible PVC, 40%. In major Western European countries, the polyvinyl chloride consumption patterns varied, as shown below. CONSUMPTION OF POLYVINYL CHLORIDE RESINS IN WESTERN EUROPE _________________________ _________ (percent)____________________________________ Federal Republic United Benelux France of Germany Italy Kingdom Rigid PVC Flexible PVC 68% 32 65% 35 62% 38 55% 45 45% 55 Total 100% 100% 100% 100% 100% SOURCE: World Petrochemicals Program, SRI International. BFG35687 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 M Trade A. Vinyl Chloride The following table presents world imports and exports of vinyl chloride monomer in 1977 by region. WORLD IMPORTS AND EXPORTS OF VINYL CHLORIDE - 1977 (thousands of metric tons) Region Imports Exports United States Canada Mexico South America Western Europe Japan Other 0 17 20 87 476 0 194 192 0 0 0 536 166 0 Total 794 894 SOURCE: World Petrochemicals Program, SRI InternationaL B. Polyvinyl Chloride Resins The following table presents world imports and exports of polyvinyl chloride resins in 1977 by region. Region WORLD IMPORTS AND EXPORTS OF POLYVINYL CHLORIDE RESINS - 1977 (thousands of metric tons) Imparts Exports United States Canada Mexico South America Western Europe Japan Other 17 40 6 106 903 11 101 108 4 7 18 1,248 90 43 Total 1,184 1,518 SOURCE: World Petrochemicals Program, SRI International. 24855038 BFG35688 Chemical Economics Handbook - SRI International in' t December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 N BIBLIOGRAPHY CHEMICAL ECONOMICS HANDBOOK - The following CEH Marketing Research Reports, Product Reviews, and Data Sheets contain additional information that is pertinent to the subject of this report. Acetylene Chlorine - Salient Statistics Ethylene Ethylene Dichloride Hydrochloric Acid - Salient Statistics Plasticizers Vinyl Acetate, Polyvinyl Acetate, and Polyvinyl Alcohol Vinyl Surface Coatings PROCESS ECONOMICS PROGRAM - The following reports contain more detailed informa tion on the manufacturing processes, process design, and process economics of the chemicals discussed in this report. Address inquiries concerning this information to the Process Economics Program, SRI International, Menlo Park, California, 94025. Polyvinyl Chloride, Reports No. 13, 13A, 13B, and 13C1, June 1966, May 1970, November 1975, and April 1977. Vinyl Chloride, Reports No. 5, 5A, 5B1, and 5B, May 1965, February 1967, October 1970, and September 1975. Other References - Below is a list of recent articles suggested for supplemental reading. Annual Series of Articles on Plastics in the United States, Modern Plastics, January 1979, pp. 45-69. "Are Plasticizer Markets Softening?" Plastics Engineering, April 1979, pp. 20-23. "California Cracks Down on VCM," Modern Plastics, July 1978, p. 18. "EPA Cuts, VCM Emissions 95% - and PVC Output 12%," Modern Plastics, March 1979, p. 49. "FDA to Set PVC Tolerance Levels," Modern Packaging, January 1979. p. 7. "New Expansions in U.S. PVC Supply Indicate Success of VCM Controls," Modern Plastics International, February 1979, p. 26. "No Easing up for Thermoplastics," Chemical Week, May 9, 1979, p. 24. "Plastic Pipe Use Growing Despite Problems," Chemical & Engineering News, March 19, 1979, pp. 15-18. "Polyvinyl Chloride The Resilient Giant'," Chemical Purchasing, September 1978, pp. 2131. "PVC," Plastics Engineering, July 1978, pp. 39-42. BFG35689 Chemical Economics Handbook - SRI International December 1979 POLYVINYL CHLORIDE RESINS Plastics and Resins 580.1884 O "PVC Industry Heads for Third Year of Growth Despite Regulatory Spate," Chemical Marketing Reporter, March 5, 1979, pp. 4, 32. "PVC Siding: Rapid Growth Spurs Technological Development," Plastics Technology, ' February 1979, pp- 67-74. "PVC Supply: Some Tightness Now, but the Big Pinch of '81 Won't Happen," Modern Plastics, February 1979, pp. 42-43. "PVC Use in Pipe Fittings Seen Growing at 9 Pet. Rate to Reach 8.3 Billion Pounds," Chemical Marketing Reporter, February 19, 1979, pp. 4, 24. "Update on Rigid Cellular PVC," Plastics World, July 1978, pp. 58-59. "VCM Market Remains Stable; Exports Reach Record Level," Chemical Marketing Reporter, January 15, 1979, p. 13. "Vinyl Chloride," Chemical & Engineering News, June 18, 1979, p. 9. "Vinyl Chloride Monomer...What You Should Know," Hydrocarbon Processing, March 1979, pp. 75-88. "What's Ahead for PVC and VCM," Chemical Engineering Progress, October 1979, pp. 13-18. "Worldwide Activity in VCM and PVC Heats up," Chemical Week, April 11, 1979, p. 54. 24855039 BFG35690 Chemical Economics Handbook - SRT Trt*rnaf-innAi trr t A -200 in i