Document MJ1J7MkRpO15rpQ8NDnVqOB3z

f FROM:R&D POLYMERS IU:Ulb IH 1 To: PVC Overview Participants I'lH^ J. J. X*+!-ir< +-KJ ( -1 r . \fLSd. :fe+h fe 4 IntoroMlM Communication From: Data: J. L Irvine Match 19, 1992 Subfact: h Agenda for the March 24 Training In Aberdeen * Attached is the Agenda for the PVC overview training next week in Aberdeen. We have you scheduled for this session. If you are supposed to be In the indepth training the tatter part of the week, lei me or Harold Coleman know and we will get you the correct agenda. The times are approximate, except for the starting time. Class will be held in the training room of the plant Lunch wilt be provided. Dress casually and comfortably, if you want to go on the plant lour bring your safety gkmmy jf you have them. If you don't, they will be provided. Be prepared in the us what you expect from the class. We can make small changes on the flyio make sure the class is a benefit to everyone. At the end we will see if we were able to meet everyone's expressed need for the class. We look forward to seeing you there. John L Irvine 44 H n VAB.0001191978 FRLTFK&D M-K-YntKta I U* VXD ll-t X I II II N. r I* RESIN/COMPOUND OVERVIEW AGENDA I 8:00 8:15 9:15 9:30 11.00 11:30 12:30 2:00 2:30 4:00 Introduction n Resin Overview Break Resin Overview // Plant Tour Lunch Flexible Compound i Break Rigid Com\\ pound * Summary, Questions, Comments Harold Coleman Harold Coleman - Harold Coleman John Irvine Randell Jackson HOC, JLI, RDJ VAB.0001191979 * rrsLji i * rs>cxu f ljl- f i k_is.cj iu* viJin To: PVC In-Depth Participants in* n. InttroNte# CommunkoHon From: Date: J. L. Irvine March 19, 1992 Subject: Agenda for the March 25-27 Training In Aberdeen Attached b the Agenda for the PVC In-depth training next week in Aberdeen. We have you scheduled for this session. If you are not supposed to be In the in-depth training, let me or Harold Coleman know. Also let us know if we have you on the wrong day or days. Come to the sessions you are supposed to attend, not necessarily the ones where we have you listed. The times are approximate, except for the starting time. Class will be held the training room of the plant. Lunch will be provided. Dress casually and comfortably. If you want to go on the plant tour bring your safety glasses if you have them. If you don't, they wit! be provided. Be prepared in the introduction to telt us what you expect from the class. We can make small changes on die fly to make sure the class is a benefit to everyone. At the end we will see If we were able to meet everyone's expressed need for the class. There will be a group dinner on Wednesday night, location still to be decided. If you are not in Wednesdays class and want to Join us, let me or Harold know so we can include you in the head count. } We look forward to seeing you there. John L. Irvine VAB.0001191980 RESIN/COMPOUND IN-DEPTH AGENDA Wednesday, March 25 8:00 Introduction 8:15 Resin Production 9:30 Break 10:00 Resin Production Continued 11:30 Lunch 12:30 Resin Properties 2:00 Break 2:30 4:00 Resin Properties Continued ra - , Resin Business^ai^Marketing 5:00 Break 6:00 Dinner " Thursday, March 26 8:00 Resin and Compound Applications 8:45 Break 9:00 9:45 Resin and Compound Applications -1 Break 10:00 Resin Competitive Situation 11:00 Plant Tour 11:30 Lunch 12:30 Flexible Formulation Technology 1:30 Break 1:45 Flexible Formulation Technology Harold Coleman Harold Coleman Harold Coleman f John Irvine John Irvine Mike Clark Harold Coleman John Irvine John Irvine Randell Jackson Randell Jackson VAB.0001191981 2:45 Break 3:00 Flexible Formulation Technology Friday, March 27 8:00 Rigid Formulation Technology 9:45 Break 10:00 Compounding and Blending 11:30 Lunch 12:30 Compound Market and Business 1:30 Adlos Randell Jackson Randell Jackson Randell Jackson Fred Williams I l VAB.0001191982 Tuesday / Sherry Truitt ^ t Jim White ^ > Greg Norman y Andy Wilson 7 Jimmy Autreyt/' Don Barclay v/ Mike Williams Debbie Botkin^ Steve Vrwv/ 7 Joe Beall 1/ Bob Seymour Sr <] Steve Hiifenan ib Linda Michels 1/ Wednesday ; * Ted Nickerson - Doug Skokna Amy Bagwell Erik Smith jr Reed Mackay l Tim Arbeiter 1 Joe Ganc * Rory Sneed Steve Vincent ? Duane Heaton Steve Kahara Mark Wolverton Charlie Muncy Carla Foshay Jill Wallace Ed Marshall Kenny Akins /* Mike McCollum // Roger drain - > ^ ^ Steve Goodman Carol Cooper Dan Miller Joseph Hegwood // Craig English // Mike Swierc /t Gary Wolf /7 Richard Williams / Doug Knittig /? Mike Clark Thursday Doug Skokna Amy Bagweil Erik Smith Reed Mackay Tim Arbeiter Joe Ganc Rory Sneed Steve Vincent ? Duane Heaton Steve Kahara Mark Wolverton Charlie Muncy Carla Foshay Jill Wallace Ed Marshall Kenny Akins Charles Woriow Mike McCollum Roger Crain Gary Wolf Debbie Lemmons Steve Goodman Carol Cooper Dan Miller Joseph Hegwood Craig English Mike Swierc Doug Knittig Mike Clark Friday Amy Bagwell Erik Smith Tim Arbeiter Joe Ganc Rory Sneed Duane Heaton Mark Wolverton Charlie Muncy Carta Foshay Jill Wallace Ed Marshall Charles Woriow Mike McCollum Roger Crain Gary Wolf Debbie Lemmons Steve Goodman Steve Hillman Dan Miller Joseph Hegwood Craig English Doug Skokna Mike Swierc Kenny Aldns Doug Knittig Mike Clark A VAB.0001191983 * HIM * ^PR VAB.0001191984 PVC OVERVIEW VAB.0001191985 PVC OVERVIEW VAB.0001191986 PVC OVERVIEW Introduction - Definitions - PVC Market Resin - Markets - VCM Technology - Polymerization Chemistry - Polymerization Processes - Vista PVC Activities - Resin Properties Compound - Flexible - Markets - Formulation - Manufacturing - Testing - What's New Rigid - Markets - Formulation Manufacturing - Testing - What's New Vista Polymers Research Summary A VAB.0001191987 i 0 i Definitions 1. Monomer - A low molecular weight molecule capable of being combined with itself or other similar molecules to produce a polymer. - A macromolecule consisting of 5 or more identical combining units called monomers. 3. Polymerization ci Cl Cl - A chemical reaction, usually carried out with a catalyst, heat or light, and often under high pressure, in which a number of relatively simple molecules combine to form a chain-like macromolecule. VAB.0001191988 Definitions (cont.) h 4. Vinvl - Refers to ail PVC-containing substances (e.g. copolymers containing VCM or floor tiles containing as little as 15% PVC are called vinyl). 5. PVC Polymer produced from vinyl chloride monomer. 6. Resin -Generally used for non-rubberlike polymers. Refers to the initial form of PVC. Never really pure. PVC resin always contaminated to some extent with initiator, stabilizer, suspending agents, and kill agents, combining units called monomers. blend' - Dry free flowing powders containing all the appropriate additives (e.g. stabilizers, plasticizers, j etc.). I -Both dryblends and pellets can be rigid or flexible compounds. VAB.0001191989 * VAB.0001191990 US COMMERCIAL THERMOPLASTICS PRODUCTION 1990 TOTAL PRODUCTION - 46.8 BILLION POUNDS BILLION POUNDS RESINS < O 22 VAB.0001191991 n V* POLYVINYLCHLORIDE - END USE MARKET PERCENT b Ethylene LCCP > VAB.0001191993 PVC Manufacturing Plants Oklahoma City Resin (5385 only) Aberdeen Resin (All MW's) Flexible Pellets (incl. PlenexTM) Rigid Blend (dryblend) Plasticizer Blane Polymers Flexible Pellets Premiere Polymers Flexible Pellets Flexible Blend (RotoflexTM) Rigid Blend (dryblend) Rigid Pellets (VistelTM, SuprelTM) Visalia Flexible Pellets PVC MAJOR MARKETS - 1990 Source: Modern Plastics, Jan. 1991 CALENDERING Building & Construction Transportation Packaging - Sheet Electrical - Tape Consumer/Institutional Furniture/Furnishings SUB-TOTAL EXTRUSION Pipe & Conduit Siding & Accessories Window Profiles Transportation Packaging - Film & Sheet Electrical - Wire & Cable Consumer/Institutional SUB-TOTAL INJECTION MOLDING Building & Construction Transportation Electrical/Electronics Consumer/Institutional Other SUB-TOTAL BLOW MOLDING (BOTTLES) COMPRESSION MOLDING (RECORDS) DISPERSION MOLDING DISPERSION COATING LATEXES EXPORT GRAND TOTAL MM LBS 348 90 115 13 287 200 1053 3610 860 401 20 365 410 307 5973 182 10 135 73 20 420 381 65 937 9297 VAB.0001191995 TOTAL SALES (MM LBS) 588 611 658 CO CO CM CO LO CO QC LU Q QC LU CO K MM CD LU cr QC LU < CL < O CL LU O X CL o 0 O LU VAB.0001191996 Vista Industry 0) o <5 ' I I I i I 1 I I I I------- 1------- 1------- ooooooooooooo (M^OOfiOStOlO^OOCMr- VAB.0001191997 * *1 >- 0> T_ CO (O U) oo Is- Is- ^ <o I wo mm omo o m in O 00 N CM 1-1- ooooo cd m o o co oo oo oo in co oocMOCMooooocomo) o in o o) o co o 00 o 00 o CM in o in i- o in o co o in i i (O 00 N r- CM CO r- co co i i oo x X < -J o Q_ < o CO < X CO (3 CO GC LU CO O Q < CO CO OoLL1 a. a. o o z: lu x O X O 0 ll < <5 CL O LU < CO U1 Q CL O LU CL $ CL UJ i-- O h" CO U- CD Q0XQQ.O TOTAL 7230 - 11345 (604) Modern Plastics, Jan. 1991 * INCLUDES ALL PLANNED EXPANSIONS * VAB.0001191998 NAMEPLATE CAPACITY 1/1/92* SUPPLIER SHINTECH OXYCHEM FORMOSA BFGOODRICH BFG 1993 VISTA GEORGIA GULF BORDEN WESTLAKE CERTAINTEED VYGEN SUSPENSION 2000 1900 1789 1600 1100 840 810 795 500 265 125 DISPERSION 200 96 150 150 48 55 VAB.0001191999 VAB.0001192000 MORE 1. SOLUBLE IN ETHYL ALCOHOL, DIETHYL ETHER, BUT NOT WATER 2. VOLUME DECREASES WHEN POLYMERIZED BY 35% SAFETY h 1. NARCOTIC 2. CAN CAUSE LOSS OF CONSCIOUSNESS AT HIGH CONCENTRATION 3. SUSPECTED CARCINOGEN A. ANGIOSARCOMA B. AOL - BONE DISORDER 4. TERATOGEN - FETUS AFFECTS IN PREGNANT WOMEN 5. OSHA LIMITS 1 A. 1 PPM OVER 8 HOURS B. 5 PPM IN 15 MINUTES 6. MONITORS (BADGES) RECOMMENDED 7. FRESH AIR MASKS REQUIRED HANDLING AND STORAGE 1. ORDINARY STEEL CONTAINERS 2. ONLY MILDLY CORROSIVE 3. MUST BE KEPT ACIDIC AND OXYGEN-FREE VAB.OOOl192001 V; vf' V *#x i< ^5i*fV.= -<j-. .>v 4X > ,p pT- ^ J-p * %'i *-> a.?-'-- A* ''f^e VlSi v^' , 0.5 ppm 1.0 ppm 5.0 ppm VAB.0001192002 * 5%V - -$ :`y- !* 3 Tt / . H. v * * Ov>* f\t; I \ 400 ppm 20 Lbs Vinyl Chloride Per Million Lbs. PVC Produced 10 ppm POLYMERIZATION VAB.0001192004 POLYMERIZATION STEPS 1) Initiation 2) Propagation 3) Chain Transfer 4) Termination MECHANISM OF POLYMERIZATION Initiation O O Free radical formation ii ii R-0-C-0-0-C"0-R o II R-O-C-O1 Propagation note head to tall addition o 2R-0-C-0' O HH STRUCTURE DF PVC HUn Un Url un un un H H HH H wwc-c-c-c7XAAc-c-c -1CA-A/wA \^>cI -CI -CI ^wv H C1H Cl I I II I Cl Cl H Cl H H Cl HEAD-TO-TAIL (98%) HEAD-TO HEAD TAIL-TO-TAIL MECHANISM OF POLYMERIZATION 3. Chain Transfer HH a^^'^C-CHCI H1 rCi1 4. Termination Recombination HH HH I1 1I H C1 C1H iIII AAA_^ ^W\ II ci ci INHERENT dL/grams VISCOSITY NUMBER AVERAGE MOLECULAR WEIGHT (grams/molt) E VAB.0001192009 MECHANISM 4. Termination Disproportionation POLYMERIZATION I AAA II I Cl CH ^AB.0001192010 POLYMERIZATION PROCESSES MASS (BULK) EMULSION SOLUTION SUSPENSION VAB.0001192011 MASS (BULK) POLYMERIZATION Manufacturers: Pechiney St. Gobain BFG - Plaquemine, LA Occi - Burlington, NJ (closing down) Two-stage batch process Polymerization starts in VCM phase, then precipitates. 1. Very uniform, porous particles. 2. High bulk density. 3. Free of suspending agent and water contaminants. Disadvantages: 1. Difficult to control temperature (mol wt). 2. More expensive than suspension. 3. Difficult to strip residual VCM. Markets: Same as suspension except for molding. VAB.0001192012 EMULSION POLYMERIZATION Manufacturers: Borden BFG Occi Formosa Georgia Gulf Process: 1. Soaps used to form "micelles" in water. 2. Water-soluble initiator encounters VCM in micelles. 3. Diffusion from monomer droplets to micelles replaces polymerized VCM. Advantages: t. Very uniform, small, nonporous particles. 2. Processes easily (plastisols) without much heat. Disadvantages: 1. High contamination level of soap. 2. Poor heat stability. 3. High cost - energy intensive drying. Markets: Plastisols - used for coatings and molding. VAB.0001192013 DISPERSION POLYMERIZATION Manufacturers: Occi (others?) Similar to emulsion, except: 1. Monomer soluble initiators. 2. No micelles are formed; instead, high mechanical shear is used in a preliminary step to form droplets. Advantages: 1. Same as emulsion. Disadvantages: 1. Same as emulsion. Markets: Same as emulsion. The terms "emulsion resins" and "dispersion resins" are used interchangeably in the industry. Resins used in plastisols can be made by either emulsion or dispersion processes. VAB.0001192014 SOLUTION POLYMERIZATION Manufacturers: Union Carbide Process: 1. Mostly P VC/poly vinyl acetate copolymers. 2. Polymerized in a solvent (n-butane), then precipitates. 3. Not much is known about UC's process. Advantages: 1. Similar physical properties as bulk. Disadvantages: 1. High cost. 2. Solvent recovery/environmental. 3. Limited market. Markets; Can liners. VAB.0001192015 SUSPENSION POLYMERIZATION Manufacturers: Vista and many others Process: 1. Mostly homopolymer, but some PVC/polyvinyl acetate copolymers. 2. VCM droplets suspended in water. 3. Initiator is monomer soluble. Advantages: 1. Easily controlled temperature. 2. Easily filtered and dried. 3. Low cost. Disadvantages: 1. Small change in conditions alters properties. 2. Not as pure as mass or solution. Markets: Extrusion, molding, calendering... Virtually unlimited. VAB.0001192016 THE SUSPENSION PROCESS THE ROLE OF WATER 1. ACT AS A CONTINUOUS PHASE AND ENABLE VCM TO BE DISPERSED 2. ACT AS A HEAT TRANSFER MEDIUM 3. CARRIER FOR PROTECTIVE COLLOID (SUSPENDING AGENT) THE ROLE OF SUSPENDING AGENT 1. CONTROLS PARTICLE-SIZE DISTRIBUTION 2. KEEPS VCM DROPLETS DISPERSED 3. FACILITATES HEAT TRANSFER AND AGITATION THE ROLE OF THE AGITATOR 1. PRODUCES DESIRED PARTICLE SIZE 2. MAINTAINS SUSPENSION DROPLETS AND PVC GRAIN 3. ENSURES GOOD HEAT TRANSFER VAB.OOOl192017 THE ROLE OF THE INITIATORS 1. CONTROLS RATE OF POLYMERIZATION 2. CONTROLS RATE OF HEAT EVOLUTION 3. AFFECTS NUMBER OF GELS IN RESIN CHAIN TRANSFER AGENTS Function: Terminate Macroradical Chain and Initiate New Cha i n. Effect: Terminate Chains at Shorter Length Than Normal for a Given Temperature. Purpose: Allows Production of Low Molecular at Lower Temperature (and Pressures). WE ight PVC VAB.OOOl192018 Ingredicuts: Munome r (s) Initiator Solubil ity Suspending Agent Reactor Agitation Market Rank (Lb. Basis) Mean Particle Diameter End Use CHARACTERISTICS OF PVC POLYMERIZATION PROCESSES Suspension PVC Resin Polymerization Type Emulsion Mass or Bulk PVC PVC VCM VCM Protect 1ve Co 11 oid High Shear 1st 150 pm Rigid Flexible Extrusion Film Blown Calender Molding VCM Water Soap Low Shear 2nd 10 pm Pastes Latex Dispersions Creams VCM VCM None High then Low 3rd 150 pm Rigid Flexible Extrusion Film Blown Calender Solution PVC VCM/Vinyl Acetate VCM None Low Distant 4th Solution Beer Can Liners VAB.OOOl192019 VISTA POLYMERIZATION PROCESS TECHNOLOGY VCM 'VAB.0001192021 POL iRIZATION CHARGE POLYMERIZATION RECOVERY 8< STRIPPING PUMP RINSE 8i CLEANING EVACUATION CYCLE , HIGH PRESS 'water POLY..FRIZAT ION SECTION PVC MANUFACTURE VCM TO RECOVERY RTKJCC UATRP AKjn ULfc^NlNU bULU11UN rCOOLING WATER ^SUPPLY 7 CITY WATER CENTRATE VAB.0001192022 *. .f CONDENSER BAFFLES VISTA REACTORS JACKET AGITATOR STEAM STRIP CENTRIFUGE DRYER SILO 0 VAB.0001192023 o5 o u Eh < Eh CO D Q o u co A o H CO o EH fc RESIN DRYING SECTION CO o5 a s D U <lu a >U04 o Eh >H w o 05 05 o D WEh u Wtf Eh Cn O 05 M 05 Q 05 Eh Eh 55 < w gCJ H(-U. u 05 <ES A o t-3 PQ a: H 05 H < oS W 05 ti < >H ^ 05 aa CO CQ 05 W Eh < H> M Cm M w2 < a. CO <C (-3 U-i VAB.0001192024 VISTA RESIN GRADES (MOLECULAR WEIGHTS) * With CTA -i. > 'p* p VAB.0001192025 pp- fc PVC RESIN APPLICATIONS 5225 Rigid Injection Molding 5265 Pipe Fittings 5305 Rigid Pipe Fittings Rigid Calendering Powder Slush Molding 5325 Powder Slush Molding 5385 Pipe Siding Profile extrusion 5395 General Flexible Applications Calendering . Molding 5415 Building Wire Communications Wire General Purpose Calendaring Flexible Automotive Molded Parts 5465 Automotive Wire Vinyl Car Tops Toys Electrical Tape VAB.0001192026 * Vista Chemical Company 1 Molecular Weight Measures of PVC Resin From W. V. Tltow, PVC Technology, 4^* Edition 0.42 0.44 0.47 0.49 0.52 0.55 0.57 0.60 0.62 0.65 0.67 0.70 0.73 0.75 0.78 0.80 0.83 0.85 0.88 0.91 0.92 0.95 0.98 1.01 1.03 1.06 1.08 1.11 1.13 1.16 1.18 1.21 1.23 1.26 1.28 1.30 1.33 1.35 1.38 1.54 1.58 1.62 1.66 1.70 1.74 1.78 1.83 1.87 1.90 1.96 1.99 2.03 2.07 2.10 2.17 2.21 2.25 2.28 2.32 2.36 2.43 2.46 2.50 2.54 2.57 2.64 2.68 2.72 2.79 2.83 2.90 2.93 2.97 3.04 3.08 0.155 0.165 0.175 0.185 0.195 0.206 0.217 0.228 0.239 0.25 0.264 0.275 0.285 0.3 0.31 0.32 0.33 0.34 0.36 0.37 0.38 0.39 0^40 0.41 0.43 0.44 0.45 0.46 0.47 0.49 0.50 0.51 0.53 v- 0.54 0.56 0.57 0.58 0.6 0.61 45.3 46.2 47.1 48.4 49.3 50.1 51.3 52.4 53.6 54.7 56.1 57.2 58.2 59.5 60.5 61.7 62.9 64.1 64.9 66.1 67.1 68.2 69.2 70.2 71.5 72.4 73.3 74.3 74.9 75.8 76.6 77.5 78.3 79.1 79.9 80.7 81.5 82.2 83.0 275 310 350 380 415 450 495 525 560 600 640 680 720 760 800 840 885 930 975 1025 1070 1120 1175 1230 1300 1350 '1420 1490 1570 1650 1720 1810 1900 1980 2070 2170 2260 2360 2460 46,600 62,000 76,300 88,700 103,800 120,600 135,200 Vista is a registered trademark of Vista Chemical Company. The above data are based on tests and experience which Vista Chemical Company believes reliable, and are supplied for informational purposes only Vista Chemical Company disclaims any liability for damage or injury which results from the use of the above data and nothing contained therein shall constitute a guarantee, warranty or representation (including freedom from patent liability) by Vista Chemical Company with respect to the data, the product described or its use for any specific purpose, even if that purpose is known to Vista Chemical Company For detailed information regarding these products, please refer to the respective Vista Chemical Company Material Safety Data Sheet. i * i VAB.0001192027 REACTOR SIZE ABERDEEN QKC FOUR 18,000 GAL FOUR 22,000 GAL TWO 33,500 GAL SIX 18,000 GAL CAPACITY ABERDEEN - 450 MM LBS/YR 5465 0 ( 0%) 5415 160 (35%) 5395 20 ( 4%) 5385 190 (42%) 5325 1-2 (< 1 %) 5305 50 (11 %) 5265 30 ( 7%) 5225 1-2 (<1%) OKC - 350 MM LBS/YR 5385 350 (100%) + 1r T3 VAB.0001192028 55 oo o llOO ooo 00 ooo e* S 10 CO <N VAB.0001192029 POT YMF.RTZATTON RECIPES 4 VAB.0001192030 VISTA ADVANCES LARGE REACTOR TECHNOLOGY STATISTICAL PROCESS CONTROL ADVANCED SUSPENDING AGENTS (RQIP) - LICENSED FROM BASF FLUID BED DRYING ENHANCED COMPUTER CONTROL EXTENSION OF RESIN TECHNOLOGY - 5225 - 5325 - 5395 - 5416 (MORE POROUS 5415) CLEAN WALL TECHNOLOGY - LICENSED FROM EVC NEXT: EXTERNAL STRIPPING IMPROVED GELS/CONTAMINATION IMPROVED CONSISTENCY A VAB.0001192031 *1 * > I i.w i. . .|i W-' * . + 1 r I * A 1963 ACQUIRED CARLON FVC PIPE CO. 1964 ACQUIRED APEX TIRE AND RUBBER CO. (COMPOUND) AND THOMPSON CHEMICAL CO. (PVC RESIN) FROM FAIN FAMILY. 1964 EXPLOSION AND FIRE AT THE HEBRONVILLE MASS. PVC PLANT. 1964 ABERDEEN MISS. PLANT STARTED-UP AND THE ASSONET MASS. PLANT BUILT. 1967 R&D MOVED FROM PONCA CITY TO ASSONET MASS. 1968 VINATEX (ENGLAND) CAME INTO EXISTENCE. 1968 FTC MADE CONOCO DIVEST OF ITS ASSONET MASS. PLANT (SOLD TO OLIN INDUSTRIES) , COMPOUNDING FACILITIES IN RHODE ISLAND (SOLD BACK TO THE FAIN FAMILY <TECKNOR--APEX>) , AND BUY OUT STAUFFER PORTION OF THE VCM PLANT. 1968 CONOCO PLASTICS FORMED FROM CARLON PIPE AND PVC PLANT IN ABERDEEN AND HEADQUARTERED IN WILTON, CONN., INCLUDING R&D. 1970 LARGE REACTOR PLANT STARTED-UP IN OKLAHOMA CITY. 1972 SOLD CARLON TO INDIAN HEAD INDUSTRIES, SHUT DOWN THE WILTON FACILITIES, MOVED R & D TO PONCA CITY, AND FORMED CONOCO CHEMICALS. 1975 ALL SMALL REACTORS SHUT DOWN. 1976 DIVESTED OF OUR HOLDINGS IN VINATEX. 1978 to 1981 PVC RESIN, INCREASED. DRY BLEND, AND COMPOUND CAPACITIES 1984 VISTA POLYMERS INC. FORMED. 1986 VISTA POLYMERS COMBINED INTO VISTA CHEMICALS. 1986 PREMIERE POLYMERS ACQUIRED. 1987 BLANE POLYMERS ACQUIRED. 1988 VYCOM STARTED 1989 R & D MOVED TO AUSTIN/ABERDEEN. VAB.0001192032 1k I*--* I--' EFFECT OF PROCESS VARIABLES ON RESIN PROPERTIES A Property A. Molecular Weight (Inherent Viscosity) B. Particle Size Distribution C. Bulk Density D. Porosity (Brabender Dry Time, Cold Plasticizer Absorption, Residual VCM) E. Gels F. Resin Color G. Heat Stability H. Moisture I. Electrical Properties 1* Process Variable 1. Polymerization Temperature 2. Chain Transfer Agents 3. Chain Coupling Agents 1. Suspending Agent Concen tration 2. Agitation 1. Static 2. Resin Particle Shape 3. Additives 1. Degree of Conversion of VCM to PVC 2. Polymerization Temperature 3. Additives 1. Cleanliness of Reactor 2. Agitation 3. Additives 1. Heat History 2. Antioxidant 1. Heat History 2. Killing Agent 3. Antioxidant 1. Drying Efficiency 1. Type Initiator 2. Additives 3. Type Poly Water vab.oooi 192033 Wf-TH*' t1 r iL o CO to o u a c f 3 z: 5 GO L a. C oE to 3 o 0 CJ c CO * 0 CO o ou a 3 co oN S- to < <L| u L E-* o gu CL E E >% U* o ^O Ho Cl co l o kc JZ o 3 GO 3 O OE J< # CO c *** CO o os o u o c t*4 Cjl < M O L o a1C0l *\ o u CO a C uO CO CO C vi "a l toco c co ro C. l OS 0 GL "3 U CL cc CO a x; 3w GO CT 3 c G 3 CO to CN c GO <o G C G GO o u o a <o < c o CJ c O Cl o 4J o 03 u *w4 GW 3G O" CL go -a G O -a < TJ U *3 < CL < coo In uooo Ll cl GO C * o ,,+ .33 0N1 U03 U to U C G u co U CL **** G GO G CO O u CJ G > u <c to >s <U CO c G Q 3 a* Li o co JD < Li G N U CO to a# G E H >> a L G 3 C G JQ 3 U PQ CO G >> U X CO iH u CO G CJ VAB.0001192034 *1 -'1' ' 1 gU- i .4 l. rc!|-4 .. iiJj 4- - T THJ_ mkJ. H U . -I .1 .i PVC PROPERTIES-- DRYER RELATED CJ <D u c tO H u 33 33 4) <U U CJ Oo 1m L Cl Q* CA OJ u 00 C 00 >1 0) e Oc u m** ^4 a f-M w to Cal u CL a uVM tx- oo 3 O uu E XO tfl CO o CO 0 to oo a* uu 3 c E Im E > o 0 0) C0 0) c o >c> E 0) 4) Ps 4J X L a L. CO a CO 4> ao *o u a> cc *o < eo CO u CO u L CO a> 4> 0) 4> a a CL L c4a> c 0) a *o a < o CL o o CJ L L. c a. CL *--1 m # m X V3 CO 3 L L. O) C E Ps k. X a CJ 00 ao 3c CL a a* a 4-1 p4 c L u (0 <U mJ 3 CO to > X L E w Eo O) CO <0 >> 0) >s 4) L. c a CO a CO < # # T3 C(0 u o oc S CoJ i>i% c --- >-ua>;. 3 CJ *--t a 3 c > X>E C X O X 4J b. to X co L *j u u CO o 3 Q> CO w Ml u * w *3 E -J E X -3 w CO <0 Vw W u MJ c 3 W 01 CO CJ CO PS C to 02 oX Q co + r VAB.0001192035 VAB.0001192036 VAB.00011^2037 Market: Wire Cable Applications: insulation. jacketing conduit power, communications, computer Vista lbs: 108MM Ibs/yr (70% Vista Flexible) Major Customers: Times Fiber, AT&T, Northwire Tandy eneral Cable Allflex FLEXIBLE COMPOUND if i- . i *t% r r 'Ji-' * i =. .. ^ .L- s' K^ulir . L-r. .h.... F i. >. VAB.0001192038 Application: Window encapsulations Vista lbs: 7MM Ibs/yr (5% of Vista Flexible) Major Customers: Donnelley, Deckerville FLEXIBLE COMPOUND * it- t- r, - 1 <4 l-i TMi- i - '-K VAB.0001192039 I I Market: Weatherstripping Vista 15MM Ibs/yr (10% Vista Flexible) Major Customers: Central Plastics, Betterbuilt Vytron Macklanbura Duncan FLEXIBLE COMPOUND + ii. t +- -I- piw ,?(. , ........ ... , VAB.0001192040 Other Uses/Markets Flexible Hose and Duct Heating Pads Coated Fence Coated Yarn 4 * T s A| : id ..d. ^ -iff*' -li ***; :y. d .* *r. *j h. I VAB.00011 92041 Formulation / Flexible Compound * PVC Resin + Plasticizer + Other Ingreds. / Other ingredients added to improve performance properties processibility Customize formulation to end-usey processing needs, and economics FLEXIBLE COMPOUND 4 'I*-'' i'i i'i I H` H . i . I- r-.r- I.IN- N 1 Hi'-N*- PI Wlr- I I VAB.0001192042 >! i i i Ingredients !ny V'iiiOOt PVC Resin PR() low cost low flammability Plasticizer flexibility Stabilizer prevents heat degradation Fillers / lowers cost <, ^ /fa : % CC-'v is- } low stability flammability cost inc. hardness r dec. flex. ( 'V&- FLEXIBLE COMPOUND m Ingredients Lubricants i better processibilty Flame Retardant^ flame resist, lower smoke \Antifungal8/ reduce fungus !\ Antimicrobials bacteria / / Pigments color FLEXIBLE COMPOUND A cost toxicity can affect other properties ^ t *- --.1 4< - HM-s . . *..y; = ^ -|J ' f Kl'm L* * * l AB.0001192044 Plasticizer / Gives PVC flexibility & rubbery feel v '/ Vista makes & purchases plasticizer / 108P & 610P made at Aberdeen from alcohols shipped from LCCP Vista also sells & trades plasticizer FLEXIBLE COMPOUND J" 1 VAB.0001192046 i 3s> Product: Wire Jacketing liKjrpdient Resin Plasticizer Filler Stabilizer Flame Retardant Lubricant Cost ($/lh 38 42 5 62 136 40 FLEXIBLE COMPOUND i if i ii * .jw-h I Vr . ( K -H, t -i- I* VAB.0001192047 1 k* . inTiHir fi-+r .--i -h. ,| .. VAB.0001192048 i _ Blend MJiiL (MhLI ) < ;< A A & <;u i VAB.0001192049 3*> p i * - H'TI k- - - -V, I ` L'WiWB fH l I 'll' ^AB.0001192050 LIQUID STABILIZER WEIGH <nSCALE L_ PLASTICIZER (4)WEIGH TANK ACTIVATOR (I) PVC RESIN POWDER FROM VINYL AREA BULK PVC RESIN STORAGE BINS (21 PLANT AIR PLASTICIZER 00 PUMP(S41 EXHAUST BUCKET CONVEYOR INTERMEDIATE HOLD TANK (I) I HOPPER (I) FILLER COLOR 1 MISC SMALL Additives HANO CHARGED TO BLENOER A BANBURY MIX(IE) R / / / (I) VINYL RIBBON DICING SCREENING AREA (2) I------- 1 II *1 I (iMMJDRIBBON blenders (2) > / / 0- WEIGH SC(A2L) E // / ' COMPOUND CONVEYOR II) LINE I 'BUCKET / / TWO ROLL CALANOERING M(IIL)L RIBBON COOLING TRO(IUI GH COOLING TANK (I) I' XJ PROOUCT PACKOUT STATIONS (2) lb BAGS OR IOOO lb i BLOWER ABERDEEN LINE I SCHEMATIC FIGURE 11 't - -:i . !-!> Kjrjfr. VAB.0001192051 k . 4l'l' fittrpivn% *-< ' n >I umn , 'VAB.0001192052 Vista's Competition < 'Ompany Vista V Capacity (MM !L>s/yr) 260 % PVC. P!i 100,50 BF Goodrich 220 100,0 Tek nor-Apex 150 0,100 Cary 110 0,0 Gary 80 0,0 North American 75 0,0 !' *d1 > y Othbl iS il FLEXIBLE COMPOUND VAB.0001192053 Testing / Why do w test? quality control product development certification y Used to predict performance / Comparative tests /Test methodology - ASTM FLEXIBLE COMPOUND 4 'T '-in i i ,i I >>VAB.0001192054 Tests I'Mifuji ty Tested Hardness (resistance to indentation) Flexibility Strength Resistance to Tearing Electrical Properties let, I Durometer Hardness Tensile (elongation) Tensile (strength) Tear strength Resistance FLEXIBLE COMPOUND ff _ VAB.0001192055 VAB.0001192056 What's New? / Rotoflex 7 PlenexTM FLEXIBLE COMPOUND VAB.0001192057 What's New? Rotoflex I ' m I 4 yDry* Flexible Blend y Made with special ingredient that absorbs excess plasticizer / Made at Premiere on dryblend unit FLEXIBLE COMPOUND I >/ Used to make automotive interior "skins" >/ Current customer: Toyota (Camry instrument y Market potential: Ibs/yr in y Powder >4 'l h ih n |J VAB.0001192059 4 What New? Plenex Low smoke flame wire cable compound plenum applications / Plenum space: area between false ceiling and floor in commercial buildings very strict smoke & flame requirements competition is flouropolymers FLEXIBLE COMPOUND t in *. \^B.0001192060 h VAB.0001192061 MARKETS FORMULATION MANUFACTURING TESTING WHATS NEW? 11 VAB.0001192062 4 VAB.0001192063 PVC PIPE i PRODUCTION PROCESS -EXTRUSION FINAL PRODUCTS -POTABLE WATER (PW) -SEWER -DRAIN. WASTE AND VENT (DWV) -IRRIGATION -ELECTRICAL -COMMUNICATIONS CONDUIT -CORRUGATED DRAINAGE VISTA PRODUCTS -5385 -80273 -80174 IMPORTANT CONSIDERATIONS -COST -OUTPUT RATES VAB.0001192064 PVC PIPE FITTINGS PRODUCTION PROCESS -INJECTION MOLDING FINAL PRODUCTS f -COUPLING FITTINGS -'`TEE" FITTINGS -'ELBOW" FITTINGS VISTA DRYBLENDS -90171 -90172 IMPORTANT CONSIDERATIONS -HEAT STABILITY -MELT FLOW iT -t ... ........................................................ I"- -1 . |.. =, f-i. - J;.j -S 1 A' -ci-rfl' *VAB.0001192065 ll.it-1- . . T t'.L'i n -tai-i ! I L 1- -i . i . '1^ ..k . . PVC PRODUCTION PROCESS THIN SHEET THICK SHEET FINAL PRODUCTS CALENDAR SHEET EXTRUDED SHEET VISTA DRYBLENDS IMPORTANT CONSIDERATIONS CALENDARING EXTRUSION BLISTER PACKAGING CREDIT CARD STOCK FLOPPY DISKS WALL COVERINGS SANITARY WARE ACID TANKS RP 421 RP 442 RP 461 SURFACE APPEARANCE IMPACT STRENGTH VAB.0001192066 VINYL PRODUCTION PROCESS -EXTRUSION FINAL PRODUCTS -HORIZONTAL SIDING -SIDING TRIM -CORNERS -SOFFIT -INDUSTRIAL SIDING -MOBILE HOME SKIRTING VISTA PRODUCT -5385 IMPORTANT CONSIDERATIONS -WEATHERABILITY -IMPACT STRENGTH -OUTPUT RATES -COST PVC PROFILES PRODUCTION PROCESS -EXTRUSION FINAL PRODUCTS INTERIOR PROFILES ('CUSTOM') I EXTERIOR PROFILES -APPLIANCES -INTERIOR CONSTRUCTION -AUTOMOTIVE -WINDOW FRAMES -DOORS -FURNITURE -MOBILE HOME SKIRTING -GUTTERS VISTA PRODUCT -RP 200T IMPORTANT CONSIDERATIONS -SURFACE APPEARANCE -WEATHER ABILITY -IMPACT STRENGTH VAB.0001192068 GOOD PROCESSING (EASE OF FABRICATION) GOOD PROPERTIES IN FINISHED PART OTHER (SECONDARY) 1 * 1` VAB.0001192069 *:iH--sfll'J- : i L-*.' rfi. A * ALWAYS: RESIN STABILIZER LUBRICANT USUALLY: PROCESSING AID IMPACT MODIFIER PIGMENT FILLER 1 * -i ' i"-1 h & . |J J ^l| Fnil ..i VAB.0001192070 * Phr: Parts per Hundred Parts Resin Reason: Convenience for formulation development Simple example: 5385 86 Stabilizer 2 Lubricant 2 Impact modifier 6 Filler 4 A VAB.0001192071 I- TOUGHNESS (IMPACT STRENGTH) APPROPRIATE STIFFNESS WEATHERABILITY AS NEEDED I APPEARANCE: SMOOTHNESS, GLOSS, AND COLOR OTHER: CHEMICAL RESISTANCE, ETC. r p+* H- - .|.i VAB.0001192072 Decision - which MW? Limitations - c -fid I'.............. VAB.0001192073 RPVC Stabilizer Selection A CaZn weak stabilizer. In past used only where very low toxicity & odor needed. May replace much Pb and BaCd in European RPVC. Vast majority of RPVC in USA is Sn stabilized. Good balance of properties. Sb generally similar to Sn but less effective. Minor. fr ihlrri. 1 1 t lI **l' 1 ' Hv +- -l- VAB.0001192074 PVC Degradation Causes: HC| generation Color Change Melt viscosity increases (cross-linking) I Physical properties change Therefore, stabilizers affect processing and end-use properties. Essential additive T I IT .... ........................ *- J.ur; : ,M.W m*. '1^- >- W*- ' I , r.| VAB.0001192075 V I 1 I Function- Assist processing: I Reduce melt viscosity and shear Boost thermal stability (often indirectly). Provide metal release Control fusion Use is mandatory. Types (theoretical) - Internal Calcium Stearate Generally use 2 or more lubricants in combination. i % > h 'I I 1 '" 11'll . T A Internal lubricants - not frequently used reduce melt viscosity only External lubricants - generally retard fusion - provide metal release reduce melt viscosity "wax" Calcium stearate - promote fusion reduce melt viscosity - costabilizer VAB.0001192077 1 '* B itf-nik * -fc A i- r VAB.0001192078 - :p. IMPACT MODIFIERS FUNCTION IMPROVE IMPACT STRENGTH MORE DUCTILE LESS BRITTLE RUBBERY COPOLYMERS MAJOR TYPES INTERIOR - MBS EXTERIOR - ABS VAB.0001192079 > *1i il'i r' : M ' ^fK- -Ij. '. H-r. - <1 : '-I1- lL..piK>p . - COLORING RIGID PVC Color Concentrate: Pigment "Dispersed" In Carrier Carrier Can Be: Wax Liquid (E.G., Plasticizer) Other Compatible Polymer (E.G., EVA) Raw Pigment VERSUS Dispersion Problems Messy lgment Color Variations Cheap Flexible Multi-Component Requires Intensive Mixer Fast Response Color Concentrate "Some" Predispersion Less Cross-Contamination Uniform Color Expensive Inflexible Single Component Can Add On - Line Slower Matching VAB.0001192080 1' !*l * it - : | Functions Reduce cost flbfooknne?) Mgrhanhm Physical ChemicaBy inert re; PVC rhmiigaii Times Caidum carbonate (almost exclusively) 1 t tr 1 ii .......... r ' v VAB.0001192081 < * "'i ,M TYPICAL RIGII COMPOUND r PVC RESIN STABILIZER LUBRICANTS PROCESSING AID IMPACT MODIFIER FILLER PIGMENT 100 0.4 - 2.0 2.0 - 4.0 0 - 3.0 0 - 8.0 0 - 10.0 1.0 15.0 BASIS OF COMPOUND THERMAL STABILITY PROCESSING EASE PROCESSING EASE IMPACT STRENGTH COST REDUCTION COLORING BALANCING PROPERTIES IS KEY 7 MECHANICAL PROPERTIES STIFFNESS / FLEXIBILITY TOUGHNESS USE TEMPERATURE RANGE 7 APPEARANCE y FIRE RETARDANCY y PROCESSABILITY y CHEMICAL RESISTANCE y INTERFACIAL PROPERTIES y WEATHERABILIT Y 1 1> N 11 r i VAB.0001192083 MANUFACTURE RIGID PVC i ti . 'i--' -rt?r<p tc QHd r j -I i. VAB.0001192084 I l OFTEN DETERMINED BY EQUIPMENT. SINGLE SCR6W8 FAVOR PELLETS, ESPECIALLY NON-VENTED SINGLES. PELLETS ARE ALSO CLEANER: LESS DUST & LEAKAGE. DRYBLEND ADVANTAGES: LOWER MANUFACTURING COST ONE LESS HEAT HISTORY (LOWER STABILIZER COST OR HIGHER STABILITY) TWIN SCREWS WORK BETTER WITH DRYBLEND LESS OPPORTUNITY FOR COMPOUNDING VARIATIONS T ' <' 'll ` 1 41.' -fWl I- . *r -t ..... H 11+ -J, ibr- . ., VAB.00011 92085 BLENDING HOMOGENEOUS MIXTURE HIGH INTENSITY MIXING HIGH SPEED HIGH SHEAR HEATING i 7 w- ' ' t l .................. r 14H** - -- * ..i . h " i 1I * sri . I *r 1air M hhld-Ui. . 1 1i- . . VAB.00011^2086 t N RESIN LUBRICANTS MODIFIERS COLORANT MA8TER BATCH BLENDER VISTA DRYBLEND UNIT-ABERDEEN MASTER BATCH USE BIN BULK SILO BOXING HOPPER STABILIZER FILLER RE9IN TI02 WELEX QC 8AMPLE '* 1 * A h-*-' -I DI8CARD OVERS* VAB.0001192087 COMMON TESTS RIGID PVC COMPOUNDS IZOD IMPACT HEAT DISTORTION TEST TENSILE TEST f n-i* -t t I VAB.00011 92089 3* -k taclli strength Is lbs maximum pulling load a nmtierlal can support before yielding or breaking. ? 1 E i'* r*- 1 1** * ' #--< i u. q- .d h . j. ... l --?- ,-m. .. -K-rn rnvir-iKiii .0001192090 Strain Ttaulto iHm|Ui Is tN ualaf Uoaik bar. 1 IV .. .j VAB.0001192091 Pfelllag Dait Ibrt laod lapaat Dut 1| l>. -J k , h"-rJ, - sr lb s: VAB.0001192092 lyptoi Cor thla test DjMtm Quito MIlUDait MMlTflf to Nwl NmUi| whoa struck os oiwfaoo + 1*. .. *- itp - H - + * i -.i-- . I VAB.0001192093 # Unnotchcd laod Notched Izod la ft/lbe per Inch. 1 . . . . . . . , . .. . . . . . . . . H .1| FIH f ML . VAB.0001192094 i 4-t SF' " t* -n 4H VAB.0001192095 ' i1 1'* * If T r. r 1 I--.- .'H. . VAB.0001192096 -- 1 APPLICATIONS VISTEL TM SPECIALTY PLUMBING FITTINGS VALVES TANK HOUSINGS OUTDOOR PRODUCTS ELECTRICAL OUTLET BOXES RAIN GUTTER FITTINGS PATIO FURNITURE GENERAL PURPOSE ELECTRIC BLANKET CONTROLS TELEPHONE JUNCTION BOXES OTHER rf 1 I I ' - ................. - fHM- h L-: . r I r V- '- I VAB.0001192097 END USE BENEFITS VISTEL'" INHERENT FLAME RETARDENT CHARACTERISTICS EXCEPTIONAL PHYSICAL STRENGTH AND IMPACT RESISTANCE GOOD STIFFNESS AND CREEP RESISTANCE RELIABLE UV COLOR STABILITY AND WEATHERABILITY EXCELLENT SURFACE APPEARANCE AND GLOSS OUTSTANDING CHEMICAL RESISTANCE Ll * v. k l|Tf-' . ->r h- r i i i VAB.00011^2098 SUPREIT ENGINEERED THERMOPLASTIC POLYMERS SUPRELTM-- FAMILY OF COMPOUNDS INCORPORATES PVC AS AN INGREDIENT COMBINATION OF POLYMERS VERY UNIQUE PROPERTIES HDT IMPACT COLD TEMPERATURE PROCESSING LATITUDE CUSTOM FORMULATED VAB.00011^2100 * PVC OVERVIEW 1I i ri| inV i .;i p J;l I VAB.0001192101 i TP i i l . irt-H ii- i i )i i i r VAB.00011^2102 i Polymers Research Group v/Purpose of Polymers Research: develop new products improve existing products troubleshoot customer problems y Approx. 35 in Austin R&D y 6 in Aberdeen plant (Tech Service Lab) PVC OVERVIEW Polymers Research Group Current Research >/ PVC based polymeric blends & alloys (e.g. SuprelTM) 7 Recycling & waste minimization y Alternatives for heavy metal additives y Lower molecular weight resins PVC OVERVIEW Polymer Technology J. P. Kirkpatrick Diirector Secretary V. G. Dougrey b H. J. Hail Senior Research Associate K. G. Mieure Development Manager Material R&D D. L. Wharry Research Manager R. E. Asay C. D. Foshay M. D. Hein D. Mok E. V. Visneski J. Wallace C. P. Walters Resin Technology H. G. Coleman Sr. Group Leader R. C. Howe J. L. Irvine J. M. Janes TESTING L. G. Clopton D. L. Ashley E. Marshall 1 M* Safety/Environ R. B. Martin Supervisor Technical Service R. D. Jackson Research Manager S. R. Goodman J. E. Ingram J. V. Miller J. M. Quackenbush Application Dev. S. H. Hookanson Research Manager BETA G. A. Butler F. E. McAndrew B. A. Rushing M. M. Tannahill WIRE/CABLE M. T. Corwin C. E. Hoover G. A. Jackson 4 ur VAB.0001192105 t HI | , Summary Why PVC? low cost good physical, chemical, weathering properties variety of processing techniques PVC resin is not useable by itself PVC Compound PVC Ream Other Ingredients Rigid Compound Flexible Compound (has plasticizer) Vista sells PVC Resin, Rigid & Flexible Compound Customers who buy resin make compound themselves PVC OVERVIEW Summary PVC Compound - two physical forms: Blend (powder) Rigid (dryblend) Flexible (Rotoflex Pellet Rigid (VistelTM F lex ible Customers process Compound into final product: Extrusion Injection Molding Calendering Vista is... 6th largest Resin Largest Flexible Compound 4th largest Rigid Compound ...producer (by capacity, domestic) PVC OVERVIEW * It V -i- i s* VAB.0001192107