Document nkaJDyR7ROpry9aR056ndeJ7a

POLYVINYL CHLORIDE RESINS BY H. E. FREY PLASTICS ANO RESINS 580.188! A SEPTEMBER 1973 TABLE OF CONTENTS STATUS AND OUTLOOK.......................................................................................................:........................... Status .......................................580.1881 C Outlook ............................................................................. ....... ....................... . ....................... 580.1881 c 580.1881 J DESCRIPTION................................................................................. . . . ....................................................................... Vinyl Chloride ....................................................................... ..... ................................................................................. Polyvinyl Chloride Resins ............................ , ............................................ ........ 580.1882 A 580.1882 A 580.1882 A MANUFACTURING PROCESSES . .................................................................................................................................. . Vinyl Chloride ............................................................ ..... .................................................................. Polyvinyl Chloride Resins .................. ............................ Polymerization of PVC Resins ......... ............................................................ 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 C 580.1882 d 580.1882 D 580.1882 D 580.1882 E 580.1882 F 580.1882 F 580.1882 G PRODUCING COMPANIES, PLANT LOCATIONS, AND CAPACITIES Vinyl Chloride Polyvinyl Chloride Resins 580.1882 H 580.1882 H 580.1882 H PRODUCTION AND SALES Vinyl Chloride Polyvinyl Chloride Resin 580.1882 M 580.1882 M 580.1882 N CONSUMPTION .............................................................................................................................................................................. Vinyl Chloride ......................................................................................................................................................... . Polyvinyl Chloride Resins .................................. ............................ . ................................................. Consumption by Process ....................................... ................ Extrusion Processes ................................................................ Calendering Processes ....... ....................... Dispersion Processes ....... ................................. . ....................................... Molding Processes ................... ...................... Solutions ........................................................... All Other Uses .................................................. .......... ............................ Consumption by End Use............................................................................................................................. Building and Construction ........................................................................................, Household Uses .............. ...................... . ....................... . Consumer Goods .... ...................... ................. Electrical Uses ......................... Packaging ..... .................................. ................ Transportation....................................................... Miscellaneous Uses......................'. . .......................................................................................... 580.1882 Q 580.1882 Q 580.1882 Q 580.1882 R 580.1882 S 580.1882 V 580.1882 X 580.1883 A 580.1883 D 580.1883 E 580.1883 F 580.1883 G 580.1883 K 580.1883 M 580.1883 N 580.1883 P 580,1883 R 580.1883 R f t \ I i a * , CHEMICAL ECONOMICS HANDBOOK STANFORD C S(**CM INIIITurt UCN10 F*ll, CAL roftMi BFS 007139 580.188S 8 > V / *! BFS 007140 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 680.1881 C SEPTEMBER 1973 STATUS AND OUTLOOK Status In 1972, at least 97% of the nearly 4,6 billion pounds of vinyl chloride consumed In the United States was used to produce polyvinyl chloride (PVC) homopolymer and copolymer resins. Production of these resins totalled over 4.2 billion pounds and, at an estimated average unit sales value of 13.0 cents per pound, the production value was approximately 550 million dollars. The status of vinyl chloride and PVC resins in 1972 is summarized in the following table. Data in this table are taken from the PRODUCING COMPANIES, PRODUCTION, CONSUMPTION, and INTERNATIONAL sections of this report. b. The difference between Production and the sum of Domestic Consumption and Exports is believed to be largely due to stock changes (imports were only 4 million pounds). About 93% of the vinyl chloride manufactured in the United States in 1972 was produced by eight companies from ethylene dichloride made by the oxychlorination of ethylene (CEH estimate). The other 7% was made by the only two producers who are still producing vinyl chloride by the addition of hydrogen chloride to acetylene. Total U.S. vinyl chloride capacity as of January 1, 1973, is believed to have been 5,765 million pounds per year (CMR. January 1, 1973, p. 30). The three largest vinyl chloride producers (Dow Chemical U.S.A., PPG Industries, Inc., and Shell Chemical Company) made vinyl chloride only whereas the others also produced polyvinyl chloride resins. Production problems at the PPG plant in Puerto Rico led to a shortage of vinyl chloride during the first half of 1973. U.S. production of vinyl chloride had an average annual growth rate of 14.9% between 1961 and 1971, and of 19.9% between 1966 and 1971. In 1972, U.S. vinyl chloride production was 19% higher than in 1971. Although almost all vinyl chloride domestically consumed is used in the production of PVC resins, some (believed to amount to less than 3% of total CHEMICAL ECONOMICS HANDBOOK S!r0*0 (SCCH INSTITUTE, MENLO PANS, CALIEOftNt* ! BFS Q07141 I r:f_ POLYVINYL CHLORIDE RESINS - CONTINUED .production)' is`used In the production of methyl chloroform, as an additive la specialty coatings* and as an additive In certain aerosol mixtures (CEH estimate), ^ . The list price of vinyl chloride decreased from 8 cents per pound in 1962 to 4.7 'cents. " per pound in 1972. In early 1972, actual selling prices are believed to have bees close . - . to- this list price. in December 1972, vinyl chloride prices climbed to 5 cents per pound, and In early 1973, they climbed further. Most long-term contract holders, however, are believed to obtain the monomer at prices far below those list prices (CMK, Marcb2, 1973, P. 12). Exports of vinyl chloride were not officially reported until 1970 when they amounted to 664 million pounds (Belgium received almost half of the total). In 1972, vinyl chloride exports amounted to 621 million pounds. Norway was the largest importer (with over 20% of the total), followed by Belgium and Spain. U.S. imports of vinyl chloride^have been negligible. In 1972, PVC resins were made by 22 U. suspension, emulsion, bulk, and solutio es using one of four basic processes-- rizatlon. About 78% of all PVC resins (bpthn^nopolymers and copolymers) produced in the United States in 1972 were producgd^bj^suspension polymerization and about 13% by emulsion poly merization. In the Unite4^&mses, all PVC resins produced by emulsion polymerization are used in plastisols (fftila\Uspersions of resins in plasticizers) or as latex. Bulk polymerizatiot&y7,'relatively new process in large-scale PVC production, was used to make 6% of the 1972 u. S. PVC production. Bulk-polymerized resins perform with excellence in calendering, extrusion, and molding. Solution polymerization (which is carried out In an organic solvent such as n--butane or cyclohexane) is used exclusively for the production of certain copolymers of vinyl chloride with vinyl acetate (usually those containing 10-25% acetate). In 1972, about 3% of the PVC resins produced in the United States were made by this process. They are mostly used in protective coatings and, to a minor extent, in adhesives. PVC resin production grew at an average annual rate of 13.4% between 1961 and 1971, but since 1966, the growth rate averaged only 9% per year. Then in 1972 alone, production grew almost 23%. Production of polyvinyl chloride resins in the first three months of 1973 was 1,175 million pounds--17.8% higher than in the comparable 1972 period, based- on SP1 statistics (Monthly Statistical Report. The Society of the Plastics Industry, Inc., March 1973). Moat large PVC resin manufacturers are also involved in the production of either compounded PVC resins or PVC end products or both. Data for the captive consumption of PVC resins by resin manufacturers have been reported by the U.S. Tariff Commission in recent years but it Is believed that the reported data are understated in all years. For example, In 1970 the reported data indicate that only 138 million pounds of resin were captively consumed. How ever, one source (MP, March 1971, p. 63) has estimated- that as much as BOO million pounds of PVC resins went into captive consumption. Captive PVC resin consumption for end products x, *1 I i BFS 007142 x POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS '..."................................. ....... 580,1881 E SEPTEMBER 1973 (not* counting compounded resins) in 1971 is believed to have been again about 800 million pounds (CEH estimate based on communication with industry). PVC resin consumption is considered from two standpoints in the following discussion; (1) by the type of process employed in converting the resin to end products and (2) by the ultimate end use. PVC resin consumption in the major process categories in 1972 is summarized in the follow ing table. U.S. Consumption of PVC Resin by Process--*1972 Percent of Total PVC Consumption All Other Total 180 4,180 49% 23 11 10 3 4 100% a. Components are; Coating--Flooring, and Textile and Paper Coating; Paste Processes--Plastisol Formulation, and All Other. b. Components are: Bottles (blow molding), 77 million pounds; Sound Records (compression molding), 148 million pounds; All Other Molding (believed to be substantially all injection molding), 185 million pounds. c. Reported as "Protective Coatings" (59 million pounds) and "Adhesives and All Other Coating Uses" (also 59 million pounds). Believed to include mostly solutions but also some dispersion and powder coatings. Sourcb: Annual Statistical Report, Plastics It Resins Materials, 1972, The Society of the Plastics Industry, Inc., April 1973, CHEMICAL ECONOMICS HANDBOOK $ t JtNF 00 !IST I TUtt CNL0 ft* C*L t F Oft N I fe ~ BFS 0B7143 S8CU881 F , POLYVINYL CHLORIDE RESINS - CONTINUED The average annual growth rate for total domestic PVC resin consumption by process between 1961 and 1971 was 13.2%. However, the average annual growth rate between 1966 and 1971 was only 9.4% per year. Then, an over 27% leap occurred in 1972 alone. Growth in domestic PVC resin consumption in 1972 was over 27%, a phenomenal increase. In the January through March period of 1973, domestic PVC resin consumption was 1,213 million pounds, another 24.9% advance over the comparable 1972 period (Monthly Statistical Report, The Society of the Plastics Industry, Inc., March 1973). Historical trends of the 1961-1971 period are briefly discussed below. PVC consumption in extrusion processes has shown particularly impressive growth--18.3% per year between 1961 and 1971 and 17.7% between 1966 and 1971. Rigid extrusions (which con sumed approximately 740 million pounds of PVC resins in 1971) have been the growth leader, mostly with pipe and conduit, where about 500 million pounds of PVC resins were used in 1971 (CEH estimate). Two large PVC resin producers are also leading PVC pipe producers. Other rigid extrusions, each consuming over 100 million pounds of PVC resins in 1971, include: (1) siding and other rigid profiles, and (2) rigid film and sheet. Flexible extrusions (in which approximately 5' 1971) consist mostly of (1) wire and cabl^(3 profile extrusions such as cove base, g$@kpts garden hose, and (3) packaging filjlfTor >unds of PVC resins were used in Lon pounds in 1971), (2) a variety of weather stripping, medical tubing, and PVC consumption in calepdeftinjM ftpdcesses approximately doubled from 1961 to 1971 but the average annual growe&from 1966 to 1971 was only 2.5% because there was no growth in calendered flooring and:alender-coated textiles in recent years. The share of total PVC resin consumption represented by calendering declined from 44% in 1961 to 36% in 1966 and to 26% in 1971. Of the 835 million pounds used in calendering processes in 1971, 474 million pounds were used in film and sheeting, 274 million pounds in flooring, and 8? million pounds in the production of calender-coated textiles. PVC consumption in dispersion processes grew at an average rate of 15.3% per year between 1961 and 1971 but only at a rate of 7,7% between 1966 and 1971, largely because of very slow growth in textile and paper coating uses. These processes employ liquid dispersions of PVC resins in plasticizers (called plastisols in their most common form) and also PVC latexes, which are used to a minor extent. These liquid dispersions are converted into end products by dipping, spraying, rotational casting (slush molding) or coating--usually in thick layers (with plastisols). Coating substrates may be metal objects (e.g,, .tool handles) or textiles, paper, or felt (for cast flooring). PVC resin consumption In molding processes had an average annual growth of 15.7% from 1961 to 1971, and a rate of only 5.6% between 1966 and 1971. The compression molding of phono graph records consumed 138 million pounds of resin in 1971 but this use has not grown in recent years. PVC resin consumption in injection molding more than doubled in 1971 to reach 135 million pounds--most of the recent growth took place in the injection molding, of pipe fittings. Another growth field is that of the blow molding of PVC bottles, where PVC resin usage rose from about 5 million pounds in 1965 to an estimated level of 70 million pounds in both 1970 and 1971. V i 4 BFS ( 007144 POLYVINYL CHLORIDE RESINS - CONTINUED -- - - ' --v- > . ' vV-;- - PLASTICS AND RESINS 580.1881 G SEPTEMBER 1973 PVC resin consumption in the form of. solutions had an average annual growth rate of 9.6% between 1961 and 1971; these solutions- (including some other forms of coatings, e.g., dispersion and powder coatings) are used in adhesives and protective coatings. Most of the poundage reported under the. U.8. Tariff Commission "All Other" category is believed to have been consumed by the- various previously specified processes in mostly unknown proportions. In addition, relatively minor amounts of PVC resins may be included that may not have been covered by the major process categories, e.g., rigid PVC foams. PVC resin consumption by end use in 1972 is summarized in the following table. U.S. Consumption of PVC Resins by End Use--1972 (Millions of Pounds) Building and Construction Household Uses 1,739 630 S04 439 357 255 256 4,180 Source: MP, January 1973, p. 58, and Annual Statistical Report, Plastics fc Resins Materials. 1972, The Society of the Plastics Industry, Inc., April 1973. After the over 27% leap of the year 1972, which resulted in the consumption figures listed in the foregoing table, an analysis of the trends during the 1966-1971 period may still be useful (older data of relevance are not available). The average annual growth rate of PVC consumption by end use was 9.9% between 1966 and 1971. PVC resin consumption in building and construction grew at an average annual rate of 13.7% between 1966 and 1971. As a percent of total PVC resin consumption by end use, it grew from 20% in 1966 to 35% in 1971. Over half of the resin consumed in 1971 (600 million pounds) was used In the production of pipe, conduit, and pipe fittings, which had a com bined average growth rate of 34% per year between 1966 and 1971. In 1971, PVC is esti mated to have had well over half of the total plastic pipe and conduit business. Almost 60% of this PVC was used in water supply pipe for residential and irrigation uses. CHEMICAL ECONOMICS HANDBOOK ST***ro0 csttacN INSTtTOTt MCHlO AAftft CAL I FOftft I * BF5 007145 500,1881 H POLYVINYL CHLORIDE RESINS - CONTINUED The ot^er major component of PVC resin consumption in building and construction is flooring. Although 325 million pounds of PVC wore used rn 1971, this market was down from 370 million pounds in 1966. The decrease is generally attributed to the very large increase, in the use of carpets in recent years. Smaller end-use areas within building and construction that have shown outstanding growth in recent years include siding (60 million pounds in 1971) and windows and other rigid profiles (55 million pounds in 1971). The remaining components are swimming pool liners, weather stripping, waterstops, lighting, and rain gutters, with a combined consumption of 115 million pounds in 1971. A new and important market is in extruded, foamed PVC rigid profiles. PVC resin consumption in household uses grew at an average annual rate of 5% between 1966 and 1971. As a percent of total PVC resin consumption by end use, it declined from 21% in 1966 to 17% in 1971. Some 260 million pounds (almost half of the total PVC resin con sumption in household uses) was in furniture upholstery in 1971 (almost all of this was used in coated fabrics). The next largest household use is in vinyl wall coverings (85 million pounds in 1971). The other components include garden hose, tablecloths and placemats, shower curtains, closet accessories, appliag&es, wood-surface films, and other uses, with a combined consumption of 219 million pQHjufs^pf) PVC resins in 1971. PVC resin consumption in consumer goodq? gri&Mt an average annual rate of less than between 1966 and 1971. As a..percerr^of &>tal PVC resin consumption, it declined from 17% in 1966 to 13% in 1971. The latest market in this category, phonograph records, consumed an estimated 125 million pou^W^p?) PVC resin in 1971 but this market had shown little growth in recent years arfi3^i^pblly declined slightly in 1971. The next largest consumer goods end use is in>f5(a good growth market in recent years), where 115 million pounds of PVC resin consumed in 1971. Other uses, with a combined consumption of 197 million pounds of PVCrresin in 1971, include toys, outerwear, sporting goods, baby pants, and other uses. PVC consumption in electrical uses grew at an average annual rate of 11% between 1966 and 1971 and remained at 11-12% of total PVC resin consumption by end use. Practically all of the consumption in 1971 was in wire and cable and close to half of this was in building wire. PVC resin consumption in packaging grew at an average annual rate of 26% between 1966 and 1971. As a percent of total PVC resin consumption by end use, it was 4% in 1966 and almost 9% in 1971. Most of the PVC resin consumption in packaging is in film and sheet (185 million pounds in 1972). PVC consumption in packaging film and sheet has been a rapid growth area since 1967. Resin consumption in film has doubled and in sheet it has in creased five-fold. Plasticized extruded film has captured a large part of the produce and meat packaging market, and rigid sheet goes mostly into blister packaging. The second largest packaging use is in bottles (70 million pounds of PVC resin in 1971), where con sumption more than tripled from 1967 to 1970. However, uncertainties from considerations of environmental protection have resulted in a flat performance in 1971. (PVC liberates hydrogen chloride when incinerated. It has been asserted that hydrogen chloride is not only a serious pollutant but it can also damage conventional incinerators, and that without incineration, PVC packaging materials represent a solid waste problem after use). Can s li , \\ H i'i ,9 if BF5 007146 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS ANO RESINS 580.1881 t SEPTEMBER 1973 coatings, bottle cap liners, and gaskets represent additional, relatively small, packaging uses, which together consumed 31 million pounds of PVC re9in in 1971, PVC resin consumption in transportation grew at an. average annual rate of 7:7% between 1966 and 1971. As a percentage of total PVC consumption, it was 8.5% in 1966 and 7.7% in 1971. The bulk of the consumption is for automotive upholstery and seat covers, auto floor mats, and vinyl auto tops. Miscellaneous uses, which advanced at an average annual rate of 4% between 1966 and 1971, include laminates (believed to include primarily luggage, covered plywood and wallboard), medical tubing (a rapid growth area), stationery supplies, and various other smaller end uses. Prices of polyvinyl chloride resins vary depending upon the type. The overall unit sales value was 18 cents .per pound in 1962 and is believed to have been about 13.5 cents per pound in 1972. As of April 1973, general-purpose PVC moved at 13 cents per pound, and dispersion resins at 22 cents per pound (communication with industry). Exports of polyvinyl chloride resins are relal the 30-40 million pounds-per-year range of 190 million pounds in the 1969-1971 pejsiegi'^C* been negligible in recent years. ely small, although they increased from ly 1960's to an estimated level of 160- rts of polyvinyl chloride resins have An estimate of 1972 world pxj given in the following t and production capacity for PVC resins by region is Wor :tion and Production Capacity for PVC Resins- -1972 (Millions of Pounds) Production Western Europe 6,500 United States 4,300 Japan 2,400 Eastern Europe Other Areas Total 1,900 1,200 16,300 a. Estimated capacities as of mld-1972. Annual Capacity 7,900 4,400 3,500 1,800 1,800 19,400 Source: CEH estimates. CHEMICAL ECONOMICS HANDBOOK ST**ro#o atst**CH mmtutt, mchlo c*Liro**i* BFS 0Q714? saaism j ,.m POLYVINYL CHLORIDE RESINS - CONTINUED Outlook PVC resin consumption in the United States is'expected to grow at an average annual rate of about 14% between 1972 and 1975, leading to a consumption level of about 6.2 billion pounds per year by 1975. U.S. production of PVC resins is expected to essentially paral lel this domestic consumption (with exports and imports remaining very small) and to show an average annual growth of 14-15% from 1972 to 1975, and to reach a level of 6.2-6.4 billion pounds in 1975. This la projected on a demand basis. The vinyl chloride monomer shortage that prevailed in aid-1973 largely because of the prolonged production difficul ties at the large PPG plant in Puerto Hico is expected to end in the last quarter of 1973. Outlook for Vinyl Chloride and PVC Resins--1975 Vinyl Chloride 1975 Average Annual (millions Growth Rate of pounds) 1972-1975 PVC Resins 1975 Average Annual (millions of pounds) Growth Hate 1972-1975 ) i \ f > large raw material base. Even though some marginal producers may be forced out in the next few years, total U.S. vinyl chloride production capacity is expected to increase to over 6 billion pounds per year with the addition of a 700 million pounds-per-year plant by Shell Oil Company, Shell Chemical Company, division, at Norco, Louisiana, in late 1973. Production of PVC resins is expected to continue to be based largely on the established methods of suspension and emulsion polymerization (the efficiency of these methods may be improved by new catalyst systems), but a continuous increase in bulk polymerization capacity is foreseen. If the installation of large new capacity based on bulk polymeri zation begins in the next few years, this process could account for as much, as 30% of U.S. capacity by the end of the decade (CEH estimate). The prospect of tight PVC resin supply for the 1973-1974 period, because of the slowness In capacity expansions, has been generally linked to PVC resin prices. At 1971 price levels, expansions were not economically feasible for producers. Between mid-1972 and mid-1973, when PVC resin prices were increased stepwise, several capacity expansions were announced. Some of these were expected to be operational in late i* .i BFS 00714S POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ............ 580.1881 K SEPTEMBER 1973 1973 (Borden, B.F. Goodrich) and others in 1974 (American Chemical, .Firestone) . GeorgiaPacific announced plans to produce PVC. Additional substantial capacity must be on the way if the projected 1975 consumption of 6.2 billion pounds is to be backed by a corre sponding production. Estimated domestic PVC resin consumption by process in 1975 is given in the following table. Estimated Domestic PVC Resin Consumption by Process--1975 Millions of Pounds Average Annual Growth Rate 1972-1975 Extrusion Calendering 3,540 1,180 20% 7 production of rigid film and sheet is expected to grow strongly, and injection molding and blow molding are expected to provide substantially all of the growth in molding. Thus, all rigid vinyl processing is expected to grow strongly except for compression molding. Estimated domestic PVC resin consumption by end use in 1975 is given in the following table. CHEMICAL ECONOMICS HANDBOOK STANFOaO atscaacM i*st i lurt WCMtO A4#a, CAL Iroawt*~- BF5 007149 SBQ.I8HC POLYVINYL CHLORIDE RESINS - CONTINUED Estimated Domestic PVC Reain Consumption by End Use--1975 Millions of Pounds Average Annual Growth Rate 1972-1975 Building and ' Construct Ion Household Uses Packaging Wire and Cable Consumer Goods Transportation Miscellaneous Uses Total 3,080 750 570 550 620 300 360 6,230 211 6 17 8 7 6 12 14.2% Siding, Panels Windows and Other Rigid Profiles Foam Profiles Other Uses Total Source: CEH estimates, 140 110 10O 170 3,080 25 25 25 10 m * BFS 007150 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1881 M SEPTEMBER 1973 Many segments of the market are expected to contribute to the growth in consumption in pipe, conduit, and pipe fittings, but pipe fittings are expected to have particularly strong growth. Leading in the expected continued expansion of PVC pipe will be low pressure pipe, particularly large-diameter water pipe (12 inches and larger). Other segments that are expected to grow vigorously include telephone conduit and residential hot water pipe--the latter is made from post-chlorinated PVC. In 0WV pipe, PVC's market share is expected to gradually increase further from an estimated 50% of the plastic DWV pipe market as of raid-1973 <CEH estimate based on communication with industry). A breakdown for the estimated 1975 consumption of PVC resins in household uses is given in the following table. Estimated Domestic PVC Consumption In Household Uses--1975 Average Annual Growth Rate 1972-1975 4% 12 Total 4 5 7 rnmmmmm 750 6% Source: CEH estimates. As these estimates suggest, only marginal growth is expected in most of the household uses. Exceptions are vinyl wall coverings (which are becoming widely accepted in insti tutions, restaurants, public and business buildings, as well as homes) and wood surface films (a rather new application of printed semi-rigid film, used in the production of lowpriced furniture). The growth potential of PVC film and sheet, the largest component of the packaging market for PVC resins, is believed to be very good for the 1972-1975 period. The market is expected to reach a consumption level of 570 million pounds by 1975--an average annual growth rate of 17% (CEH estimate). The use of PVC resins in blow-molded containers has been under the cloud of disputed acceptability from a waste disposal point of view. However, recently the use of PVC resins in liquor bottles of all sixes has received the endorsement of the Alcohol, Tobacco and Firearms Division of the Internal Revenue Service. This is taken as a very encouraging development by most industry observers (MP, May 1972, pp. 16 and 18). Thus, a resumption in the growth of PVC resin consumption in blow-molded containers was in full swing in 1972 and consumption is expected to grow at a minimum rate of 21% annually and CHEMICAL ECONOMICS HANOBOOK 5 T AM F 0 *0 E9E**CM TUI | HCNL0 *AHA, CAltrOftWIA i BFS 007151 680.188* H POLYVINYL CHLORIDE RESINS - CONTINUED to reach* a level of at least 140 alllion pounds per year by 1975 (CEH estimate). However, the growth beyond that is, at this point, difficult to predict with any degree of relia bility because this field is so new. Wire and cable production constitutes substantially all PVC consumption in electrical uses. Building wire and communication wire together account for 65% of all PVC usage in wire and cable and are expected to consume a total of 390 million pounds of PVC resins by 1975--a growth rate of 10-12% per year (CEH estimate). Building wire is expected to remain the largest application for PVC because of the anticipated continuing strength of the con struction business. However, PVC's inroads into communication wire are also expected to deepen (PH. May 1969, pp. 31 and 32). Other wire applications are expected to be marginal growth areas for PVC (CEH estimate), Bionograph records, the largest component of consumer goods, are expected to show only modest growth, approximately 5% per year, to reach approximately 173 million pounds of PVC resin consumption by 1975 (CEH estimate). The second largest consumer applicati children's shoes, and in innersol annually to reach 190 million ppu C resins, footwear (mostly in lower priced lining, and soling), is expected to grow about 10% 1975 (CEH estimate). All other consumer goods-'-applications of PVC, including toys, outerwear, baby pants, sport ing goods and variified other uses in this area (such as home movie screens), are expected to continwa.1rffwHeir established patterns and are expected to grow at rates be tween 5 and 8%.J0r ywa?'. However, there are two exceptions: wigs and plastic Christmas trees. Both'`&pLr^latively small and recent consumer applications which are expected to show above average growth in the next several years. Diverse miscellaneous uses that are believed to have a growth potential of greater than 10% per year between 1972 and 1975 include foamed carpet underpadding, biomedical applica tions, credit cards, and rigid PVC foams (CEH estimates). One industry source believes that future PVC consumption for rigid foams could become substantial. PVC resin prices are expected to remain firm as resin supply tightens in the second half of 1973. Further gradual increases across the board are likely in the 1973-1975 period (CEH estimate based on communication with industry). * I [g * m I i BFS % ) t' 0B7152 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS ANO RESINS 58Q.1882 A SEPTEMBER 1973 DESCRIPTION Vinyl Chloride Vinyl chloride,* a gaseous reactive intermediate which is derived from ethylene or acety lene, is essentially all consumed in the production of polyvinyl chloride and copolymer resins. Only a minor amount is consumed in other uses (e.g., as a chemical intermediate). Polyvinyl Chloride Resins The term "polyvinyl chloride (PVC) resins" is meant to include vinyl chloride homopolymers with the repeating unit -CH^CHCl- and copolymers of vinyl chloride with minor amounts of vinyl acetate, ethylene, propylene, vinylidene chloride, or acrylates. Most are available in the form of white powders that, after compounding with a number of auxiliary ingredi ents, are converted into a large variety of plastic or resinous end products through several types of processes. Because PVC resins are thermoplastic, all but one of these processes for converting PVC powders employ heat to make the end product (coating resins are processed by dissolving the resin anct'irap'fyi.ng it from solution). Industrial development of PVC res- some 40 years ago. Production on a full com- mercial scale began in German} 1931*8nd in the United States in the late 1930's, after W. Semon at The B. F. Goodrich CdtSpany had discovered that polyvinyl chloride, when heated in. the presence of a high-boiling liquid (a plasticizer), formed a flexible plastic material th^^r^^abled rubber or leather. Because plasticized PVC showed itself to be a good iagSy.^og4 resistant to the weather, and nonflansnable, it was put to military uses in World Diversified compounding and processing technology, which developed particularly in *the late 1940`s and early 1950's, quickly led to many broad-scale com mercial uses. The processing and performance characteristics of PVC resins can be varied with the molecu lar weight, which for most commercial PVC resins lies between 50,000 and 120,000, Equally important to the characteristics of the resins is the presence or absence of plasticizer. Most PVC plastics produced in past decades were flexible types, containing plasticizer. While the many processes for plasticized PVC are relatively easy to carry out, the process ing of PVC compounds containing essentially no plasticizer (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. The general performance characteristics of PVC plastics include mechanical toughness, 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. Those PVC plastics which contain less than 10% by weight of plasticizer tend to exhibit poor impact strength at low temperatures. * Details about the properties and industrial handling and storage of vinyl chloride may be found in the article by Shelley, P. G., and E. J. Sills, "Monomer Storage and Protection," CEP, April 1969, pp. 29-36. CHEMICAL ECONOMICS HANDBOOK STANro0 ACStAHCH INSriTOfC, MCKIO C*lir0NI BFS 0Q7153 sao.1883 B POLYVINYL CHLORIDE RESINS - CONTINUED Majoruse areas for plasticized PVC Include flexible fil* and sheeting, flooring, furniture and automobile upholstery, and electrical wire Insolation.' Typical uses for rigid PVC are mostly construction materials such as pipe, conduit and pipe fittings, siding, and window sashes. It is also used to form rigid fils and sheet such as is used In blister packaging, for credit cards, and in the blow adding of bottles. Although the great majority of PVC resins used in the various processes to manufacture PVC plastics are homopolymers of vinyl chloride,' copolymers are still essential in some pro cesses, where they are used alone or in admixture with hooopolymers. The most Important commercial copolymers of vinyl chloride are those with vinyl acetate. The higher molecular weight resins with an acetate content of about 2-8% are used for calendering and extrusion, where somewhat faster processing is possible because of their better flow properties compared with those of conventional homopolymers. Copolymers con taining over 8% vinyl acetate flow even more readily under the application of heat and pressure and are, therefore, favored in the production of phonograph records. These copolymers are also capable of binding particularly large amounts of mineral fillers and pigments, a capability utilized in the production of vinyl-asbestos floor tile. Because the solubility in esters and ketones of vinyl chloride copolymers with an acetate content of 10-20% is much greater than that of homopolymers, these resins are used in solution coatings. The commercial copolymers of vinyl chloKt8te>fath ethylene and propylene contain 1-8% of ethylene or propylene and are predomtaant&yjused in the manufacturing of unplasticized (rigid) PVC products. Such copolymers ^cafl!be processed faster and have better impact strength than comparable horaopmlymerSi, without any sacrifice in dimensional stability and other important perfornanc^pr&perties. Copolymers of tfinylchiorMlVwith vinylidene chloride are more soluble in solvents than homopolymers and fmeyLaregood film formers. The few resins of this type that are on the market today are, ore, mostly used in specialty coatings (in solution and, in some applications, in latex form). A few emulsion (latex) copolymers of vinyl chloride and ethyl, n-butyl, or 2-ethylhexyl acrylate are used in the production of wall coverings, nonwovens, and house paint. Post-chlorinated PVC honopolymer resins have long been in existence but were of little commercial importance until recently. Products made from them have better heat resistance (and higher densities) than products made from ordinary PVC resins. The main application for these resins is in residential hot water pipe. MANUFACTURING PROCESSES Vinyl Chloride About 93% of the vinyl chloride produced in the United States in 1972 was produced from ethylene dichloride made by the.oxychlorination of ethylene (CEH estimate). In this process, ethylene is reacted with hydrogen chloride and oxygen to give ethylene dlchlorido, which is subsequently cracked to produce vinyl chloride monomer and hydrogen chloride (the ) r i BFS 007154 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS ANO RESINS 580.t882 C SEPTEMBER 1973 latter is recycled to the oxychlorination reactor). The other 7% of the vinyl chloride produced in the United States in 1972 was made by the addition of hydrogen chloride to acetylene (see the CEH report on Acetylene for additional Information on this process). A new version of the route from ethylene (called the Chioe process) of improved versa tility and efficiency was developed by Produits Chimiques Pechiney-Saint-Gobain S.A.* It is characterized by the following stages: (1) hot chlorination of ethylene; (2) oxy chlorination yielding dichloroethane, trichloroethane, and tetrachloroethane; (3) cold chlorination of ethylene dichloride; and (4) distillation of the products of oxychlorin ation and cold chlorination. A new process (called the Transcat process), described as an essentially single-step process beginning with ethane feedstock and integrating the reactions of chlorination, oxychlorination, and dehydrochlorination into a single reactor system employing a novel molten salt catalyst, was developed jointly by the Lummus Company and Armstrong Cork Company <P/CE, April 1971, p. 5). The process has been operated on a pilot-plant scale for some time. Plans for its commercialization have not been reported thus far. See the CEH report on Ethylene Dichloride for additional information on the manufacturing processes used to make vinyl chloride. Polyvinyl Chloride Resins Vinyl chloride, a gas at room temperatur&T^s^sed in liquid form under pressure when it is polymerized by one of the four<6asic processes--suspension, emulsion, bulk, and solu tion polymerization--described'Mn tHe following discussion,^ In all processes, the A53^wmIrazation is initiated by free radicals (produced by the ther mal deeoraposit ionjtrf^v gmchjr initiators as peroxides of persulfates) and proceeds at temper atures of 40-70Cw^Wthe evolution of heat. The rate of polymerization is particularly sensitive to the reaction temperature and the concentration of initiators. The molecularweight distribution of the final product, which is of key importance to the processing characteristics of the resin, is influenced substantially by the temperature of reaction. * Details of this process were reported in Informations Chimie, May-June 1971, pp. 37-47, and OfeGJ, November 8, 1971, pp. 64 and 65. f The following is a listing of references recommended for supplemental reading. Encyclopedia of Polymer Science and Technology, Volume 14, Interscience Publishers, New York, 1971, pp. 320-358; ECN PVC Process Survey. January 29, 1971; Thomas, J. C., "New Improved Bulk PVC Process," HP, November 1968, pp. 192-196; "Huels PVC Batch Process Does Well Under Computer Control," OfcCJ, December 16, 1968, pp, 78-81; and Schroeter, G., Kunststoffe, June 1970, pp. 363-366. CHEMICAL ECONOMICS HANDBOOK sr4*fo*o scsiAac* institute, mcnio *** CAUFOMU BFS 007155 sea.ia83.i7 . * hi ;? - POLYVINYL CHLORIDE RESINS - CONTINUED , A. Polymerization of PVC Regina , L,. Suspension Polymerization . , About 78% of all PVC resins (both homopolymers and copolymers) produced in the . United States in 1972 were produced by suspension polymerisation. The polymer!- . zation. is carried out in an aqueous system in which monomer droplets are main tained 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., carboxymethylcellulose). Generally, suspension polymerization is operated as a batch process employing glass-lined reactors (having a capacity of 2-6 thousand gallons in older plants and larger in newer plants). The reactor is first charged with deionized water, and then a protective colloid (0.05 to 2% of the weight of the monomer), a buffer (e.g., sodium,acetate) and an Initiator (e.g., lauryl peroxide, azobisisobutyroni- trile, or isopropyl peroxydicarbonate*) are added. The vinyl chloride and, in the case of copolymer production, the second moryjflier (e.g., vinyl acetate, propylene, or vinylidene chloride) are then intern! introduced in controlled ratios. The mixture is then brought to the zaYion temperature (about 50 C) and, after variable induction periods-dlepenimlg'on the initiator used, the polymeri zation starts. The heat of^ polWer^zation is removed from the system to maintain the desired reaction te: the polymerization ure.' When lauryl peroxide is used as the initiator, tlally complete after a period of about 16 hours. A dispersion MTxex^tavely 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 dried in a o flash dryer, in which it is subjected to an air stream at about 80 C; complete drying usually requires more than one passage. The dry polymer is screened, generally through a 40-mesh screen, and shipped in bulk or packed in multiwall paper bags. 2. Emulsion Polymerization About 13% of the PVC resins produced in the United States in 1972 were produced by emulsion polymerization which is basically very similar to the suspension process except that relatively large amounts of emulsifying agents are used, usually in pairs where one agent is soluble in the monomer and the other in water. Such systems, combined with powerful agitation, very effectively prevent the coales cence of polymer particles and, as a result, resins of a very small particle size are obtained. The drying methods are also designed to maintain a small particle si2e; spray dryers are frequently used. Complete removal of emulsifiers is never achieved in resins produced by this process, so that articles of high clarity (as needed in packaging film) or of very low water absorption (as needed in wire * Uniroyal, Inc., has licensed the use of this catalyst to a number of leading U.S. PVC producers (C&.EN, August 26, 1966, p. 22). BF5 00 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS ANO RESINS 580.1882 E SEPTEMBER 1973 insulation) cannot be produced from such resins. The generally higher price of emulsion-polymerized resins compared to that of suspension-polymerized resins is, nevertheless, accepted by users who need compounds in liquid form (fluid dis persions of PVC resins in plasticizers, called plastisols) for the manufacturing of end products. In the United States, all resins produced by emulsion polymeri zation are used for plastisols (and, to a minor extent, in latex form). In Europe, emulsion polymerization processes have been refined further than in the United States so that general-purpose resins (useful for calendering and extrusion) are also produced there by variations of the emulsion process. 3, Bulk Polymerization In this relatively new process,* which was used to make about 6% of the PVC resin produced in the United States in 1972, vinyl chloride is polymerized without the addition of other liquids. A two-stage version of the process, which was developed in recent years by Pechiney-Saint-Gobain of France, is so attractive that it has been licensed all over the world (ECN, April 3, 1970, p. 14). (U.S. licensees are Occidental Petroleum Corporation, Hooker Chemical Corporation, subsidiary; The Goodyear Tire & Rubber Company, Chemical^ JVision; and The B. F. Goodrich Company, B. F. Goodrich Chemical Company, diyil In the two-stage bulk polym&riJzaticJb^rocess, a suitably shaped reactor is pro vided for the initial |^uid pha^e of the reaction, and a differently designed autoclave is the^ixsmd ><3? agitate the dry, powdery mass effectively until the con- version f provided b rattnoBpWxo polymer reaches a level of about 90%. Heat exchange is j^sdlstillation of monomer and its recondensation within the reactor and in ext al condensers. The rate of output of the two-stage bulk polymeriza tion plants* is said to be more than twice as high as that of good suspension process plants of comparable size (i.e., with a comparable number and size of reactors). It is generally expected that two-stage bulk polymerization of vinyl chloride will be widely used world-wide in the next several years. Bulk polymerized PVC resins resemble tbe suspension resins in appearance and are characterized by high particle uniformity and purity. This results in end products of unusually good optical clarity (important for packaging uses). Also, these resins have remarkably good heat stability and improved fusion properties, i.e., they can be processed with the ease of conventional vinyl chloride-vinyl acetate copolymers. * Union Carbide Corporation's so-called nonsolvent process is basically also a bulk polymerization process. It has been operated on a small scale (about 25 million pounds per year) at Texas City, Texas, for about 20 years, t An indication of the possible future technology of bulk polymerization is the work on low-temperature, low-pressure systems (e.g., as described by Mazzolini, C., L. patron, A. Iforettl, and M. Campanelli, IfcEC Product Research and Development, December 1970, pp. 504-511). CHEMICAL ECONOMICS HANDBOOK s i uroao *CSt**CH I ms?ifore *tHO PANS, CtU'OMU BF5 007157 I18tt ` --- rt,>_v.7-~ POLYVINYL CHLORIDE RESINS - CONTINUED i -- 4.: Solution Polymerization ' . Although, solution polymerization is over -10 years old, only about 3^ of the PTC . resins produced in the United States in 1971 were produced by this method, in this process, the monomers arc first dissolved in an organic solvent (such as n-butane or cyclohexane) in an autoclave. After the addition of a peroxide initiatorand heating of the stirred solution to 40C, polymerization begins and the polymer precipitates as the reaction proceeds. : Solution polymerization is used exclusively for the production of copolymers of vinyl chloride with vinyl acetate (usually those containing 10-25% acetate). These solution-polymerized copolymers are remarkably pure and uniform and their chief value lies in their unique solubility and film-forming characteristics. A greatly improved form of the original process, developed by Union Carbide Corporation, is used for the production of these specialty coating resins. B. Compounding of PVC Resins PVC resins are compounded with a number of auxiliar^rTfafacials before they are con verted to end products. -In the case of flexibl^T^; gtas^ticized PVC products, the chemical types and exact amounts of nlas"?>clzers^s4a are most important--the amount may range from about 10% (fsh^et? to 100% (for very soft film) of the weight of the resin, are chiefly higher alcohol esters of phthalic acid (e.g., dioctyl Dialkyl esters of dibasic aliphatic acids (e.g., dioctyl adipate) are us^f in conjunction with phthalates when flexibility at low temperatures is a requirement. Polyester plasticizers (e.g., adipic acid-glycol polyesters) and epoxy plasticizers (e.g., epoxidized soybean oil) confer the perman ence and resistance to leaching needed in food packaging and in baby pants. (See the CEH reports on Higher Alcohols (Cg and Up), Phthalic Anhydride, and Adipic Acid and the CEH data sheets on plasticizers lor further information on plasticizers.) Second ary plasticizers, such as highly chlorinated paraffins, are sometimes also used as extenders (see the CEH report on Linear Alkylate Sulfonates for additional informa tion). Other important compounding ingredients are light stabilizers and heat stabi lizers. Among the most frequently used are heavy metal salts (e.g., of lead, tin, barium-zinc and cadmium-zinc) or organo-tin compounds: Less than 0.1% to 2%', depend ing on the type and the fabricating process used, is added.* Pigments and fillers are incorporated depending on the end use. Where flexibility and toughness are needed in an end product, vinyl compounds tolerate only relatively light filler loadings. * The following book is recommended for supplemental reading on vinyl stabilizers, in particular, and vinyl compounding, in general: Sarvetniek, Harold A., Polyvinyl Chloride, Van Nostrand Reinhold Company, New York, 1969. ) i ; ! BFS 007158 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS .......... 680.1883 G SSTEMBER 1973 Compounding begins with pre-mixing and is followed by very intense mixing because uni form distribution (expecially of stabilizers) is mandatory for trouble-free processing and uniform product quality. Recently, work has been reported on performing compound ing steps in the polymerization vessel prior to discharging the resin. This method is believed to be in use in the large-scale production of certain rigid compounds and is believed to be very economical. Most compounds, 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 generally subjected to a hot mixing step at fusing temperature; this may be done on a two-roll mill or mixing extruder. In the case of plastisols, compounding is strictly a stir-in process (except that pigments are predispersed with plasticizer over a threeroll 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-^ygral processes. Extrusion (employing mostly multiple-screw machines in Europe^Miipa^ti^single-screw machines in the United States) is used to produce both rj^dfextH^dBKi (e.g., pipe and-conduit, siding, and window sashes) and flexible ejebrusr^tap 0(e.^T, electrical wire insulation, garden hose, and packaging film). To arge extruder, preheated, mixed compound in chip form may be conveyed (ftomge/or directly from a mixing extruder. Extrusion lines are engineered for the types of products to be extruded, from electri cal wire insulation to pipe of 18 inches diameter. The extruders are continuously fed witb compound, which is either purchased or prepared in an on-site compounding plant. The approximate cost of a single extrusion line varies considerably depending on the size of the extruder, its type, and the auxiliary equipment; a typical cost range is $300,000 to $800,000. Rigid and flexible vinyl sheets are generally produced on four-roll calenders. The sheets may be combined with a fabric as it leaves the calender, or this may be done subsequently in a separate laminating step. A typical calender train costs 2 to 3 million dollars. Today's calenders run widths usually to 72 inches and some as broad as 92 inches, and they produce film and sheet at rates averaging more than 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--MP, April 1969, p. 24). Dispersions or plastisols are used for fabric coating (either on knife machines, roller coaters, or casting machines), and in the production of a low-cost type of vinyl floor tile where plastisol is cast on a felt base. Plastisols are also used in rotational molding (e.g., for toys and traffic cones) and in the dipping and hotspraying of tool handles and appliance parts. i CHEMICAL ECONOMICS HANDBOOK 5'*"roo *tsc**CH iHsrtrurc, Memo c*t. i i* BFS Q07159 "POLYVINYL CHLORIDE RESINS - CONTINUED %* " ' ' .......................................... ' The use of compression mold ins for PVC resins is restricted to the production of phono graph records. Injection molding of rigid PVC has been developed largely in the 1960's and is mostly employed in the production of pipe fittings, and to a much smaller extent in the production of parts for communications equipment, business machines, and toys. A complex and still-emerging technology in the processing of compounded PVC resins is the blow molding of containers. PRODUCING COMPANIES. PLANT LOCATIONS. AND CAPACITIES Vinyl Chloride For a list of vinyl chloride producers and their plant locations and capacities, see the CEH report on Ethylene Pichloride. As indicated there, the total U.S. vinyl chloride pro duction capacity was 5,565 million pounds per year as of October 1971 with 90% of this based on production from ethylene dichloride. Only Mn n n rht4l Tnc. (a joint venture of Borden Inc., and Uniroyal, Inc.), with a capacity of-^ISi iwAl'ypi pounds per year at Geismer, Louisiana, and Tenneco Chemicals, Inc. (a majar'^oapStt^l^of Tenneco Inc), Chemicals Division, with a capacity of 225 mil1 iory'flounaB^jper year at Houston, Texas, were still producing vinyl chloride monomer^^f-co^-ag^^lene as of February 1, 1972. As of January 1, 1973, U.S. vinyl chloride ^dig_Jestiniated to have totaled 5,765 million pounds per year (CMR, January 1, 1973, The 700 million pounds-per-year vinyl chloride plant of Shell Oil Company, Shell Chemical Company, division, at Deer Park, Texas, was expanded to a capacity of 840 million pounds per year, and the company expects to complete a second 700 million pounds-per-year plant at Norco, Louisiana, in late 1973. Of the ten domestic vinyl chloride producers in 1973, three produced vinyl chloride onlyDow Chemical U.S.A., PPG Industries, Inc., and Shell Chemical Company--whereas the others also produced polyvinyl chloride resins. A shortage of vinyl chloride had been widely predicted for the second half of 1973. Con tributing to this trend was the reported curtailment of vinyl chloride production for lack of naphtha feedstock and other reasons at the large PPG plant at Guayanilla, Puerto Rico (CMR, April 30, 1973, pp. 3 and 14). As of mid-1973, the anticipated monomer shortage was a reality as production problems, linked to Insufficient electrical power supply for the south shore region of Puerto Rico, were still not all resolved. Newly installed generators are expected to become operational in October 1973 (industry source). Polyvinyl Chloride Resins The U.S. producers of PVC resins and the annual capacities of their plants are listed in the following table. i < !*- BFS 00 F1 SB POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.188* I SEPTEMBER 1973 Company and Plant Location Air Products and Chemicals, Inc Plastics Division Calvert City, Kentucky Pensacola, Florida American Chemical Corporation (jointly owned by ARCO Chemical Company, division of Atlantic Richfield Company, and Stauffer Chemical Company) Long Beach, California Borden Inc Capacity as of Mid-1972 (Millions of Pounds per Year) 120 SO 12S 285 Diamond Shamrock Corporation Diamond Shamrock Chemical Company, subsidiary Plastics Division Delaware City, Delaware Deer Park, Texas Ethyl Corporation Industrial Chemicals Division Baton Rouge, Louisiana The Firestone Tire & Rubber Company Firestone Plastics Company, division Perryville, Maryland Pottstown, Pennsylvania The General Tire & Rubber Company Chemical/Plastics Division Ashtabula, Ohio The 8. F. Goodrich Company B. F. Goodrich Chemical Company, division Long Beach, California Henry, Illinois Louisville, Kentucky Avon Lake, Ohio Pedricktown, New Jersey 220 80 \ 2g0 1 180 130 140 100 125 125 275 125 130 CHEMICAL ECONOMICS HANDBOOK "(Scaach INITITOTI, utftLO CAlifoamia BFS 0071 SI 680.1882 J POLYVINYL CHLORIDE RESINS - CONTINUED Company and Plant Location______________ The Goodyear Tire & Rubber Company Chemical Division Plaquemine, Louisiana Niagara Falls, New York Great American Chemical Corporation Fitchburg, Massachusetts Keysor-Century Corporation Saugus, California Monsanto Company Monsanto Polymers & Petrochemicals Corapanj National Starch and Chemical Meredosia, Illinois, ft ion Occidental Petroleum Corporation Hooker Chemical Corporation, subsidiary Ruco Division Burlington, New Jersey Hicksville, New York % 01in Corporation Thompson Plastics Company, division Assonet, Massachusetts Pantasote Company Passaic, New Jersey Point Pleasant, West Virginia Robintech, Inc, Painesville, Ohio Stauffer Chemical Company Plastics Division Delaware City, Delaware Tenneco Chemicals, Inc. (a major component of Tenneco Inc.)c Tenneco Plastics Division Burlington,, Now Jersey Flemington,, New Jersey Capacity as o Mid-1972 (Millions of Pounds per Year) 100 100 40 35 150 10 180 10 150 220b 160 165 60 * 9 1 J A BF5 i t OQ7162 POLYVINYL CHLORIDE RESINS - CONTINUED -iO.'.'. - PLASTICS AND RESINS 580.1882 K SEPTEMBER 1973 Company and Plant Location Union Carbide Corporation Chemicals and Plastics Division Texas City, Texas South Charleston, West Virginia Uniroyal, Inc. Uniroyal Chemical, division Painesvllle, Ohio Total ' Capacity as of Mid-1972 (Millions of Pounds per Year) 200 120 140 4,420 a. This plant was acquired from The Dow Ch :ompany in 1969 and subsequently expanded. Another expansion to 201 funds per year is planned (Plastics Technology, May 1973, p. 20). -*f b. This plant was acquired f^omxwji^l chemical Corporation in 1972 and capacity has been increased to-a2^8=illion pounds per year In 1973 (MP, May 1973, p. 12). Construction of jr~300=m5.hi4on pounds--per--year plant at Pasadena, Texas, has been startedf^OSpp^ei^Ion is due in 1974 (MP, May 1973, p, 12). Source: CEH estimates based on trade publications and communication with Industry. Additional new plants under construction include: Certain-Teed Products Corporation, at Lake Charles, Louisiana (200 million pounds per year, due on stream in late 1974); Georgia-Pacific Corporation at Plaquemine, Louisiana (200 million pounds per year, in late 1974); and Shintech, Inc. (owned jointly by Robintech, Inc. and Shin-Etsu Chemical Industry Co., Ltd. of Japan), at Freeport, Texas (250 million pounds, in mid-1975) (iff, May 1973, p. 12). It is generally recognized that published capacity figures frequently do not correspond very closely to actual plant capacity. Published capacities are often overstated because (1) design capacities presume the continuous production of one type of resin and all pro ducers make various types of resins in each plant and (2) there are scheduled and unscheduled shutdowns which are not taken into consideration in so-called nameplate capa city figures. Of the total 1972 FVC capacity, it is estimated that 78%, or about 3,400 million pounds, was based on the suspension process, which is used by all producers. Some 12%, or about 530 million pounds, was based on the emulsion process, which is used by B. F. Goodrich, Conoco, Diamond Shamrock, Ethyl, Firestone, Goodyear, Monsanto, Olin, Tenneco, Union Carbide, and Uniroyal. Also, National Starch and Chemical Corporation produces its vinyl chloride copolymer latices by the emulsion process. About 6% of total PVC capacity or 280 million pounds, was based on the bulk polymerization process of Pochiney-Saint-Gobain of France; the following table gives a breakdown of that bulk polymerization capacity. CHEMICAL ECONOMICS HANDBOOK 5T *Nf 0D *CSC*CM msinufi MENLO *, C*I.IF0*NI* BF5 0971 S3 580.1882 L POLYVINYL CHLORIDE RESINS - CONTINUED 0 v-s` Polyvinyl Chloride Bulk Polymerization Capacity as of id-1972 The B. F. Goodrich Company B. F, Goodrich Chemical Company, division Pedricktown, New Jersey The Goodyear Tire & Rubber Company Chemical Division Plaqueraine, Louisiana Occidental Petroleum Corporation Hooker Chemical Corporation, subsidiary Ruco Division Burlington, New Jersey Total Millions of Pounds per* Year 40 80 160 215 l Source: CEH estimates based on c^muS^i^t^pn^with industry. Less than 4%, or about ISO polymerization--estimat pounds for Firestone, and i.litm\fdunds of the total capacity, was based on solution list of 120 million pounds for Union Carbide, 10 million million pounds for Goodrich (CEH estimates). As of early 1973, total U.S. capacity for PVC resins is estimated to have been near the 5 billion pounds-per-year level. In 1973, existing PVC capacity is believed to be used to the limit although a monomer shortage in the second half of 1973 may force some output reduc tions in some plants. The B. F. Goodrich Company announced a 30% incremental expansion of its PVC capacity in existing plants in 1973 and 1974 (CMB, October 30, 1972, p. 3). Other new PVC capacity that has been reported includes the following: American Chemical Corporation, additional 40 million pounds at Long Beach, California; Georgia Pacific Corporation, a new 200 million pounds-per-year plant; The Firestone Tire & Rubber Company, to expand to a total capacity of 400 million pounds per year; and Borden, Inc., to add 60 million pounds at existing plants (CMR, November 20, 1972, op. 5 and 35). However, addi tional substantial capacity must be on the way if the projected 1975 consumption of 6.2 billion pounds is to be backed by a corresponding production. Most large resin manufacturers also produce compounds for sale, or for feeding their own end-product manufacturing operations. For example. Continental Oil Company, Conoco Chemicals Division, has a compound production capacity of 175 million pounds per year at Aberdeen, Mississippi (1970 Annual Report. Continental Oil Company). The Plastics Division of Diamond Shamrock Chemical Company has two compound plants with a combined capacity of 175 million pounds per year. B.-F. Goodrich Chemical Company has long operated several large compound facilities. Among the numerous other large suppliers of compounded resins are Allied Chemical Corporation (particularly dry-blends), Ethyl Corporation, Monsanto Company, Pantasoto Company (particularly pelletized compounds), Tennoco Chemicals, Inc,, and Union Carbide Corporation. )' .iiir.fcwtuaw BFS 0071S4 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 1 580.1882 M SEPTEMBER 1973 PRODUCTION AND SALES Vinyl Chloride The following table provides data on U.S. vinyl chloride production and sales* Production and Sales of Vinyl Chloride (Millions of Pounds) Production Sales 1952 1953 1954 321.4 401.7 393.2 59.5 1955 1956 1957 1958 1959 528.6 596.5 627.1 691.4 76,0 103.9 1960 1964 1,311.5 1,435.2 1,615.0 352.3 424.3 515.5 500.8 597.1 1965 1966 1967 1968 1969 1970 1971a 1972 2,000.0 2,499.5 2,423 .6 2,968 .9 3,735 .9 4,040 .2 4,335 .8 5,175 .3 687.8 836.2 951.7 1,463.1 2,358.7 2,720.2 3,003.6 -- See MANUAL CF CURRENT INDICATORS for additional data. a. Data for 1971 and 1972 are preliminary, (continued) CHEMICAL ECONOMICS HAN0B00K Sr**r0*0 *tS|CH iNsrt run tfCNlO PARK, CtlirOINIt BFS 007165 5B0.18S2 N POLYVINYL CHLORIDE RESINS - CONTINUED Sources <A> Synthetic Organic Chemicals Production and Sales, U.S. Tariff Commission (ProductIon and SaLos data for 1952-1970). (B) Synthetic Organic Chcnicals, U.S. . y*y' : . "..-Production and Sales of Miscellaneous r Chemicals, 1971 Preliminary, U.S, v.,.v . Tariff Commission (preliminary data .V for 1971). (C) Preliminary Report on U.S. Production of Selected Synthetic Organic Chemicals, S.O.C. Series C/P-73-1, U.S. Tariff Commission (preliminary Production datum for 1972). For data on production of vinyl chloride by process, Dichloride and Acetylene. CEH reports on Ethylene Polyvinyl Chloride Resins The following table preS^fi^sWar^^rf U.S. production, sales (including sales for export), and captive use of polyvx*y^-cKloride resins as reported by the U.S. Tariff Commission. The continuous growth of production from 1945 to 1969 proceeded at an average annual rate of 16%; however, between 1966 and 1971, this growth rate averaged only 9% per year. Then in 1972 alone, PYC production advanced over 23%. * o BFS 007166 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1882 O SEPTEMBER 1973 8,000 7.000 6,000 5.000 4.000 3.000 2.000 MILLIONS OF POUNDS PRODUCTION 1,000 900 800 700 600 500 400 300 200 100 90 B0 70 60 50 40 30 20 1940 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 a. A breakdown of SALES ANO CAPTIVE USE is included in the table. Tut,.', v -iio -1 - < . < BFS 00F16F 580.1882 P POLYVINYL CHLORIDE RESINS - CONTINUED 1945 1946 1947 1948 1949 1950 1951 1952 1953 1954 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 Suspension Homopolymers 1.224 1,303 1.713 2,052 2,247 2,475 3.149 U.S. PRODUCTION. SALES. AND CAPTIVE USE OF PVC RESINS (Millions of Pounds) Production_______________________________ _____ Sales and Captive Use Suspension Copolymers Dispersion Resins and Latex Total Sales Captive Use By Resins Producers Total 79 79 115 115 128 128 162 162 220 220 315 315 333 333 342 342 394 394 397 397 506 506 612 612 634 634 648 648 876 876 900 966 1.151 1.207 1.374 159 273 900 966 1,151 1,366 1.647 1.715 1.816 1.928 2.330 2.748 140 310, 184 220" 168 2,112 2,550 2.916 521 366 3,115 2,847 138b 2,985 512 453 3,440 3,394 559 550 4,2SS See MANUAL OF CURRENT INDICATORS for additional data. a. Includes 678 million pounds of PVC homopoiymer, 283 million pounds of vinyi chloride-acetate copolymer, and 16 million pounds of other PVC copolymers in this year. b. Calculated as "Sates and Use" minus ''Sales.*' SOURCES: (A) (B) (Cl SYNTHETIC ORGANIC CHEMICALS, U.S. PRODUCTION AND SALES. U.S. Tariff Commission (data for 1945-1970 and data in footnote a). MONTHLY STATISTICAL REPORT, The Society of the Plastics Industry, Inc.. December 1971 (data for 1971). ANNUAL STATISTICAL REPORT. PLASTICS & RESINS MATERIALS, 1972. The Society of the Plastics Industry, Inc., April 1973 (data for 1972). r BFS 00F1SS Sr POLYVINYL CHLORIDE RESINS CONTINUED PLASTICS ANO RESINS , 580.1882 Q SEPTEMBER 1973 Production of polyvinyl chloride resins in the first three months of 1973 was over 1,175 million pounds, 17.8% more than in the comparable 1972 period (Monthly Statistical Report, The Society of the Plastics Industry, Inp., March 1973). Data on production of PVC resins by process in the preceding table indicate that most of the growth has been in suspension homopolymer resins--an average growth rate of 15.5% from 1966 to 1972 (an estimated 200-250 million pounds of resins produced by. bulk polymerization are believed to be included in the production reported for suspension homopolymers in each of the years 1971 and 1972--CEH estimate). The production of dispersion resins and latex (made by the emulsion process and known to include small amounts of copolymers) rose at an average annual rate of 18.2% in the same period, and the production of suspension copoly mers declined at an average annual rate of 5.5% between 1966 and 1971, and then increased 9% in 1972, according to these statistics. In the future, resins produced by bulk polymeri zation are expected to account for a steadily increasing share of total production (CEH estimate). It is believed that the reported data for captive consumption in the preceding table are understated in all years. For example, in 1970 thj^f*epra&ed data indicate that only 138 million pounds of resin were captively consumedC'^lro^'^er, one source estimated that in 1970 as much as 800 million pounds of PVC *4sinfwj^re captively consumed (MP, March 1971, p. 63) leaving resin sales (including^ cwmui^leareslns) on the open market at 2.0-2.2 billion pounds. Captive PVC resite consumption for end products (not counting compounded resins) in 1971 is believed/f^R'jScv^'wen again about 800 million pounds (CEH estimate based on communication with ^Particularly well known are the large captive PVC end- product manufacturing operations of Borden, Diamond Shamrock, Stauffer, Uniroyal, and the captive PVC pipe manufacturing facilities of Ethyl Corporation and Olin Corporation. CONSUMPTION Vinyl Chloride Vinyl chloride is used almost entirely for the production of polyvinyl chloride homopolymer and copolymer resins. The remainder, estimated at less than 3% of total production or between 100 and 150 million pounds in 1972 (CEH estimate), was used in a variety of appli cations such as (1) the production of methyl chloroform (see the CEH report on Methyl Chloroform for more Information), (2) as an additive to specialty coatings, and (3) as an additive in certain aerosol mixtures (see DS, June 1970, pp. 26, 28, 35, and 36 for informa tion on vinyl chloride in aerosols). Polyvinyl Chloride Resins The consumption of PVC resins in the United States was over 3.2 billion pounds in 1971 compared with 2 billion pounds in 1966--an average annual growth of over 9% in the fiveyear period. In 1972, a phenomenal 4,180 million pounds of PVC resins were consumed, more than a 27% advance in one year alone. O CHEMICAL ECONOMICS HANDBOOK (SIU) oc cS**ch institute. MENLO Nm BFS 007169 -T 560.1882 ft mu ' POLYVINYL CHLORIDE RESINS - CONTINUED 'Ty tr m tw .'uasumr.y f try a rt- Except for the solution gradeand other coating resins (consumption of which was under -V-i-S. 100 Billion pounds car leas than 4% of total consumption), and PVC latices, both of which. : are mostly used in coatings all PVC resins are used in the production of plastics products. These PVC products are produced by some 8,000 fabricators, either from pur-_ - chased compounded resins (most merchant compounded resins are produced by the PVC resin * v.,-. manufacturers in large, highly automated plants) or from compounded resins that the fabri cators prepare themselves. Processing of the compounded resins to the end products requires (with the exception of * some plastisol uses) specially designed and highly capital-intensive operations. This . fact, and the very competitive nature of the PVC plastics business in all of its segments, explains the specialization by process of most PVC plastics producers. Consumption of PVC resins by the processes used to make end products is discussed in the next section. This is followed by another section which gives a breakdown of PVC resin consumption by end use'and a discussion of these end-use markets. A Consumption by Process The following table summarizes reporteddo^est^^^TC^resins consumption according to Tariff Commission categories. Aftej^thSkjtale, detailed breakdowns of this con sumption are given, accompanie^Hhy'cbx&ef discussions. Extrusion Calend&e^ OF PVC RESINS BY PROCESS (Millions of Pounds) Molding3 Solutions1' Miscellaneous Total 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 230 238 272 317 399 483 574 596 739 1.000 392 89 424 100 490 105 553 144 652 . 178 686 203 736 287 660 231 650 272 793 279 70 39 72 36 78 97 4-5 99 - 121 _ 179 54 177 72 200 83 248 84 83 903 95 965 130 1.12) 206 1,323 249 1577 295 1,788 228 2.058 305 2541 491 2,435 350 2.754 1970 1971p 1972 1.095 1,295 2562 705 835 963 281 415 457* 254 309 410" 85 90 118 376 2.796 281 3,225 180 4.180 Sm MANUAL OF CURRENT INDICATORS for additional data. a. Terminology usad by tha Tariff Commission for thast categories and thair subcatagoritt hat baan inconsittant over tha years. Reported deta were regrouped to permit this comparative organisation. b. Deta ara reported under "Protective Coatings and Adhesives'' and "All Other Coating Uses." although not ell resin reported hart is processed in solution applications. _ c. Components ara: Coating-Flooring, and Textile and Paper Coating: Paste Procassas-Plastitol Formulation, and All Other d. Components are: Bottles (blow molding). 77 million pounds: Sound Records (compression molding), 148 million pounds: fUl Other Molding (believed to be substantially all injection molding). 185 million pounds. a. Reported at "Protective Coatings'* 159 million pounds) and "Adhesives end All Other Coating Uses" (also 59 million pounds!. Believed to include mostly solutions but also some dispersion and powdar coatings. SOURCES: (A) (8) <a ID) SYNTHETIC ORGANIC CHEMICALS. US. PRODUCTION ANO SALES, U.S. Tariff Commission (data for Total Domestic Consumption, designated as "Sales" or "Sales and Use" by the source, tor 1960 through 1970). SYNTHETIC ORGANIC CHEMICALS. U.S. PRODUCTION AND SALES OF PLASTICS ANO RESIN MATERIALS. 1971 Preliminary, U.S. Tariff Commission (preliminary data lor 1971). ANNUAL STATISTICAL REPORT. PLASTICS & RESINS MATERIALS. 1972, The Society of the Plastics Industry. Inc.. April 1973 (data for 19721, CEH estimates (components of some data for 1960 and 1961 as detailed in subsaouent tablet). * Detailed information on PVC compounding and processing nay be found in the following sources: Brighton, C. A., "Vinyl Chloride Polymers, Compounding and Fabricating, *' Encyclopedia of Polymer Science and Technology. Volume 1-1, Interscience Publishers, New York, 1971, pp. 39-1-452; and McKelvey, J. M., Polymer Processing. John Wiley & Sons, Inc., New York, 1932. i j i 4 BFS Q07170 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ---------- 580.1882 S SEPTEMBER 1973 The small difference between the sum of the reported domestic consumption and exports of PTC resins in 1972 and the reported U.S. production of these resins is believed to be largely due to year-to-year stock changes (imports were only 4.4 million pounds in 1972), 1. Extrusion Processes Domestic PVC resin consumption in extrusion processes in recent years is given in the following table. ___________U.S. Consumption of PVC Resins in Extrusion Processes Millions of Pounds Wire and Cable Film and Sheet All Other Total Total as a Percent of All PVC Consumption 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 197 Ip 1972 343 439 179 220 773* 1,392< (230) (238) 272 317 399 483 574 596 739 1,000 1,095 1,295 2,052d 26% 25 24 24 25 27 28 29 30 36 36 40 49 a. Includes all PVC resins consumed for pipe, conduit, tubing and rod, and all other rigid, semirigid, and flexible profile extrusions, such as garden hose. Consumption of PVC resins in garden hose was reported as follows (millions of pounds): 1962 1963 6 8 1964 1965 14 11 b. Includes 497 million pounds consumed for pipe and conduit and 276 million pounds for other extrusions. c. Includes 1,008 million pounds for rigid pipe and tubing, and 384 million pounds for all other extrusions. d. Add total is lower than the sums of the individual categories because of rounding. (continued) CHEMICAL ECONOMICS HANfMIOOK {Sitl) 5rfo# CJC*Ch INSTIfutt, MCNIO *** C ALI r0*I * BFS 0071 71 580.1883 T POLYVINYL CHLORIDE RESINS - CONTINUED t Sources: (A) CEH estimates (estimates for 1960 and 1961 in the table). (B> Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (data for 1962-1970). (C) Synthetic Organic Chemicals, U.S. Production and Sales of Plastics and Resin Materials. 1971 Preliminary, U.S. Tariff Commission (preliminary data for 1971). (0) Annual Statistical Report, Plastics & Resins Materials, 1972, The Society of the Plastics Industry, Inc., April 1973 (data for 1972). Extrusion processes differ depending on the types of end products; from a process standpoint, it is significant whether these end products are rigid or flexible. Therefore, the following discussion is divided correspondingly. Rigid Extrusions. The PVC resins most rigid extrusions are suspension homopolymers blended with vinyl chltSSS^Avinyl acetate copolymers (of low vinyl acetate content) or propylene^o >olym^ps. Post-chlorinated homopolymers are also used. The resins are bleadedwjk balance the required physical properties of the end product with easy&i(F=5^eed of processing. In 1971, 717 million pounds or 55% of all PVC re*f!T&ss"5i^a>'in extrusion processes went into rigid extrusions. The following in 1971. ^ti^lated breakdown of PVC resin consumption in rigid extrusions \C^ Estimated U.S. Consumption of PVC Resins in Rigid Extrusions--1971 Millions of Pounds Pipe and Conduit 497 Siding and Other Rigid Profiles 130 Film and Sheet Architectural and engineering 90 55 Packaging Total 35 717 Source: CEH estimates. o BFS 007172 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ........................... ......... 580.1882 U SEPTEMBER 1973 The bulk of the sensational 58% increase of PVC resin consumption in extrusion in the year 1972 alone went into rigid extrusions, as detailed later in the section oJT this report on Consumption by End Use. All products in the field of rigid PVC extrusion have shown particularly rapid growth in the past ten years and are expected to remain the principal growth areas for PVC resins between 1972 and 1980 (CEH estimate). An emerging.field of importance is that of foamed rigid profiles (extruded molding). Pipe and conduit constitutes the largest and the fastest growth segment of extruded PVC plastics. Pipe extrusion constitutes a sizable captive market for two PVC resin producers--Ethyl Corporation and Olin Corporation. Usage of vinyl chloride-vinyl acetate copolymers is heavy in the production of extruded rigid film and sheet,* also a growth area of above-average potential (CEH estimate). Flexible Extrusions. General-purpose homopolymer resins are used in flexible extrusions where 578 million pounds (qj^ 45% of all PVC resins used in extrusion) were consumed in 1971. An estimatpehtrC8$kdows of PVC resin consumption in flexible extrusions in 1971 follows: Estimated U.S. Cons PVC Resins in Flexible Extrusions--1971 Millions of Pounds Medlpal tubing Garden hose Gaskets and weather stripping Vaterstop sheetrib Cove base Packaging Film Total 343 150 37 35 30 27 21 85 578 Source: CEH estimates. % The term "film" is usually used for thicknesses under 6 mils (0.006 inches), whereas the term "sheet" applies to greater thicknesses. 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 H tstACM institute, mcwio **, cniroanu BFS 007173 POLYVINYL CHLORIDE RESINS - CONTINUED III the wire and cable markets, PVC is used as a jacketing material-for telephone station wire, but its largest wire and cable use is in so-called construction wire. Most flexible, extruded PVC film is highly plasticized and is used largely for f' oo,d^ packaging. . .; *%, Of the varied flexible PVC profile extrusions, medical tubing and so-called wateratop sheetrib (which is embedded in concrete slabs and aquaduct3> have shown remarkable growth in recent years. Although numerous types of profile gaskets (primarily weather stripping) are extruded from PVC, other materials have replaced PVC is many of these applications. 2. Calendering Processes A breakdown of domestic PVC resin consumption in calendering processes in recent years is given in the following table. US. Consumption of PVC Resins in Calendering Processes 1970 197 Ip 1972 Millions of founds (382) 474 556 <145)C 186 205 244 262 297 265 244 270 247 274 333 (40) (42) (60) (70) (80) (90) (80) (75) (85) (90) (76) 87 74 392 424 490 559 652 686 736 660 650 793 705 835 963 Total as a Percent of All PVC Consumption 43% 44 44 42 41 39 36 32 27 29 25 26 23 a. Designated by the sources as ''All Other Calendering. b. Data for 1966-1970 are estimates of the calendered film and sheeting portion of the reported consumption in all calendering except flooring. c. Data for 1960 and 1961 are estimates of the calendered portion of the total reported consumption for flooring, which was 156 million pounds for I960 and 185 million pounds for 1961. (continued) BF5 00FI 74 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1882 rt SEPTEMBER 1973 d. Data for 1960-1965 are estimates of the calender-coated portion of the total reported consumption for all paper and textile coating uses. Data for 19661970 are estimates of the calender-coated textiles portion of the reported consumption in all calendering except flooring. e. Total consumption in 1967--1970 is believed to have actually been higher by 100 million pounds or more in each year. This consumption is believed to be included in the Tariff Commission data on "All Other Uses." Sources: (A) Synthetic Organic Chemicals, U.S, Production and Sales, U.S. Tariff Commission (Film and Sheeting data for 1960-1965, Flooring data for 1962-1970, Total data for 1966-1970, and data in footnote c). (B) Synthetic Organic Chemicals, U.S. Production and Sales of Plastics and Resin Materials, 1971 Preliminary, U.S. Tariff Commission (preliminary data for 1971). (C) Annual Statistical Report, Plasms k Resins Materials, 1972, The Society of the Plastics Ind c., April 1973 (data for 1972). (D) CEH estimates rentheses and estimate in footnote e). Most PVC resins consumed use of copolymers (wit jnderlng are general-purpose homopolymers. The sly high molecular weights and low vinyl acetate contents) has decline! Reaper homopolymers with comparable ease of processing were developed. "Mtee bulk-polymerized homopolymers with even better calender* ing characteristic^-were introduced and these are expected to eliminate the usage of conventional calendering copolymer resins with low vinyl acetate content and to gradually reduce the use of higher vinyl acetate content resins in rigid sheet and in floor tile. As the preceding table indicates, overall PVC consumption in calendering increased sharply in the early 1960's as a result of rapid growth in all three major consump tion areas. More recently, growth has been more moderate except in some specific end uses for film and sheeting that have shown strong growth, e.g., rigid packaging films, specialty films for tapes, swimming pool liners, and printed overlay film for wood. (Individual end uses in all applications of calendered PVC products are discussed In the section of this report on Consumption by End Use.) Calendered film and sheeting is used in a wide variety of applications; the major outlets arc household uses, consumer goods, transportation, and packaging. The choice of the type of resin used in the production of rigid and semirigid sheeting depends not only on its calendering characteristics (permitting high speeds), but also on required end-use properties, e.g., formability. Rapid thermoforming with or without vacuum is an important requirement in many packaging appli cations, and copolymers are favored where fast deep-draw formability is needed. chemical economics handbook s f *r o # o msiMCN mist i tui i, mrnto k, cuirotm BFS 007175 580.1882 X POLYVINYL CHLORIDE RESINS - CONTINUED O An estimated 154 PVC calenders were believed to be operating in the United States in 1968-1969 (MP, December 1969, p. 10). Reportedly, in 1970 about 60% of all calen dered PVC film and sheeting (corresponding to over 400 million pounds of PVC resin and believed to include flooring and coated textiles) were produced captively by about 10 PVC producers. There is a similar number of calender operators who do not produce PVC resins. Some of the largest of these are Fields Plastics and Chemicals, Inc., Plymouth Rubber Company, Chrysler Corporation, and Ford Motor Company--each with four or more calenders (CEH estimate based on communication with industry). Leading producers of rigid calendered film and sheeting from PVC homopolymers and copolymers are the Nixon-flaldwin Division of Tenneco Chemicals. Inc., Iloechst Polymer Corporation, subsidiary of American Hoechst Corporation (100% owned by Farbwerke Hoechst AG of West Germany), and Phillips Products Co., Inc. (MP, August 1969, p. 19; May 1970, p. 20; and Septembe;evl9?0, p. 18). The largest single outlet for calendered used are mostly vinyl chloride-vinyl acet content; these can bind particularl$Clarge asbestos flooring; the resins aolymers with 8 to 18% vinyl acetate jounts of mineral fillers. Calender-coated fabrics are^uhe^jfo3*for furniture upholstery, for seating, interior trim and vinyl/rcfcrfl^ror automobiles (Landau tops) , and for a variety of smaller end uses, -dfe^cgs^ 7VC resin consumption in calender-coated textiles is always strongly depera^Kt on business conditions in furniture and in automobiles. Q 3. Dispersion Processes Reported domestic PVC resin consumption in dispersion is shown in the following table. U.S. Consumption of PVC Resins in Dispersion Proeessesa Millions of Pounds Plastisol Formulating and Molding Textile and Paper Coating Flooring Total Total as a Percent of All PVC Consumption I960 1961 1962 1963 1964 ' 1965 1966 1967 1968 1969 1970 I971p 1972 (continued) (30> (30) 2Sb 34b 39b 43b 92 78 107 112 113 156d 150 (24) (30) (30) (58) (76) (91) I33c 101 108 101 93 142 173 (35) (40) 47 52 63 69 62 52 57 66 75 117 134 (89) (100) (105) (144) (178) (203) 287 231 272 279 281 415 457 10% 10 9 11 11 11 14 11 11 10 10 13 11 O BFS 0071 7S POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1882 V SEPTEMBER 1973 a. Includes predominantly the PVC resin content of plastisols, and also that of organosols (solvent-modified plastisols), and latexes. b. Reported as used in slush molding (rotational molding or rotocasting). c. Includes 117 million pounds of PVC resins reported for "coating" and 16 million pounds for unspecified "other" textile and paper applications. d. Includes 106 million pounds of PVC resins used in "plastisol formulation" and 50 million pounds for "other paste processes." e. Of this total, an estimated 35 million pounds are believed to have been used in latex form. o The Society of the Plastics Industry, Inc., April 1973 (data for 1972). (D) CEH estimates (all estimates for 1960 and 1961, Textile and Paper Coating estimates for 1962-1965, and estimate in foot note e). Most PVC dispersion resins are homopolymers, although some copolymers do find use (all are prepared by the emulsion process). Blending resins (used in conjunction with dispersion resins to lower the cost) are also mostly homopolymers (but usually prepared by the suspension process [MP, October 1970, pp. 132-136]). Fluid dispersions of vinyl resins include predominantly plastisols, which some times may contain minor amounts of solvents. (Classic organosols, which contain a carefully formulated balance of solvents, are no longer in widespread use.) Plasti sols are processed as fluid compounds so their flow behavior over a range of shear stresses is important. The individual processes include knife coating, roller coat ing, casting (used for coated fabrics), rotational molding (to make hollow objects such as beach balls), dipping (for gloves and tool handles), and hot spraying (thick protective coatings on metal objects like tool housings). Rotational molding is believed to be the largest application under the category Plastisol Formulating and Molding. CHEMICAL ECONOMICS HANDBOOK sr*prcmo <mse*c* msnnm, menlo **, c **. i ** i * BFS 00F1FF sacueea z POLYVINYL CHLORIDE RESINS - CONTINUED It is estimated that less than 10% of total dispersion rosin consumption (e.g.r an estimated 40 million pounds in 1972) is used in latex form (CKH estimate). Some of these latex resins are copolymers with minor amounts of vinyl acetate; ethyl-, n--butyl-, or 2-ethylhcxyl acrylate; or vinylidene chloride. The usage of PVC 'latices is restricted to a number of specialized applications which include the following: (1) the saturation ami coating of paper and paperboard, (2) the impregnation of nonwnvens used in the dielectric assembly of automotive trim parts (such as <Ionr panels), (3) the production of vinyl wall coverings, and (4) as a component in one type of house paint (see the CEH report on Vinyl -Surface Coatings for details on this house paint). As the preceding table indicates, dispersion resin consumption grow at an average annual rate of L5.3r< between 1961 and 1971. The 48% increase in the reported con sumption of dispersion resins from 1970 to 1971 and the large increase from 1965 to 1966 were accompanied by a marked reduction in the reported consumption of PVC resins in ''Miscellaneous" applications, so it djjfficnrs possible that actual gains in dispersion resin consumption may not have -fteAp great as these data suggest. How ever, it i3 known that the coated-type'TOy&Jaooring took up significant quantities of dispersion resins in 1971. Iiv<TOditirar, carpet backing consumed much more dis persion resin in 1971 than in. lWwwaotrend that continued in 1972 and 1973. The term "plastisol fcmnttistfteg as used by the Tariff Commission is believed to refer to commercial alasut^tools which are prepared and sold by a large number of small compounderay&^afv'equally large number of small users. In 1971, approxi mately 70 million^ounds of PVC resins are estimated to have been used for such commercial plastisols. The remaining 36 million pounds that were reported under "Plastisol Formulation" in 1971, plus the 50 million pounds reported under "Other Paste Processes," are all believed to have been used in rotational molding (CEH estimate). o The consumption of dispersion resins in rotational molding, as it was estimated for the year 1970, is shown in the following table. 0.3. Consumption of PVC Dispersion Resins in Rotational Molding--1970 Millions of Pounds Toys and Novelties 30 Miscellaneous Consumer Articles 30 Automotive (arm rests, head rests, crash pad skins, gear box covers) 12.5 Recreational (bicycle saddles, beach balls, basketballs) 12.5 Total 85.0 o Source: Hmh-rn Plastics, March 1971, pp. 52--56, BFS 007178 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ........ ........ 580.1983 A SEPTEMBER 1973 The production of plastisol-coated fabrics and papers for use in automobiles, furniture, garments, luggage, wall coverings, outer apparel, shoes, and a multi tude of other uses has shown consistent growth despite competition from calendercoated 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. A particularly fast growing and relatively new market for vinyl dispersion resins in the*textile-coating field is in foamed carpet backings. Such PVC backings not only provide cushioning for tufted carpets and, at the same time, lock the tufting yarns in place, but also help the carpet meet current flammability requirements. The widespread use of relatively low-melting polypropylene tufting backings prompted the development of new paste-forming PVC copolymers which allow fusion of the vinyl foam backing at or below 300F. The consumption of vinyl dispersion resins in cast flooring (such as that produced by Congoleum Industries, Inc., a subsidiary of Bath Industries, Inc.) has increased remarkably in the last three ytfTre ^Sbstiy at the expense of calendered vinyl flooring. Additional iatfdwaa. tion^oif PVC dispersion resin consumption may be found in Bucskoy'lS^hTT^ H&ature Markets for Vinyl Dispersion Resins," a paper presented berojfevtheyl^th Film, Sheeting and Coated Fabrics Conference, The Society of the PlaaiHTs Industry, Inc., New York, November 1971. 4. Molding Processes Reported domestic PVC resin consumption in the various molding processes is shown in the following table. U.S. Consumption of PVC Resins in Molding Processes Millions of Pounds Compression Molding Injection Molding15 Blow Molding*5 Total Total as a Percent of All PVC Consumption I960 1961 1962 1963 1964 (58) (58) 61 78 75 (12) (14) (17) (19) . (24) 0 (70) 0 (72) 0 78 0 97 0 99 8% 7 7 7 6 1965 1966 1967 1968 1969 1970 197lp 1972 90 114 105 122 138 141 138 148 (26) (50) <52> (55) (64) (66) 135c 185 (5) (15) (20) (23) (46) (47)d 36d 77 121 179 177 200 248 254 309 410 7 9 9 8 9 9 10 10 (continued) CHEMICAL ECONOMIC HANOBOOK 5'*ifa>o rsuc- iismoit, umo chiioinu BFS 007179 POLYVINYL CHLORIDE RESINS - CONT1NUEO a. Designated by the Tariff Commission as "Sound Records." .` . b. Data for 1960-1965 were reported as "All Other Molding" and for 1966-1970 as "injection and Blow Molding" (combined). c.' Designated by the Tariff Commission as "All Other Molding." d; It is widely believed that actual consumption in blow molding in 1970 and 1971 was considerably higher. Estimates for PVC resin consumption in blowmolded bottles are on the order of 70 million pounds in both years (see the . section on Packaging on p. 580.1883P). e. Reported components are: Bottles (blow molding), Sound Records (compression molding), and All Other Molding (b<jfl3)eved to be substantially all injection molding).' Sources: (A) CEH g^timSfcejs ^(esftlmates for 1960 and 1961 and estimates for Apn Molding and Blow Molding for 1965-1970). Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariff Commission (data for 1962-1970). (C) Synthetic Organic Chemicals, U.S. Production and Sales of Plastics and Resin Materials, 1971 Preliminary, U.S. Tariff Commission (preliminary data for 1971). (D) Annual Statistical Report, Plastics & Resins Materials. 1972, The Society of the Plastics Industry, Inc., April 1973 (data for 1972). PVC resin consumption in the various (technically very different and unrelated) molding processes had a combined average annual growth of 15.7% from 1961 to 1971, and a rate of only 5.6% between 1966 and 1971. Then in 1972, a 33% increase occurred. As the data in the table show, however, the growth rate for resin con sumption in the three different molding processes varied greatly. Compression Molding. PVC consumption in compression molding, which includes essentially only sound records, grew at an average annual rate of slightly over 8% between 1960 and 1972. To obtain adequate replicas of the sound vibrations in the grooves of records, particular flow properties of the compound (which consists of 98% PVC resins) are needed so that it can conform to the required surface pattern in micro scopic detail. High vinyl acetate content (10-16%) copolymers, specially designed for this purpose, are used in the compression molding of phonograph records. o o BFS 00 rise n r> POLYVINYL CHLORIDE RESINS - CONTINUED .......................... plastics and aesins 5S0.18B3 C SEPTEMBER t973 Infection Molding, The resins most frequently used in PVC Injection molding are medium molecular weight homopolymers and some lower molecular weight vinyl chloride-vinyl acetate copolymers. An estimated 90% of all PVC resins con sumed in injection molding ts used for pipe fittings and the balance is mostly used for industrial parts, e.g., fan blades for chemically resistant exhaust systems. ; PVC consumption in injection molding increased by an average of almost 26% per year from 1961 to 1971; between 1966 and 1971, an average growth rate of 22% prevailed--thus, this category Is an outstanding growth field. The doubling of consumption in 1971 is believed to have been due to the following: (1) the operation of newly installed multiple-screw injection machines, (2) the general increase in PVC piping installations in many phases of construction, and (3) the strong resiurgence of building activity in 1971. In 1972, resin consumption increased again by 37% in injection molding. Blow Molding-. The blow molding of PVC resin is a relatively recently developed, sophisticated, and highly capital-intensive technology used primarily for the mass production of PVC bottles and requires special resins, special compounds, and special equipment. PVC resin consumption in blow molding grew steeply f^om 1965 to 1972 (see foot note d in the preceding table concerning data fc^<alt&&and 1971). Data on the 1971 consumption are conflicting (see the sec^iaA>n\d>ackaging in this report); it appears that some decline occurred in 19f*^tov>connection with industry con cern about the possibility of govemm^ttimpojn limitations on the large scale use of PVC bottles in the future.^ In mid-1971, an estimated aa&y^fitediion machines (of which more than 95% were imported) and an estimated. 10y proprietary machines (designed and built by some leading PVC bottle prMa^^^themselves) were in operation in the United States. The technical problems That have been successfully solved in recent years to develop efficient production technology for the blow molding of PVC bottles were formidable and are too complex for treatment in this report. (Technical details may be found in the following articles: "Plastic--Bottle Future: Grafted to Proliferating Molecules," Modern Packaging, May 1969, pp. 78-83; and Waechter, C. "What's Happening in PVC Blow Molding," SPE Journal, July 1971, pp. 43-47.) Heat stability during processing was a major problem in the early stages of the development of the technology for blow molding of PVC bottles. To overcome this problem, vinyl chloride-olefin copolymers were developed (by Air Products and Chemicals, Inc. and Union Carbide Corporation) that proved very successful in blow molding. Special compounds based on bulk-polymerized homopolymers and on sus pension homopolymers (the latter usually in admixture with such copolymers as a lauryl ether-vinyl chloride copolymer made by GAF Corporation) are offered to processors CHEMICAL ECONOMICS HANDBOOK SrSf0B0 INSflTVIC, HCNtO MM, C*Liro**l* BF5 007181 580.1883 0 * POLYVINYL CHLORIDE RESINS - CONTINUED Data on PVC resin consumption in solution applications in. recent years are given in the followin'.: table. this consumption has been reported as "Protective Coatings and Adhesives," and recently together with a category called ''All Other Coating Uses." It. is believed that, the bulk of this consumption has been In applications where the resin Ls put in solution, although somedispersion coating resins and powder coating resins are probably included.. ______U.S. Consumption of PVC Resins In Solutions3 I960 1961 1962 1963 1964 1965 1966 1967 1968 1969 Millions of Pounds 39 36 45 (50) (50) (50) 54 72 83- a 85 90b 118c Total as a Percent of All PVC Consumption 4% 4 4 4 3 3 3 4 3 3 3 3 3 a. Reported in the source as "Protective Coatings and Adhesives" in 1960-1962 and 1966-1970. In 1971 also includes All Other Coating Uses Believed to include mostly solutions but also some dispersion and powder coatings. b. Includes 41 million pounds reported as used in "Protective Coatings and Adhesives" and 49 million pounds reported as used in "All Other Coating Uses." c. Reported as "Protective Coatings" (59 million pounds) and "Adhesives and All Other Coating Uses" (also 59 million pounds). Believed to include mostly solutions but also some dispersion and powder coatings. . Sources: (A) Synthetic Organic Chemicals, U.S. Production and Sales, U.S, Tariff Commission (data for 1960--1962 and 1966-1970). (B) CEH estimates (estimates for 1963-1965). (C) Synthetic Organic Chemicals, U.S. Production and Sales of Plastics and Resin Materials, 1971 Preliminary, U.S. Tariff Commission (preliminary data for 1971), (D) Annual Statistical Report, Plastics fc. Rosins Materials, 1972, The Society of the Plastics industry, Inc., April 1973 (data for 1972). BF5 0071S2 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ..... .......................... 580.1883 E SEPTEMBER 1973 All solution-grade resins are made by solution polymerization and most are vinyl chloride-vinyl acetate copolymers with vinyl acetate contents of 8 to 12%. One type often used in adhesives has a small amount of free carboxyl groups and another often used in protective coatings has a small amount of free hydroxyl groups. Typical solvents used in the solutions are cyclohexanone, tetrahydrofuran, methyl ethyl ketone, and diisobutyl ketone; however, some of the resins tolerate the presence of minor quantities of low-cost aromatic hydrocarbon diluents. (For more information on the use of PVC solution resins in coatings, see the freq report on Vinyl Surface Coatings.) PVC resin consumption in the form of solutions (including some other forms of coat ings) had an average annual growth rate of 9.7% between 1960 and 1972, as indicated in the preceding table. 6. All Other Uses The Tariff Commission has maintained this category largely to balance statistics (the great bulk reported under this heading actually belongs in the individual process categories previously discussed).. The following table presents the reported data with pertinent commentary footnote* PVC resin consumption in some spedfeuwar^uses may not have been covered by the main process categories. They may d&iciut^r; for example, the production of rigid vinyl foams. a ption of PVC Resins in All Other Uses 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971p 1972 Millions of Pounds <83)a (95)a U30)b 206C 249c 295c 228 305d 491d 350d 376d 281 180 a. The actual figures reported for 1960 and 1961 were 113 million pounds and 125 million pounds, respectively. An estimated 30 million pounds of resins used in commercial plastisols were subtracted in each year and added to the table on U.S. Consumption of PVC Resins in Dispersion Processes (p. 580.1882X). (continued) CHEMICAL ECONOMICS HANDBOOK (SEui) srtxroao rcscmcn mist nun MtNLO cmrOOMU BFS 0071 S3 580 1383 F POLYVINYL CHLORIDE RESINS - CONTINUED *- b. The 161 Billion pounds-actualljr reported by the source includes an estimated 40 million pounds of exports (included in the INTERNATIONAL section statistics on Exports), c. Believed to include about SO million pounds used in protective coatings and adhesives in each of the years 1963, 1964, and 1965. d. It is generally believed that at least 100 million pounds of each of these amounts were actually consumed in calendering. Sources: (A) Synthetic Organic Chemicals, U.S, Production and Sales, U.S. Tariff Commission (data for 1960-1970). (B) Synthetic Organic Chemicals, ti.S. Production and Sales of Plastics and Resin Materials, 1971 Preliminary, U.S. Tariff Commission (preliminary datum for 1971), (C) Annual Statistical Report, Plastics fc Resins Materials, 1972, The Society of the Plastics ^wjustry, Inc., April 1973 (datum for 1972). (0) CEH estimates (data !btes b, c, and d). B. Consumption by End Use o The breakdown of PVC con jy end use given in the following section is based largely on the annual mi fion of end use data by Modern Plastics magazine. This total consumption ;e usually varies somewhat from PVC consumption by process data reported by th Tariff Commission. Considering the size and diversity of the markets for PVC resins, however, this difference is not believed to require analysis. Some relatively small end uses are not included in the Modern Plastics data; these are believed to include applications where soluble copolymers are con sumed, e.g., industrial protective coatings and topcoatings, as well as printing inks applied by rotogravure printing on most of the vinyl-coated fabrics and film produced, and perhaps powder coatings (see the CEH report on Vinyl Surface Coatings for more information). Examples of other small-volume end uses for PVC resins that are not mentioned in the Modern Plastics data are rigid vinyl foams, foamed carpet underpadding, and coated fabrics for tarpaulins and inflatable structures. No effort has been made to establish the volume of these relatively small markets. O O T BFS 007184 POLYVINYL CHLORIDE RESINS - CONTINUED plastics and resins S8Q.18B3 G SEPTEMBER 1973 The following breakdown of PVC resin consumption by major end-use category in recent years shows that the average annual growth rate of PVC consumption by end use was 9.9% between 1966 and 1971. Then total PVC consumption by end use increased over 27% in 1972 alone. woaswpcinn (Millions of Poind*) 1966 1967 1MB 1969 Buildlax and Construct ion (613) 996 MB 17 Household (Jcs 1440) 410 443 913 Coniwer Oootin (330) 330 373 374 iltetrlnl Uses 336 223 301 409 Psekeclnc (90) 107 161 229 Trensnortstlon -Miscellaneous Uses Totsl (173) (161) (3,037) 160 (191) <3,007) 199 123 2.369 234 141 2.712 1970 1971 1973 1,006 1. IBS 1, 739 313 964 630 434 437 504 433 389 439 > 273 223 264 339 163 199 , 396 3,037 2,266 4,180 Sourees: (A) CH ntlMUi (aitlntn for 1966 (B) CBI Mtlntcs based on d Statistical Report. Plaa UK., April 1973 (<j VnlAn Plant tcs. January 1973, p, SB, and Annual R4bln Materials, 1972, n Society of it* Plastics Industry, <C> Modem PlaatK itker data). The major end uses shown in this table are discussed and further breakdowns are given In the following sections. 1. Building and Construction A breakdown of PVC resin consumption in building and construction in recent years is given In the following table. The data in the table indicate that PVC resin consumption in building and con struction has grown at an average annual rate of 13.7% between 1966 and 1971. In 1972 alone, a 49% increase in PVC resin usage in construction took place. As a percent of total PVC resin consumption by end use, it grw from 20% in 1966 to 42% in 1972. U CHEMICAL ECONOMICS HANOBOOH (KlU) $iih<od sue amc mjTirurt, hcmio mi, caiifobjiia BFS 007185 580.1883 H POLYVINYL CHLORIDE RESINS - CONTINUED 11 of nc Resins In Building and Construction (Stiltons of Pnuids) indoaa ud ; n* Mrf r* Other Rigid 3rlasing Mttwr w*tr Light la* Rata Conduit Pitting* Flooring IMlni Profit*. Pool liners Strippim; Stop* fixture* Cuttera Total lfM its It 370 (22) (19) -- -- ---- -- (915) 19*7 (1SS) (30) 303 25 20 20 25 19 7 4 599 1999 196 34 302 35 25 30 29 18 8 4 999' 1*99 239 92 347 . SO 3S 32 29 20 9 9 A17 1970 (480) 1971 (910) 1972 1,009 86 323 325 343* <) (60> 70 45 53 I06h 35 40 44 30 20 32 27 9 10 3le 11 7 1,006 7 1,195 1,739 a. Tito SP1 reported 333 sltHos pounds ot PVC used for calendered flooring plus 133 allllnn pounds for coated flooring. Modern Plastics listed a total of 344 alllion pounds only. k. Include* SI Billion pounds of extrudod foaa aoldlnu. e. Inclisles rats gutter*. Sources: (A) CB< estlaates (all data la parentheses). (B) cai estlaates baaed oe Annual Sixth* Society of tbe Plasties Industi Report. Plastics 4 Resins Materials. 1972, The d Modern_PlMMc, ja ry 1973, p. 59 (data for 1972). (C) Modem Plastics, January 1 other data). Pipe, Conduit, and e Fittings. Between 1966 and 1971, PVC resin consumption In pipe, condjii in 1972 aloi(e^ ipe fittings grew at an average annual rate of 34%, and st 80%. ABS, othw- styrene copolymers, and polyethylene compete with PVC in the plastic pipe and conduit markets. Overall, CEH estimates that PVC had well over half of the total plastic pipe and conduit business in 1972; a breakdown by segment of the PVC pipe and conduit markets, and fittings, for 1973 follows: Estimated PVC Consumption in Pipe and Conduit---1973 Pipe and Conduit Communications duct Electrical conduit Pressure pipe* * Drain, waste, andvent pipe Sewer pipeb Other0 Total Fittings Total Millions of Pounds 114 75 792 99 55 31 1,166 264 1,430 a. Includes water supply and distribution, and gas distribution lines. b. Includes home sewor piping and sower mains. c. Includes oil and gas production lines, and chemical processing pipe Source: Modern Plastics, March 1973, p. 59. CHEMICAL ECONOMICS MAN0B00K Sr*NOS0 *l5Ch laSTITUTt, MINLO Ptkl, (HlfOlltU BFS 007136 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS A>;(> RS'-tiMS S80.1883 I SEPTEMBER *973 The share that each type of plastic holds of each market is determined to a great extent by each material's particular ability to competitively match the cost and performance requirements in the individual applications. For example, PVC is leading: in water supply pipe and conduit but has smaller---although not insignifi cant--shares in {a) gas distribution pipe (where polyethylene leads), (b) IXW pipe (where ABS is dominant), and (c) sewer pipe (where PVC has just begun to move in strongly). About 75% of the PVC resin used in pipe production was compounded Into powder blends by the pipe producer in recent years. However, new blending techniques developed by some resin producers indicated a change in this pattern as some resin producers prepared to become major sources for ready-to-extrude pipe compounds (MP, July 1971, pp. 72 and 76, and September 1971, p. 14). Plastic pipe is cheaper and much less costly to install than conventional cast iron piping, but-its acceptance reportedly is strongly resisted by plumbers* unions and cast iron pipe interests (CE, July 28, 1969, pp. 76, 78, and 80). However, market fundamentals (demand, lower cost, satisfactory performance) favor continued strong expansion of plastic pipe. In 1969, plastic pipe sales amounted to a mere 3% of the total U.S. pipe sales (industrial and residential). expected continued expansion of xbe low pressure pipe, particularly large nchw and^Targer), and sewer pipe. Cither end uses also ly include telephone conduit and residential hot-water ^jyifst^chlorinated PVC. In DWV pipe, PVC's market share is believed % as of mid-1973, and PVC is expected to gradually increase its market share (CEH estimate based on communication with industry). PVC consumption in pipe, conduit, and pipe fittings is expected to rise at an average annual rate of 22-24% between 1972 and 1975 and at a slightly lower rate thereafter, so that PVC resin usage in this field will be slightly over 2 billion pounds by 1975 and at least 4.1 billion pounds by 1980 (CEH estimates). Flooring. Of total PVC resin consumption in building and construction, flooring's share declined from 60% in 1966 to 28% in 1971 when only 325 million pounds of PVC resins were used in flooring. A slight upturn occurred in 1972. Until 1970, flooring was the largest single end use for PVC. PVC tile and sheet for floor covering is produced in a variety of types. In 1969, 67% of all PVC flooring produced was of the vinyl-asbestos type (those compounds are based on vinyl chloride-vinyl acetate copolymers and contain only 15% rosin), 30% were roll goods, and 3% were of the solid, homogeneous type (MP, December 1969, p. 16). In recent years, coated vinyl flooring (plastisol-coated felts) have moved into the lower-cost markets at the expense of calendered vinyl-asbestos tile. BFS 0071S7 580.1883 J POLYVINYL CHLORIDE RESINS - CONTINUED Because of the persisting trend toward increased usage of carpeting, the market for PVC flooring has declined Trom about 3Ctt> of all basic floor coverings in 1961 to about 30% in 1971 (CEH estimates). SPI data far 1972 show 333 million pounds of PVC used for calendered and 134 million pounds for coated flooring, but Modern Plastics showed only 313 million pounds for all PVC flooring in 1972. The latter figure is believed to be more accurate. By 1973, PVC consumption in flooring is estimated to reach 400 million pounds per year--an average growth rate of about 5% annually from the 343 million pounds believed consumed in 1972 (CEH estimates). However, this does not include a possible requirement of, according to one source, as much as 250 million pounds of PVC resins (half of them dispersion resins and the other half blending resins) which has been estimated for consumption in foamed vinyl carpet backing by 1975. Vinyl foam is expected to compete strongly with styrene-butadiene copolymer backcoatings because it effectively imparts the flame retardance properties now required by U.S. government regulations (MP, April 1971, p. 86). Siding, Windows, and Other Rigid Profiles. The average annual growth rate between 1966 and 1971 was 22% for siding and 20% for windows and other rigid profiles. In 1972, siding advanced further, and a new category of rigid profile extrusion, foamed molding, was reported. This technology has developed over the last several years. Most PVC siding is sold in the rep^figerihstSi market and in mobile homes, where it competes with aluminum siding.''^fiMTnew'^types of vinyl siding, produced by the thermoforming of rigid sfteeft, sipdiate stone and wood shingles. Recently, PVC siding has also lMq^taoreNidely used in new residential construction (major pro ducers are , South Bend, Indiana, Bird St Son, Walpole, Massachusetts, and eyT-Products Corp., Valley Forge, Pennsylvania). PVC siding is expectecT%o grow at an average annual rate of about 25% from 1972 to 1975 (CEH estimates).. PVC consumption in window frames is mostly in vinyl-clad wood at the present time; vinyl is extruded directly over a wood core of the sash, while corner joints are given a welded seal after assembly. In another method, rigid PVC extrusions are attached to wooden frames with adhesives. All-PVC window frames have been in the development stage for some time, but their commercial future is still uncertain. Rigid profiles other than window frames afe spline for storm windows and doors, rigid weather stripping, and rigid molding. An expandable PVC extrusion compound introduced by The Goodyear Tire & Rubber Company in 1971 lends itself to the production of a rigid foam molding with an integral skin, on which a woodgrain pattern can be printed. The product is distributed by Champion International Corporation (formerly U.S. Plywood-Champion Papers, Inc.). Other major producers are B. F. Goodrich and Georgia-Pacific. It has been estimated that 50% of this rigid, cellular PVC molding goes into mobile homes, and that it has captured about 8% of the prefinished wood molding market; by 1975, as much as 200 million pounds of PVC have been estimated to be required for extruded PVC foam molding <PW, Juno 1973, pp. 42-45). o BBS 0071 SB o tmst POLYVINYL CHLORIDE RESINS - CONTINUED Plastics and resins .................. ........................ 580.1883 K SEPTEMBER 1973 These rigid extrusions (siding, windows, and other rigid profiles) are expected to grow at an average annual rate of 25% between 1972 and 1975, and probably to 1980. Particularly strong growth is expected in window frames. Rigid foam profile extrusions are estimated to grow about 20% per year in the same period (CEH esti mates). Other Uses in Building and Construction. Other end uses in this market are led by swimming pooi liners (calendered sheet 8 to 30 mils thick), which became popular in the late 1960's and had an average annual growth rate of 19% between 1967 and 1971. Foremost among producers of pool liners are the PVC resin producers (MP, June 1969, p. 12). Combined PVC usage in swimming pool liners, weather stripping, water stops, light ing fixtures, and rain gutters amounted to roughly 10% of PVC resin consumption in all building and construction uses in 1971. All of these applications are expected to show moderate growth--an average rate of approximately 10% per year--between 1972 and 1975 (CEH estimates). 2. Household Uses PVC resin consumption in household usgSK is shown in the following table. PVC resin consumption in householdusTOtereajJ at an average annual rate of 5% between 1966 and 1971, but 1972 saw a^Si^gt 12% increase. As a percentage of total PVC resin consumption by eni^_ufse, )Kwas 21% in 1966 and 15% in 1972. U.S. Conauaption of KC Resins in Household Usee (Billions of Pounds) Furniture Upholstery vail Coverings Garden Hose Tablecloths and Placesutts Shoeer Curtains Closet Acceeeorlee Appliance* *ood-- Surface Ftlss Other Total 1966 (200) (80) (27) (30) (29> (20) (18) -- (40) (440) 1967 188 81 29 29 20 1W8 218 80 30 26 21 1969 260 70 33 29 23 20 18 22 ` 17 24 19 -- 31 410 12 37 443 19 40 913 1970 1971 1972 247 280 319 80 89 128* 39 39 44 30 25 83d 104 29 24 17 30 513 39 30 90 564 _35 .. 630 a. Believed to include Institutions snd restaurants, other businesses, *nd public buildings as ell as hose*. b. Includes closet accessories, shoeer curtains, tablecloths, and pises--ta. c. Includes oed-surfsce files. Sources: (A) CEH estlaotes (estl--tes tor 1966). <B) Modern Plastics. January issues (sll other data). CHEMICAL ECONOMICS HAN0BOOK <lSUp STaxfOSO (SOSCM IMSTlfutC MCNt.0 rasa catiro*nia BF5 0B7189 580.1083 V. POLYVINYL CHLORIDE RESINS - CONTINUED " Furniture Upholstery. About 46 to 50% of PVC resins consumed for all household uses is in furniture upholstery; this percentage remained substantially the sane between 1966 and 1972. Vinyl-coated fabrics established themselves firmly in furniture in the early 1960's, particularly in low-priced lines. Hacking fabrics changed from mostly cotton to mostly rayon in recent years for reasons of material economics. Today, almost all furniture upholstery containing PVC is in the form of coated fabrics. Over 90% of these fabrics are believed to be calendered sheet. Only a relatively small quantity of high-style expanded vinyls cast from plastisoi is used {mostly in high-priced furniture). After an apparently strong advance in 1972, the vinyl furniture upholstery market is expected to show only slight growth (about 4% per year between 1972 and 1975); however, it will always mirror fluctuations in the furniture business (CEH esti mate). All Other Household Uses. Wall coverings is the second largest household use and accounts for about 16% of PVC resin consumption in this category. PVC wall cover ings are in most cases coated fabrics (predominantly sheetings and sateens) with a film thickness of 5 to 20 mils. Even though classified under household uses, most of the vinyl wall coverings produced are believed to go into institutions such as hospitals, nursing homes, and schoaJ^Ond into public buildings, business places, and restaurants. Vinyl's durabAl'Sa\a^d/toughness make it appropriate for use in institutions. Vinyl is also faorlj^fire resistant (depending on the type and amount of plasticizer fi^tpe^cowjjound), scuff resistant, and washable. Embossing and printing large variety of styled products. teidh^'ts expected to increase more in wall coverings than in any other ige--at an average rate of 12% per year in the 1972-75 period (CEH esti- Other household uses of PVC resins also include garden hose, tablecloths and placemats, shower curtains, unsupported film and coated papers with pressure-sensitive adhesive backings (for what are called closet accessories), and some unspecified uses such as window shades. These are established markets that are expected to show marginal growth---4 to 5% per year on the average--between 1972 and 1975. The relatively small market for PVC resins (mostly in the form of gaskets) in appli ances is expected to grow about 7% per year, and PVC consumption in wood-surfacing films, an often publicized and rather new application of semirigid film, is expected to increase between 1972 and 1975 at an average annual rate of about 12% (CEH esti mates). BFS 00 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS ANO RESINS 580.1883 M SEPTEMBER 19TJ 3. Consumer Goods PVC resin consumption in consumer goods is shown in the following table. L\ S. Consumption of PVC Resins in Consumer Goods (Millions of pounds) Sound Records Footwear Toys Outerwear Sporting Goods Babv Pants Other Total 1966 1967 114 104 60* -- 83b 57c -- 45 -- -- -- -- (350) 19 12d 320 1968 122 90 64 46 26 19 8 375 1969 116 100 58 40 30 21 9 374 1970 1971 1972 140 125 148 110 60 115 62 141 75 47 S3 66 35 40 48 23 9 424 20 22 437 24 _ 504 a. Reported as "Soles and Heels." b. Includes 23 million pounds designs for shoes. ar (slipovers) and 60 million pounds Includes 13 million pc ids f^J Rjayballs, 18 million pounds for dolls, 19 million pounds for inflat: ^nd 7 million pounds for other toys. d. Designateifcuai ' ^Clothing.' Sources: estimate (Total estimate for 1966), (B) Annual Statistical Report, Plastics & Resins Materials, 1972, The Society of the Plastics Industry, Inc., April 1973 (1972 datum for Sound Records). (C) Modern Plastics, January Issues (all other data). PVC resin consumption in consumer goods grew at an average annual rate of only 4.5^ between 1966 and 1971, indicating near-saturatlon of the markets. Renewed strength was apparent in 1972, however. The largest single consumer goods application is in sound records but, as the data in the preceding table indicate, growth in this area was quite marginal from 1966 to 1972. Average annual growth between 1972 and 1975 is expected to be about 57 (CEH estimate). The second largest application of PVC In the field of consumer goods is in foot wear, Most of this is for lower priced children's shoes, and a lesser portion is used for innersolcs, socklining, and soling. This PVC market is expected to grow about lt/T annually from 1972 to 1975 (CLII estimate). CHEMICAL ECONOMICS mANOROO* > OUC >ESC*Ch IliTMUK , Wl >110 BFS 0Q71 91 660.1833 N POLYVINYL CHLORIDE RESINS - CONTINUED "Most other applications of PVC resins in consumer goods (including toys, outerwear, sporting goods, baby pants, and various unspecified other uses such as home movie screens) are expected to continue in their established patterns and are expected to grow at rates between 5 and 8% per year. However, there are two exceptions: wigs and plastic Christmas trees. Both are relatively small and recent consumer applications which are expected to show above average growth in the next several years (see the CEH report on Vlnyon Fibers for more Information on PVC consumption in wigs). . 4. Electrical Uses PVC resin consumption in electrical uses, as shown in the following table, has grown at an average annual rate of 11% between 1966 and 1971, and almost 19% in 1972. As a percentage of total PVC consumption by end use, it was 11% in 1966 and slightly less in 1972. 1966 U.S. Consumption of PVC Resins in Electrical Uses (Millions of Pounds) Wire and Cable Other Total 226 -- 226 O for communications wire and cable, and 22 million pounds for automotive electrical wire and cable. Sources: (A) Annual Statistical Report, Plastics fc Resins Materials, 1972, The Society of the Plastics Industry, Inc., April 1973 (datura for 1972). (B) Modern Plastics, January issues (all other data). O BFS 00F192 vJ POLYVINYL CHLORIDE RESINS CONTINUED PLASTICS AND RESINS 580.1883 0 SEPTEMBER 1973 Wire and Cable. PVC consumption in the wire and cable field breaks down as shown in the following table. U.S. Consumption of PVC Resins in Wire and Cable-1971 Building Wire Communication Wire Flexible Cord (for Household Lamps, Extension Cords) Automotive Electrical Wire and Other Auto Uses Appliance Wire Total 47% 18 16 12 7 10W Source: Communication with industry. The particularly strong advance of PVC consumption in wire and cable in 1969 reflected an ongoing trend from coppa^to aluminum conductors; the latter are larger in diameter (because a gretfr^m.uiae of aluminum is needed for the sPaVmC ecolomapdetcesap.aitchity)^aend^th^usaffcsSLtitrec. msoreanindseuXlaatsitoonmemraatineri,,allra,roauacn,dthbelm. . tnsota- tion. Polyolefifte^SPfe better electrical insulators, but PVC is a better jacketing material wlyST'^ri^l^t'ance to flexing is required in a wire or cable. PVC's domi nance Mf^ialdjmg wire suggests increasing consumption in this field in the next several\jy%ars because of the anticipated continuing strength of the construction business^ FVC*s inroads into communication wire (PUT, May 1969, pp. 31-32) are also expected to deepen. Thus, in the fields of building and communications wire (which together accounted for 65% of all PVC usage in wire and cable in 1971), the average annual growth between 1972 and 1975 is expected to be between 10 and 12% but in the remaining wire applications, growth is expected to be marginal--on the order of 5% per year* Total PVC consumption in wire and cable is expected to grow at an average annual rate of about 8% between 1972 and 1975 (CEH estimates). Other Electrical Uses. The main "other" use for PVC in the electrical field is in electrical insulating tape where PVC competes with several other materials. Never theless, consumption for electrical tape is expected to increase gradually (CEH estimate). CHEMICAL economics handbook S T 0*0 isec* IfcSTITUTt, ftO CAt-IFOa*'* BFS 0071 S3 580.1683 P POLYVINYL CHLORIDE RESINS - CONTINUED 5. Packaging PVC resin consumption in packaging, as shown in the following table, grew at an average annual rate of 26% between 1966 and 1971. As a percentage of total PVC consumption by end use, It was 4% in 1966 and almost .9% in-1971. 1966 1967 1968 1969 1970 1971 1972 Film 55 55b 90 . 105 115 110 135 u.s. Consumption of PVC Resins in Packaging Sheet0 (Millions of Pounds) Bottles Coatings Bottle Cap Liners and Gaskets 11 15c 20 50 9 22 29 46 15c 22d 15 -- -- 12 60 75 107 70 70e 77 15 16 20 12 15 18 Total (90) 107 161 228 272 286 357 a Believed to be all rigid sheet taining less than 10% plasticizer) b Reported as "Used for Fojai'yac g." The estimated sheet Packaging.' rtiomof the 30 million pounds reported for Son-Food d. Believed bottle cap linings. e. The revi^kd^figure (of January 1973) is only 50 million pounds, which was also reported by the SPI. Sources: (A) CEH estimates (Total estimate for 1966 in the table and estimates in footnotes a and c). (B) Annual Statistical Report, Plastics L Resins Materials, 1972, The Society of the Plastics Industry, Inc., April 1973 (1972 datum for Bottles). (C) Modern Plastics, January issues (all other data). Film and Sheet. Of the estimated 185 million pounds of PVC film and sheeting used for packaging applications in 1971, 65 million pounds are believed to have been calendered rigid sheet (about half homopolymer and half copolymer), 35 million pounds extruded rigid film and sheet, and 85 million pounds highly plasticized extruded film* (CEH estimates). * A relatively small quantity of PVC packaging film is cast from solution by The Gotxiyear Tire & Rubber Company <MP, November 1969, p. 18). O o BFS 007194 POLYVINYL CHLORIDE RESINS - CONTINUED plastics and resins 580.1883 Q SEPTEMBER 1973 Of the 65 million pounds of calendered rigid sheet, about 40 million pounds are believed to have been used in blister packaging (illustrative are packages for hardware and pharmaceuticals) and the remaining 25 million pounds probably, went into other packaging applications involving thermoforming, such as lids for greeting card boxes. Most of the 35 million pounds of extruded rigid material is believed to have been film, of which 15 million pounds were used in food packaging. The remaining 20 million pounds of extruded rigid film and sheet went in nonfood packaging uses. For many packaging applications, PVC film is laminated to poly ethylene film that has been coated with polyvinylidene chloride to meet all per formance requirements of the package. r The 85 million pounds of highly plasticized extruded film were used in meat packaging and have captured a large part of produce packaging <CEH estimates based on communication with industry). At present, 5-mil food-grade film is used for packaging meat, cheese, and crackers; 10-mil film is used for single portions of jam and syrup; and 20-mil film is used for processed meats. The growth potential for PVC resins in film and sheet packaging applications is believed to be very good for the 1972-1975 period in spite of concern about the possible harmful effects of PVC products on the environment (PVC liberates hydro gen chloride when incinerated. It has been asserted that hydrogen chloride is not only a serious pollutant but that it can also damage conventional incinerators, and and that without incineration, JJWdcjBfcckaging materials represent a solid waste problem after use). An ave^-ttgeStgl`itetn rate of about 17% annually appears likely for PVC film and sheet.dCmos'WjRjvt'gid and semirigid) in this market between 1972 and 1975 (CEH estimrf^. 3 ^ to reported data, PVC consumption in bottles grew from 11 mil] of pounc 'in 1966 to 70 million pounds in 1970--an average annual growth rate /ever, 1971 consumption was first reported to have been 70 million which was later revised to only slightly over 50 million pounds. PVC corn- petes with polyethylene and, to a lesser extent, with polypropylene in the plastic bottles market (Modern Packaging, March 1971, pp. 30-34), Typical uses include liquor, cooking oil, salad dressing, liquid detergent, and cosmetic and toiletry bottles. The blow molding of PVC bottles has been a field of much excitement and speculation in recent years because of its largo potential. The high expectations (250 million pounds of PVC bottles in 1975 and 500 million pounds in 1980, according to MP, October 1971, p. 96) were mixed with uncertainty in 1971 as a result of concern over the previously mentioned environmental considerations concerning PVC as a packaging material in general. But since that time, developments have given rise to a more optimistic view (MP, May 1972, pp. 16 and 18) and a minimum growth rate of 21% per year between 1972 and 1975 is expected (CEH estimate). CHEMICAL ECONOMICS HAN0B00* stun 00 l St **c msmun f Hto . CJkUrOM BFS 007195 580.1883 R POLYVINYL CHLORIDE RESINS - CONTINUED t 6. Transportation As shown in the following table, PVC resin consumption in transportation gvew at an average annual rate of 6,,5'.l between 1966 and 1972. As a percentage of total PVC consumption by end use, it was 8.51": in 19613 and 6,1''= in 1972. 1966 1967 1968 1969 1970 1971 1972 U.S. Consumption of PVC Resins in Transportation (Millions of Pounds! Upholstery a and Seat Covers (130) 130 140 160 150 170 180 Auto Tops (15) -- 25 27 30 32 35 Auto Flcormats (30) 30 34 37 35 37 40 Other Trim -- -- -- 10 10 15 -- Total (175) 160 199 234 225 254 255 a. Believed to include seat covers and trim for trucks, aircraft, boats, and recreational vehicles as well as passenger cars, and to include other interior trim in those years (1966-1968) wbe^^S^s is not separately reported. Sources: CEH estimates (jgst5^i^s or 1966). (B) Modern PJ^si January issues (all other data). o The bulk of PV(Vu,Sgns^.ds*stransport9tion is in automotive upholstery and seat covers, mostly in MrmjJofcoated fabrics, and vinyl auto tops (Landau roofs), which have been ave&wributor to increased overall PVC consumption in this field. Seat ing materiaXKnitted from slit PVC film wrapped around a core of nylon filament has appeared in some cars (Daily News Record, September 8, 1971, p. 17). Accompanied by the fluctuations in the automotive market, PVC resin consumption in transportation is expected to continue to show an averaco annual growth rate on the order of 61i from 1972 to 1975 (CHI estimate). 7. Miscellaneous Uses The miscellaneous category encompasses diverse end uses that are in no way inter related; therefore, their combined I'VC resin consumption is of no analytical value except as a component of the total consumption in all uses. As the table below indicates, the largest of these miscellaneous end uses is in laminates. These laminates are believed to include vinyl clad metal, which is used predominantly in luggage, amt in some .appliances and automotive applications, c.g., gear box enclosures, plywood covered with printed film, and wallboard. o BF5 007196 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1883 s SEPTEMBER 1973 Ff U.S. Consumption of PVC Resins in Miscellaneous Uses (Millions of Rounds) 1966 laminates -- Medical Tubing -- Stationery Supplies Agri culture Credit Cards -- Tools and Hardware -- Novelties -- Other -- Total (161) 1967 -- -- --' -- -- -- -- (191) 1968 33 23 22 - 20 6 9 9 -- 122 1969 36 28 25 23 9 10 10 -- 141 1970 1971 1972 38 39 48 32 37 46 27 24 11 10 10 10 162 28 24 12 11 10 34 195 35 29 15 13 13 57 256 Sources (A) CEH estimates (estimates for Total for 1966 and-1967; and estimate for Other in 1972). (B) Modem Plastics, January issues (all other data). The use of PVC resins in ntedlcali^Dfc&Ig increased at an average annual rate of 19% between 1968 and 1972. _3$c|udedrfo this market in 1971 were an estimated 10 million pounds used in bipp^oical applications in or on the human body or in contact with human blood.plastics use in the medical field, of which PVC had about 67% in 193dAisMeSepfected to double by 1976 (Ctf, June 16, 1971, p. 24). Stationer^- supply uses for PVC include ring hinders, sheet separators, and many other items. Clear rigid and semirigid film and sheet is usually made from copoly mer resins, as are most credit cards. Credit cards is a relatively small specialty application but it had an average annual growth rate of 26% between 1968 and 1972. Other miscellaneous applications of PVC resins not specifically covered in the pre ceding table include carpet underpadding, vinyon fibers (see the CEH report on Vinyon Fibers for additional information on this end use), rigid PVC foams, and traffic cones (the latter alone accounting for perhaps 3 to 5 million pounds of PVC resins). One industry source believes that future consumption of PVC resins in rigid foams could become substantial. CHEMICAL ECONOMICS HAN0B00K ifNIOI*0 CSECN INjUIlJtt M(NLD f* C li'0*I* BFS 007197 580.1883 T POLYVINYL CHLORIDE RESINS - CONTINUED PRICE* and unit s xs value Vinyl Chloride A history of vinyl chloride prices and unit sales values is given in the following table and graph. Price and Unit Sales Value--Vinyl Chloride (Cents per Pound) Pricea,b Unit Sales Value 1952 1953 1954 -- -- 13.25 13 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 10.50 11.00 11.00 11.00 12.50 10 11 11 11 11 10 8 7 7 6 1965 1966 6 6 5 5 4 1970 1971 1972 1973 4.75 4.73 4.75 5.00 4 4p a. List prices taken on or near July 1 of each year. Whenever a range of prices was given in the sourcet the lowest was used b. Price bases are: 1954-1955 1956-1960 1961-1968 1969-1972 1973 Tanksr freight equalized Tanks, works Tanks, works, minimum freight allowed East Polymer grade, tanks, works, freight equalized East Polymer grade, tanks, f.o.b. works (continued) o BFS 00FI9S POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AMO BFSINS 580.1883 U SEPTEMBER 1973 Sources: (A) CMR (Price data). (B) Synthetic Organic Chemicals, U.S. Production and Sales, U.S. Tariif Commission (Unit Sales Value data for 1952-1970). (C) Synthetic Organic Chemicals, U.S. Production and Sales of Miscellaneous Chemicals, 1971 Preliminary, U.S. Taritf Commission (preliminary 1971 Unit Sales Value datum). In early. 1971, actual selling prices of vinyl chloride reportedly moved up somewhat from the level of as low as 4.5 cents per pound which had prevailed prior to that time. It is believed that rising costs made these firmer prices mandatory. Part of the picture was the prospect of rising chlorine costs and the probability of tighter ethylene supply in the future (MP, March 1971, pp. 61 and 62). In early 1972, actual selling prices are believed to have been close to the list price of 4.75 cents per pound. Xn December 1972, vinyl chloride prices climbed to 5 cents per pound, and in early 1973 they climbed further. 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. Polyvinyl Chloride Resins Actual selling prices are generally lower prices, e.g., general-purpose resins in late 1971 are believed to have sold 5 cents per pound when the list price was 12.5 cents per pound. However,x*n industry prices were very close to list prices. As of April 1973, gener^irj>osrPVC moved at 13 cents per pound, and dispersion resins at 22 cents per pouBdWfipmmunication with industry). Although the new .pAadts 4nkpioylng very large reactors and more efficient catalyst systems are believed to tflr^^fe^economical, the savings so achieved are believed to be substan tially offset, if*kot exceeded, by rising costs in labor, packaging and warehousing, fuel and other supplies, and taxes. Thus, profit levels were generally recognized as so poor in the 1971-72 period that capacity increases needed for 1973-74 were not set in motion in time to prevent a general resin shortage during the second half of 1973. CHEMICAL ECONOMICS HAN0800K tSHj) srt*<o*o i st *ck mtniuK MtMLO , c*LtroM* BFS eeri99 590.1883 V POLYVINYL CHLORIDE RESINS - CONTINUED 1950 1951 19S2 1953 1954 ' 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 General Purpose PRICE AND UNIT SALES VALUE-POLYVINYL CHLORIDE RESINS '(Cents per Pound! ___________ Priced- Dispersion (Emulsion) Grade Acetate Copolymer Vinytidene Chloride Copolymer tfrit Sales Value 38 38 38 38 38 31 27 27 23.5 23.5 i as 16.0 16.0 16.016.0 16.0 14.0 13.5 10.0 11.0 11.5 12.5 41 41 41 41 41 34 30 30 26.5 26.5 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 24.0 32 32 28.5 28.0 23.0 20.5 20.5 20.5 16.5 ias 16.5 16.5 20.5 20.5 35 3t 31 30 30 26 26 26 26 26 26 26 26 26 26 26 26 26 26 27 28 37 39 38 38 34 31 29 25 23 19= 18 18 17 17 17 16 14 14 13 13p a. Price histories are shown for those resins believed to individual company's products, it should neither field, nor that there are no simitar products., product appear in the following notes. - commonly used. Although the prices may be for an ,that this comoany is necessarily the predominant one in the ightly different specifications) available. Descriptions of each b- Prices are those in effect at the efK&ofl each }&ef and (except for VINYUDENE CHLORIDE COPOLYMER) are for truck load quantities of material oafked in^o-pound bags, minimum transportation allowed or prepaid. (1) GENERAL PURf^^-~^iroyal Chemical's Marvinol VR-22, VR-23, VR-24, VR-25. VR-26, VR-31, VR-33, for standard cafenaSr^Sa wtrusion processing. (2) DtS^^le^(,gw3LSlQN) GRAOE: Uniroyal Chemical's Marvinol VR-50 and VR-51, for plestisols. (3) ACE1^^,'C0P0LYMER: Oata for 1956-1967 are for Uniroyal Chemical's Marvinol VR-60. 15% vinyl acetate, for record molding. Oata for 1970-1971 are for B. F. Goodrich Chemical's Geon Resin 428, for record molding. (4) VINYLIDENE CHLORIDE COPOLYMER: Dow Chemical Company U.S.A.'s Latex 874 (prior to 1965, this product was known as Latex 7448). This material averages 50% solids, and prices quoted are for each pound of dry soiids, tank car quantities, f.o.b. shipping point, minimum transportation paid, in alt state* east of the eastern boundary of Idaho, Utah, and Arizona. c. The UNIT SALES VALUE for PVC homopolymer was 18 cents per pound and the average for all PVC copolymers was 23 cents per pound. SOURCES: (A) (B) SYNTHETIC ORGANIC CHEMICALS, U.S. PRODUCTION AND SALES, U.S. Tariff Commission (UNIT SALES VALUE data for 1950-1970). SYNTHETIC ORGANIC CHEMICALS, U.S. PRODUCTION AND SALES OF PLASTICS AND RESIN MATERIALS, 1971 Preliminary, U.S. Tariff Commission (preliminary UNIT SALES VALUE datum for 1971). Communication with industry (all other date). o o BFS 00720Q POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS * sMtt3 w SEPTEMBER 1973 ' a. Price data on ACETATE COPOLYMER and VINYLIOENE CHLORIDE COPOLYMER ara included in tl* table. CHfcMICAL ECONOMICS HANDBOOK, *1*1; STANFORD RESEARCH INSTITUTE. MENiO ?***, CAUFOMNU BF5 007201 itfSl SMte **'*. "V POLYVINYL CHLORIDE RESINS - CONTINUED vT . INTERNATIONAL ' Trade' A. Exports _ 1. Vinyl Chloride ;y- Separate data on U.S. exports of vinyl chloride were not reported until 1970. A breakdown of exports by country of destination is given in the following table. U. S. Exports of Vinyl Chloride (Millions of Pounds) 1970 1971 Mexico Brazil United Kingdom Belgium France Norway 42.0 -- 40.5 294.8 73.2 -- 49.7 18.7 212.2 159.3 46.7 -- 1972 84.8 80.7 29.2 111.4 33.2 129.4 o O a. Total export values were 34.3 million dollars in 1970, 30.9 million dollars in 1971, and 31.0 million dollars in 1972. Source: U.S. Exports, FT 410, U. S. Department of Commerce, Bureau of the Census. Vinyl chloride exports in the first two months of 1973 were 12% above those of the comparable 1972 period (U,S, Exports, FT 410, U.S. Department of Commerce, Bureau of the Census). 2. Polyvinyl Chloride Resins U.S. exports of PVC resins since 1960 are shown in the following table. Both the data reported by the Bureau of the Census and those reported by the Tariff Commission arc presented for comparison. BFS 007202 r- . t-' POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 980.1883 V SEPTEMBER 1973 I960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 Uncompounded -- -- -- -- -- U.S. Exports of Polyvinyl Chloride Resins4 _______ _____(Millions of Pounds) Bureau of the Census Compounded Reported Estimated Resin Content*5 Estimated Total -- ___ (35) ---- (30) ---- (40) ---- ---- -- 48 50 42 74 129 31 37 34 38 38 (25) (30) (27) (30) (30) (73) (80) (69) (104) (159) 132 118 119 35 34 40 (28) (27) (32) (160) (145) (151) See MANUAL OF CURRENT INDICATORS for additional data. . Tariff Commission Total '___ --- -- 42 70 68 69 71 ' 114 162 188 169p -- a. Included are all homopolymer and co' chloride. resins containing 50% or more vinyl b. Based on an estimated av e PVC resin content of approximately 80%. Sources: (A) U.S. E 410, U.S, Department of Commerce, Bureau of the pounded and Reported Compounded data in the table). (B) SyritoffCic Organic Chemicals, U.S. Production and Sales. U.S. Tariff Commission (Tariff Commission data in the table for 1963-1970). (C) Synthetic Organic Chemicals, U.S. Production and Sales of Plastics and Resin Materials, 1971 Preliminary, U.S. Tariff Commission (preliminary Tariff Commission datum for 1971). (D) CQ1 estimates (all other data in the table and estimate In footnote b). Total exports of PVC resins in the January through March 1973 period were 36.0 million pounds (Monthly Statistical Report, The Society of the Plastics Industry, Inc., March 1973). If continued at the same rate, total 1973 PVC resin exports would amount to about 145 million pounds. B. Imports U.S. imports of vinyl chloride were negligible from 1964 through March 1973. Since 1968, they have been less than one million pounds per year (U. S. Imports. FT 246, U.S. Department of Commerce, Bureau of the Census [data for 1964-19711 and U.S. Imports for Consumption, IM 146, Schedule 4, Parts 1-3, U.S. Department of Commerce, Bureau of the Census [data for 1972 and 1973}). CHEMICAL ECONOMICS HAN0800K ST AN* QA0 *CSC **tn WSI I Tull HOIIO MI, C*UfO)HI - BFS 007203 S80.18&3 Z POLYVINYL CHLORIDE RESINS - CONTINUED 0.S. imports of polyvinyl chloride resins also were small in 1964*1972 as shown in the following- table: v' ` " O.S. Imports of Polyvinyl ' ___________Chloride Resins Millions of Pounds 1964 5 1965 1966 1967 1969 1969 7 9 14 17 6 1970 1971 1972 6 4 4 Sources: (A) U.S. Imports, FT 246, U.S. Department of Commerce, Bureau o\&esCensus (data for 1964-1971). U.S. Imports?for consumption, 1M 146, U. S. Department irce, Bureau of the Census (datum ). Polyvinyl chloride imports for January through March 1973 (a total of 9 million pounds) have already more than doubled the total annual 1972 imports (U.S, Imports for Consumption, IM 146, Schedule 4, Parts 4-13, U.S. Department of Commerce, Bureau of the Census). World Production and Capacity The following table gives a regional breakdown of estimated 1972 production and annual production capacities for PVC resins. World Production and Production Capacity For PVC Rosins--1972 (Millions of Pounds) Production Annual Capacity** Western Europe United States Japan Eastern Europe Other Areas 6,500 4,300 2,400 1,900 1,200 7,900 4,400 3,500 1,800 1.800 Total 16,300 19,400 a, Estimated capacities as ot mill-1972. Source: CEH estimates based on inlormation in trade publications. BFS 0Q7204 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1884 A SEPTEMBER 1973 The leading producer of PVC resins in Western-Europe is West Germany with a capacity of about 2.4 billion pounds per year in 1972, followed by France, Italy, and the United Kingdom, each with an annual capacity of roughly 1.3 billion pounds in 1972. Of the PVC capacity of Eastern Europe, the U.S.S.R. is estimated to have about 700 million pounds per year and East Germany 400-500 million pounds per year in 1972 (CEU estimates). Japan has had a substantial overcapacity in PVC for several years, and in 1972 had to take steps to restrict PVC production. \J Producing Companies The following list of foreign polyvinyl chloride producers has been compiled from various trade publications. The list may not be complete nor up to date; no attempt has been made to verify the accuracy of the reported information with the companies listed. Vinyl chloride capacity has been included when obtainable from the same articles used for polyvinyl chloride information. (See the CEH Acetylene and Ethylene Dichloride reports and the Ethylene and Major Ethylene Derivatives-International Plant Survey for further informa tion on foreign vinyl chloride producers.)' When salient statistics Information on able in trade publications, the ijwfromati producing companies for that peuntry^j c .1 chloride for a specific country was availas been included before the list of individual NORTH AMERICA Canada Available statistics are as follows:* 1970 1971 1972 Production 158a 161a 205 Polyvinyl Chloride Resins - Canada (Millions of Pounds) Imports Exports Consumption 47a S2a 60 17 20 20 205a 213a 245 Annual Capacity 190 190 200 a. The source not only reported raw resin but also some compounded resins (on a gross weight basis). To convert the compounded resins to raw resin, it was assumed that the average resin content of the compounded material was 70%. Source: Canadian Plastics, February issues. * Worldwide listings of ethylene dichloride and vinyl chloride monomer plants and capaci ties are available in the Chemical Economics Handbook International World Hydrocarbons reports. CHEMICAL ECONOMICS HANDBOOK trmioio uu>ch msnruK mcmlo c*iiro*i* BFS 007205 58a188* 8 POLYVINYL CHLORIDE RESINS - CONTINUED 3. Tk Goodrich Canada Limited (owned 100" by The B. F. Goodrich Company) 1. Niagara, Ontario. In 1972, capacity was 50 million pounds per year. Vinyl chloride is supplied by Dow Chemical of Canada, Limited; Gulf Oil Canada Limited; or from the United States (CCP, August 1971, p. 15). 2. Shawinigan, Quebec. Capacity is 15 million pounds per year. A 20 million pouncts-per- year expansion is under consideration (Canadian Plastics, February 1973, p. 26). Imperial Oil Limited (owned 70" by Exxon Corporation), Esso Chemical Canada Division, Sarnia, Ontario. In 1972, capacity was 60 million pounds per year. The vinyl chloride is supplied by Dow Chemical of Canada, Limited; Gulf Oil Canada Limited; or from U.S. producers (CCP, August 1971, p. 15). Monsanto Canada, Limited (owned 100% by Monsanto Company), La Salle, Quebec. In 1972, capacity was 40 million pounds per year (Canadian Plastics, February 1973, p. 26). Mexico Polyvinyl chloride resins production was 83 million pounds in 1970, imports were estimated at 5 million pounds, consumption was estimated at 88 million pounds, and annual capacity was estimated at 86 million pounds. In 1971, annual capacity was estimated at 130 million pounds (CA, September 3, 1971, p. 10, and^gfftf^estimates). Geon de Mexico. SA (owned 40% by_The^^F^Goodrich Company and 60% by Celulosa y Derivados, SA [CYDSA], Mexico City, D.F.<lr)| 1969f^the combined capacity of this plant and the Industrias Resistol SApi^rh. at^ei&eria was estimated at 53 million pounds per year (CII, 1/1969, p. 16). Geon(^qTpL capacity for polyvinyl chloride resins and compounds was estimated at 3g2 milPa^jj/pounds per year in 1968 (Bullard, Fredda Jean, "Mexico's Natural Gas," Studie^ia Sktan-American Business No. 5, Bureau of Business Research, The University of Texas at Austin, 1968, p. 230). In May 1972, plans to expand polyvinyl chloride resins capacity were under consideration (CW, May 17, 1972, p. 33). o Industrias Resistol SA (1RSA) (owned 37% by Monsanto Company and 63% by Resistol SA and Desarrollo Economico SC), Lecheria, Mexico, D.F. In 1969, the combined capacity of this plant and the Geon de Mexico, SA, plant at Mexico City, D.F., was estimated at 53 million pounds per year. Plans for a large expansion in capacity were being considered in 1969 (CII. 1/1969, p. 16). Petroleos Mexicanos (PEMEX). Pajaritos. In 1969, the vinyl chloride capacity of this plant was 44 million pounds per year and an expansion of 121 million pounds per year was under construction (MP, January 1969, p. 119). Plastleos Omega, SA, Mexico D.F. 1/1969, p. 16). In 1967, capacity was 7 million pounds per year (CII. Polimeros do Mexico (owned 60% by Banco de Comercio SA and Banco del Atlantico SA; 20% by Farbwerke Hoechst AG [West Germany]; and 20% by Rhone-Progil [France]), San Martin Texmelucan, Puebla. In 1970, the capacity of this plant, which uses Pechiney-Saint-Gobuin's two-step bulk polymerization process, was 44 million pounds per year (1C, July-August 197Q, p. 94). BFS 007206 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ......................................... 580.1884 C SEPTEMBER 1973 Promociones Industriales Mexicanas SA. Puebla, Puebla. pounds per year (C1I, 1/1969, p. 16). In 1969, capacity was 30 million Nicaragua " Poliaeros Centroamericanos, SA (POI.ICASA), Managua. In 1969, Adela Investment Company, SA, was reported to have made an investment of S167.000 in a polyvinyl chloride resins plant which was to use imported monomer (Abrahams, A. E., and D. Gerumsky, "Financing Petrochemical Ventures in Latin America," ID/WG.34/12, Interregional Petrochemical Symposium on the Development of the Petrochemical Industries in Developing Countries, Baku, U.S.S.R., October 20-31, 1969, United Nations Industrial Development Organization, p. 43). SOUTH AMERICA Argentina Polyvinyl chloride resins production in 1970 was 48 million pounds and consumption was 57 million pounds (Department of State Airgram, DIB 71 10 041, August 30, 1971). Annual capacity in 1972 was estimated at 77 million ppdnds per year (CEH estimate based on trade publications). In 1972, polyvinyl chloride resj*s (CW, October 4, 1972, p. 38>?, or 1976 was estimated to reach 172 million pounds Company in forma tion/"f<5K following Argentine producers is based on information in the Department of a3e^ijrgram. DIB 72 10 336, September 25, 1972. Electroclor SA Industrial y Comercial (owned 40% by public interests, 30% by Duperial S.A.I.C., and 30% by Celulosa Argentina SA), Capitan Bermudez, Santa Fe. In 1972, the capacity of this plant (based on ICI technology) was 40 million pounds per year. Plans to expand capacity to 141 million pounds per year in 1975, or to build a new plant jointly owned by Indupa SA, are being considered. Indupa SA (owned 43% by Rhone-Progil [France]), Cinco Saltos, Rio Negro. was 26 million pounds per year. In 1972, capacity Viplastic SA (wholly owned subsidiary of Monsanto Company), Chacras de Coria, Mendoza. 1972, capacity was 11 million pounds per year. In CHEMICAL ECONOMICS HANDBOOK <$lub sf*%oo mjfirun M( HO P * , CALIFOB*** SFS 007207 580.1884 D POLYVINYL CHLORIDE RESINS - CONTINUED Brazil Available statistics arc as follows; 1970 1971 1972 Production Polyvinyl Chloride Resins - Brazil (Mi 11 ion m ot Pounds) Impo r t * Consumption Annual Capacity. -- 103 108 48 (102) 163 265 205 269 192 295 Sources; (A) (B) (C) <D) The Chemical Industry, South America, Chemical Data Services, 1973, p. 96 (1970 Imports datura). ECN, April 13, 1973, p. 10 (all Production and Consumption data for 1970 and 1971). CW, March 14, 1973, p. 29 (1972 Imports and Consumption data). CEH estimates based on trade literature (all other data). Brasivil-Resinas Vinilicas Ltria. (owned 33% by C3sd2siphe Werke Hills AG Cwest Germany], 17% by Bayer AG [West Germany], and 50% by Uni^vdS^ndy^rias Petroquimicas SA [UNIPAR]), Riberao Pires, Sao Paulo. In 1972, caaacitflr^a^SS million pounds per year. Plans are under consideration to double the p'WSsan^ capacity (CA, July 7, 1972, p. 20). Feedstock is supplied by Consorcio Pau3aiKMPs.de Monomero Ltda. (Copamo)'s monomer plant at Santo Andre. o Carbocloro SA Ind cas (a joint venture of Diamond Shamrock Corporation and Unias de Industrias\(p^woquimicas SA [UNIPAR]), at an unspecified location, Polyvinyl chloride resins and copolymers capacity is 20 million pounds per year (The Chemical Industry South America, Chemical Data Services, 1973, p. 96). Geon do Brasil Industria e Comercio, SA (owned 25% by The B. F. Goodrich Company and 75% by S/A Industrias Reunidas F. Muturazzo), Vila Bela, Sao Paulo. In 1972, capacity was 33 million pounds per year. Capacity is being expanded to 55 million pounds per year (CW, December 20, 1972, p. 24). Hulsbrasil-Resinas Vinilicas Ltda. (owned 33% by Cheraische Werke Hlils AG [west Germany], 17% by Bayer AG [West Germanyj, and 50% by Uniao de Industrias Petroquimicas SA [UNIPARj), Piassaquera, Sao Paulo. Hulsbrasil started to build a 110 million pounds-per-year poly vinyl chloride resins plant in 1971. The feedstock reportedly will be supplied from the monomer plant of Consorcio Puulista de Monomero Ltda. (Copamo) at Santo Andre (ClI, 2/1971, p. 60). Industrias Quimicas Eletrn-cioro SA (a subsidiary of Solvay it Cie [Belgium] and Imperial Chemical Industries Limited Lt'nited Kingdom]), Sao Andre, Sao Paulo. Polyvinyl chloride resins capacity was 154 million pounds per year in 1972 (Chemical Age International. November 3, 1972, p. 18), BFS 0072B8 POLYVINYL CHLORIDE RESINS - CONTINUED ?UAST1CS ANO RESINS 580.1884 E ' SEPTEMBER t9?3 Petrobraa Quimica SA (a subsidiary of Petroloo Braslleiro SA), Mitsubishi Chemical Industries Limited (Japan), Xissho-Iwai Co., Ltd. fJupun) (each with 30% ownership), and Comargo Correa SA (10% ownership), Cumacari, Bahia. Approval from the Brazilian government' to establish a new firm and to construct a 331 million pounds-per-year vinyl chloride plant and a 309 . , . million pounds-per-year polyvinyl chloride resins plant is pending (JCW. January 18, 1973, P. IK Chile . '..J.' .... Chilean Government (formerly Petroquimica-Dow SA owned 60% by The Dow Chemical Company, 20% by Petroquimica Chilena SA, 10% by Empresa Nacional del Petroleo, and 10% by Dow Quimica Chilena SAJ), Concepcion. Plans to expand the present 33 million pounds-per-year plant to 66 million pounds per year have been included in the Chilean five-year plan (0GJ, September 20, 1971, p. 80). Colombia In 1971, annual capacity was estimated at 45 million pounds (CEH estimate based on trade publications). Colombiana de Carburo y Derivados SA (COLCARBURO), million pounds per year. Monomer is produced Commerce, Bureau of Domestic Commerce, MarofRl dellin, Antioquia. Capacity is 17 y (Chemicals, U.S. Department of 24). Petroquimica Colombiana SA, Mamo million pounds per year. VipqU per-year plant is under Li^ar. Polyvinyl chloride resins capacity is 35 oride is presently imported, but a 35 million poundsn at Cartagena (HP, May 1972, p. 44-CC). Plasticas y Product 7-13 million pounds 1973, p. 175). Zipaquira, Tolema. Polyvinyl chloride resins capacity is er year (The Chemical Industry, South America, Chemical Data Services, Peru Petroleos del Peru (Petroperu) (a state-owned enterprise), near Lima. A 55 million poundsper-year vinyl chloride plant, a 44 million pounds-per-year suspension-grade plant and a 22 million pounds-per-year emulsion-grade polyvinyl chloride plant are planned for comple tion in 1976 (CA, March 31, 1972, p. 4). Socledad Paramonga Ltda., Paramonga. Plant capacity data are not available. Venezuela Venezolana Industria do Plasticos (25% owned by The B. F. Goodrich Company and 75% by Instituto Vcnezolano de Petroquimica and private investors), El Tablazo. A plant is scheduled to be built by late 1973 with a 100 million pounds-per-year capacity using B. F. Goodrich technology (RA, October 1971, p. 30). CHEMICAL ECONOMICS HANDBOOK 5uniod aisotCH irSH run * MtMlO P*, ciiro*Niv- BFS 007209 sBe.tssa f * a POLYVINYL CHLORIOE RESINS - CONTINUED WESTERS EUROPE Austria Production of polyvinyl chloride resins was 79 million pounds in 1970 (The Chemical ~Industry, 1970/197L. OECD, p. 153). - Halvic Kunststoffwerke GmbH (81.9% owned by Solvay & Cie. [Belgium] and 18.1% by the Austrian State), Halle. The plant has a capacity of 141 million pounds per year and is based on Solvay technology (ECS Austria Survey, July 2, 1971, p. 50). ' .. Belgium . '.:v > ' ~' Polyvinyl chloride resins consumption was 143 million pounds in 1970 and 165 million pounds in 1971 (Chemical Age International, December 15, 1972, p. 25). Annual capacity for 1970 and 1971 is estimated to have been 357 million pounds per year (CEH estimates based on trade publications). Badische-Phillips Petroleum NV (Badlphil) (owned 50% by Phillips Petroleum Company and 50% by BASF AG [West Germany]), Antwerp. Capacity of the plant is 170 million pounds per year. The vinyl chloride is supplied by BASF (CA, November 27, 1970, p. 7, and communi cation with industry). Solvic, SA pour 1*Industrie des Matieres Plastiqoe Imperial Chemical Industries Limited [United Kidfgpd: 1970 was 198 million pounds per year. PlurtClfl \\nc owned 75% by Solvay & Cie and 25% by Jemeppe-sur-Sambre. Capacity in ase capacity to 253 million pounds per year are expected to be complete ifi 197^>' The vinyl chloride is supplied on site by a 440 million pounds-per-year p^efet ( ,oJune 9, 1972, p. 14). Denmark Polyvinyl chloride r^giTTs are not yet produced in Denmark, although one source estimated in 1970 that Danish consumption would be 75 million pounds in 1970 and 110 million pounds in 1975 (ECN Polymer Intermediates, October 30, 1970, pp. 5 and 12). KemaNorri AB (Sweden), Lonza AG (Switzerland), and Rhone-Progil (France) (owned 93% by Rhone-Poulenc SA and 7% by Pechincy Ugine Kuhlmann) were planning to build a medium-sized plant at Skaelskor, Sjalland. The plant, which was to use Pechiney-Saint-Gobain's mass polymerization process, has been delayed until the polyvinyl chloride resins market improved sufficiently (ECN, May 19, 1972, p. 34). Finland One source estimated in 1970 that consumption would be 62 million pounds in 1970 and 90 million pounds in 1975 (ECN Polymer Intermediates, October 30, 1970, pp. 5 and 12). O BFS 007210 POLYVINYL CHLORIDE RESINS - CONTINUED .................... PLASTICS AND RgSINS 580.1884 G SEPTEMBER 1973 Pekema Ov (owned 44% by Neste Oy, 6% by Enso-Gutzeit AB, 20% by Kymmene Aktiebolag, 5% by Nokia Oy, 15% by Pargas Kalkbergs AB, 5% by Sateri Oy, 2.5% by Stromberg AB, and 2.5% by Upo Oy), Porvoo. Vinyl chloride capacity is 110 million pounds per year and polyvinyl chloride resins capacity i3 66 million pounds per year. Expansion of the polyvinyl chloride resins plant to 110 million pounds per year within two to three years is under consideration (ECX, February 16, 1973, p. 16). France Available statistics are as follows: 1970 1971 1972 Production 1,003 1,009 1,187 Polyvinyl Chloride Resins - France (Millions of Pounds) Imports Exports Consumption Annual Capacity*1 223 -- -- 198 -- -- 1,031 -- -- (1,030) (1,100) (1,188) a. By 1973-1975, total capacity is expected to reach nearly 2 billion pounds per year if all the presently planned expansions and new plants come on stream. Sources: (A) Chimie Actualites, Febru^nt Krt1972, p. 18 (all data for 1970 except Annual CapaciTS^L CEH estiraates-4ifcspd oirntrade publications (Annual Capacity estimatestV^ ^ 1972, pp. 5 and 51 (1971 Production datum). rtf&effcal Age International, April 6, 1973, p. 5 (1972 'reduction datum). Aquitaine Total Organico (a subsidiary of ATO), Balan, Ain. Capacity is 154 million pounds per year. Plans to increase capacity by 220 million pounds per year by 1976 with a new plant are being considered (ECN, December 10, 1971, p. 20). The vinyl chloride is purchased from Rhone-Progil at Saint Fons and Societe Dauphinoise de Fabrications Chimiques (DAOFAC) at Jarrie (ECN. January 23, 197Q, p. 14). CDF Chimie (a subsidiary of Charbonnages de France). Plans are being discussed to build a 220 million pounds-per-year plant by the end of 1974 at Douvrin (near Douai) or Carling (Lorraine). Limburgse Vinyl Maatschappij-NV (The Netherlands) has agreed to supply vinyl chloride monomer (ECN, July 7, 1972, p. 16). CHEMICAL ECONOMICS HANDBOOK 5unioo aiscucH iNsn run KiHO p*#, C L I f 0HN I * BFS 007211 680.188* M POLYVINYL CHLORIDE RESINS - CONTINUED Societe Oauphinoise de Fabrications Cbimiques (DAUFAC? (owned 25% by Rhone-Progi1, 50% by Rhone-Poulenc SA, and 25^ by Pechiney Ugine Kuhlmann), Jarrie, Isere, The company has a vinyl chloride plant based on The B. F. Goodrich Company/Farbwerke Hoechst AG technology: capacity is 440 million pounds per year. The vinyl chloride is sold to the polyvinyl chloride resins plants of Rhone-Poulenc SA, Rhone-Progil, and- Piastiraer SA (ECS New- Plants 1972, February 23, 1973, p. 58). Some vinyl chloride is produced from ethylene supplied by Societe Nationale des Petroles d'Aquitaine (SNPA) and then used by Aquitaine Total Organico. Plastimer SA (owned 50% by Pechiney Ugine Kuhlmann and 50% by Rhone-Progil). Brignoud, Isere. Capacity was 154 million pounds per year in 1970. Capacity is being expanded to 264 million pounds per year with completion expected in 1973. DAUFAC supplies the vinyl chloride (ECN French Survey, November 26, 1971, p. 80, and ECN New Plants 1972, February 23, 1973, p. 46). Rhone-Progil (owned 93% by Rhone-Poulenc SA and 7% by Pechiney Ifgine Kuhlmann). A. Vinyl Chloride 1. Lavera. Vinyl chloride capacity is 440 million pounds per year (ECU New Plants 1972, February 23, 1973, p. 58). 2. Saint Auban, Basses Alpes. Capacity is estimated to be 264 million pounds per year. Further expansion to 331 million pounds per year is planned (OPD, July 19, 1971, p. 47, and ECN, August 8, 1969, p. 10). ' 3. Saint Fons, Rhone. Capacity is 132 million pounds per year (ECN, January 23, 1970, p. 14). B. Polyvinyl Chloride 1. Montlucon, Allier. In 1968, canjuNf^vis^33 million pounds per year (ECN, January 3, 1969, p. 18). 2. Saint Auban, Basses Ai petS^vjPqlyvlny 1 chloride resins capacity was 230 million pounds per year ifcaj <ECw, January 3, 1969, p. 18, and C&.EN, August 3, 1970, p. 31). 3. Saint Fops> fthonp^5*-^In 1969, capacity was 132 million pounds per year (ECN, January 3, 1969, Rhone-Poulenc SA (owned 7% by Pechiney Ugine Kuhlmann), Peage de Roussillon, Isere. Capacity was 88 million pounds per year in 1970 (C&EN. August 3, 1970, p. 31). Solvic SA (owned 75% by Solvay & Cie CBelgium] and 25% by Imperial Chemical Industries Limited (.United Kingdom]), Tavaux, Jura. Capacity for vinyl chloride (from ethylene feedstock) was 440 million pounds per year in 1969, About 50% was consumed on site for polyvinyl chloride resins production (OPD. March 31, 1969, p. 40). Polyvinyl chloride resins capacity is 397 million pounds per year (ECN, August 28, 1970, p. 12, and ECN Now Plants 1971. February 25, 1972, p. 58). i BF5 00 580.1884 J j POLYVINYL CHL0R10E RESINS - CONTINUED Lonza<Werke GmbH {100% owned by Lcnza AG [Switzerland]), Waldshut. 55 million pounds per year (OPD, September i, 1969, pp. 5 and 47). In 1969, capacity was tfacker-Chcmie GmbH (50% owned by Farbwerke Hoechs* AG and 50% bv the Wicker Family Corp.). Burghausen and Cologne. Total capacity at both sites is 683 million pounds per year. Vmyl chloride is produced at Burghausen and some is shipped to Cologne as needed <Fry, December 22/29, 1972, p. 7). Greece Nicos Varriinovannis and CdF Chimie (France). Korinth. Plans are under consideration to build a 110 million pounds-per-year poiyvinyl chloride resins plant which will use imported monomer (ECN, June 15, 1973, p. 16). Esso-Pappas Chemical AE (a subsidiary of Exxon Corporation), Diavata, Thessaloniki. Polyvinyl chloride resins capacity is 61 million pounds per year. Capacity is being expanded to 99 milliOH pounds per year with completion of the plant expected eariv in 1974 (CW, May 23, 1973, p. 46). Vinyl chloride is supplied by Esso Hellas Chemical Com pany (also a part of the Esso-Pappas group), also at Diavata (ECN'. May 30, 1969, p. 10). I talv o V* W M M W ""*"- a. Calculated: Equals Production + Imports - Exports. Sources: (A) Chimie Actualites. February 10, 1972, p. 18 (all data for 1970 except Annual Capacity). (B) Chemical Age International, October 6, 1972, p. 22 (1971 Pro duction and Exports data). (C) CEH estimates based on information in trade publications (Annual Capacity estimates). (D) ECN, June 29, 1973, p. 8 (1972 Production datum). Italy's total capacity for polyvinyl chloride resins is expected to reach nearly 1.8 billion pounds per year when all of the presently planned expansions and new plants have come on stream (CEH estimate based on information in trade publications). x. o <: \ T BF5 007214 S. i f ilfflflllfrtirr'. POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1834 K SEPTEMBER 1973 Societe Chimlca Ravenna SpA (owned 51% by ANIC SpA and 49% by Wacker-Chemie GmbH Lw'est Germanyj), Ravenna. Capacity is 154 million pounds per year (based on Pechiney- Saint-Gobain technology), of which 66 million pounds is suspension grade and 88 million pounds is emulsion grade. Vinyl chloride capacity is 165 million pounds per year (Chemical Age Survey. Italian Projects, April 28, 1972, p. S13). Societa Italiana Serie Acetica Sintetica SpA (SISAS). Pioltello Limito (near Milan). In late 1970, a 99 million pounds-per-year PVC plant was under construction (Cl 1, 4/1970, p. 115). Montecatini Edison SpA 1. Brindisi. In late 1970, capacity was 276 million pounds per year (CII. 4/1970, p. 115). Vinyl chloride is also produced at this location. 2. Porto Marghera. Polyvinyl chloride resins capacity is 529 million pounds per year (Chemical Age International Survey, Italian Projects, April 27, 1973, p. S21). Vinyl chloride is also produced at this location. Polisarda (a subsidiary of Societa Italiana Resjjie SpA), Porto Torres. Capacity is 220 million pounds per year (ECN, January 15, 18). An additional 154 million pounds-per-year plant is under construtfC^nVrflShXMaical Age Survey, Italian Projects, April 28, 1972, p. S22). Viclon,'^alsffQ^Societa Italiana Resine SpA subsidiary) has a vinyl chloride plant /(ft- thisNlocation. 115). ndina, Matera. In late 1970, capacity was 99 million pounds expansion of 22 million pounds per year planned (CII, 4/1970, chloride plant is also located at this site. Quirinia SpA (a subsidiary of Rumianca, SpA), Assemini. In late 1969, capacity was 66 million pounds per year (CII, 4/1969, p. 115). Capacity is being expanded by 220 million pounds per year with completion planned for 1973 (Chemical Age International Survey, Italian Projects, April 27, 1973, p. S22). Sodio SpA (also owned by Rumianca, SpA) has a vinyl chloride plant at the same site. SARP (owned 65% by Ente Minerario Siciliano and 35% by Societa Italiana Resine SpA), between Palma di Montechiaro and Licata. In May 1972, plans for a polyvinyl chloride resins plant had been approved (ECN, May 26, 1972, p. 10). Solvtc, Industria Deile .Materie Plastiche SpA (a subsidiary of Solvay L Cie [Belgium]). Ferrara. In late 1970, capacity was 110 million pounds per year (CII, 4/1970, p. 115). Plans to expand by 110 million pounds per year by 1972 were being considered in 1970 (CILEN. August 3, 1970, p. 31). G OCMlCAi.. ECONOMICS HANTRorsK NlUt sr*c xfni.0 **, cturoniM BFS 007215 580.1884 t POLYVINYL CHLORIDE RESINS - CONTINUED The Netherlands NV Netherlands*? Staatsmijnen (DSM). Beek. The plant, based on Sumitomo technology, has a capacity of 165 million pounds per year. Capacity is being expanded to 220 million pounds per year with completion expected in 1975 (FCN, May 11, 1973, p. 16). Vinyl chloride is presently supplied domestically and.by imports from (ieraany (ECS, February 19. 1972, p. !). Vinyl chloride is also being supplied via pipeline by Limburgse Vinyl Maatschappiy NV from its Tessenderloo, Belgium,, plant. The pipeline capacity is 441 million pounds per year which allows for future polyvinyl chloride expansion (CE. October 19, 1970. p. 73). 5hell Nederland Chcmie NV (a subsidiary of Shell Petroleum NV), Pernis. Capacity is 352 million pounds per year (CA, August 7, 1970, p. 1G. and HP, Section 2, June 1973, p. 22). Vinyl chloride is supplied by AKZO Chemie Verkoopkantoor N'V, Salt Chemical Division, at Botlek (ECN, July 23, 1971, p. 4). Norway Production of polyvinyl chloride resins was 104 million pounds in 1970 (The Chemical Industry, 1970/1971, OECD. 1972, p. 153). Nearly one-third of the polyvinyl chloride resins produced are exported to the United Kingdom (CMR, May 1, 1972, pp. 7 and 12). Norsk Hydro AS, Heroya. In early 1971, capacity was 132 million pounds per year. Both Continental Oil Company and BP ChemicgA3A}ternationa1 Limited (a subsidiary of The British Petroleum Company Limited) wdre^^pplying the vinyl chloride (ECN. May 14, 1971, p. 10). In April 1972, planSxWre announced to increase polyvinyl chloride resins production by an unspecified quahtlty (PCN, April 24, 1972, p. 2). Portugal Production ofpolyvinyl chloride resins was 26 million pounds in 1970 (The Chemical Industry. 1970/1971, OECD, 1972, p. 153). Companhia Industrial de Resinas Sinteticas SAftL (CIRES) (a joint Portuguese-Japanese enterprise with 25% owned by Shlnetsu Chemical Industry Co., Ltd.), Avetro. In mid-1970, capacity was 22 million pounds per year (ECN, July 24, 1970, p. 10). Plans to increase the capacity to 58 million pounds per year have been approved (ECN, January 14, 1972, p. 18). Companhia Uniao Fabril SARI., Sines. The firm has obtained government permission to build a 95 million pounds-per-year polyvinyl chloride resins plant (CA, August 18, 1972, p. 17). Spain Production of polyvinyl chloride resins was 207 million pounds in 1970, and consumption was estimated at 249 million pounds. In 1970, consumption was projected to reach 617 million pounds by 1975 (The Chemical Industry. 1970/1971, OECD, 1972, p, 153, and ECN Polymer Intermediates, October 30, 1970, p 12). Compania Aragonesa de Industries Quimicas, SA, Sabinanigo, Huesca. 4 million pounds per year (Oilgas. October 1969, p. 11). In 1969, capacity was BFS 0072IS POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS 580.1884 M SEPTEMBER t973 Hispavte Industrial SA (owned 75% by Solvay & Cie [Belgium] and 25% by. Imperial Chemical Industries Limited .United Kingdom]) 1. Martorell, Barcelona. A 55 million pounds--per--year plant came on stream in 1969 (ECN August 15, 1969, p. 2). Viniclor SA has a 264-million pounds--per--year vinyl chloride plant at this site (ECN, January 12, 1973, p. 8). 2. Torreiavega, Santander. In 1969, capacity was 99 million pounds per year (Oilgas. October 1969, p. 11). Viniclor SA has a vinyl chloride plant at the same location. Monsanto Iberica SA (wholly owned by Aiscondel SA which is a joint venture of Monsanto Company and Desarrollos lndustriales) Monzon. Huesca. In early 1971, capacity was 95 million pounds per year and the capacity was being expanded to 132 million pounds per year. Vinyl chloride is supplied from Monsanto Iberica's new plant at Vilaseca, Tarragona (ECN, February 5, 1971, p. 4). In 1974, the company hopes to have a polyvinyl chloride plant at Tarragona with a capacity of 330 million pounds per year (Chemical Age International, December 8, 1972, p. 9). Resinas Poliesteres, SA (Reposa) (owned 40% by Rhone-Progil, 30% by The Dow Chemical Company, and 30% by Union Expiosivos Rio Tinto, SA) 1. Hemani (near Guipuzcoa). Capacity is 110 million pounds per year (ECN New Plants 1970, February 26, 1971, p. 60). 2. Mirando de Ebro, Burgos. Polyvinyl year (ECN New Plants 1970, Fe [ins capacity is 66 million pounds per 60). Sweden Consumption of chloride resins ranged between 152 and 176 million pounds in 1970 (Brighton, A., "Vinyl Chloride Polymers (Introduction)," Encyclopedia of Polymer Science and Technology, Volume 14, Interscience Publishers, New York, 1971, pp. 306 and 307, and ECN, July 23, 1971, p. 16). KemaNord AB 1. Stenungsund. In late 1970, capacity of the plant (which is based on a self- developed process) was 55 million pounds per year. Vinyl chloride is produced on site (ECN, December 18/25, 1970, pp. 44 and 46). 2. Stockviksverken. Capacity of the plant (which is based on the Lonza AG emulsion process) is 53 million pounds per year. Capacity is being expanded by 44 million pounds per year and is expected on stream in 1974 (ECN, March 23, 1973, p. 14). Vinyl chloride is supplied by the company's plant at Stenungsund. Switzerland Estimated consumption of polyvinyl chloride resins in 1970 was 62 million pounds (Encyclopedia of Polymer Science and Technology, Volume 14, Interscience Publishers, New York, 1971, pp. 306 and 307). Lonza AG, I,alden. In 1970, capacity was 44 million pounds per year (ECN Polymer Intermod intos, October 30, 1970, p. 9). LM l C Ai. ECONOMICS HANDBOOK tJSIti) stanioao miiiiu'f , wfm.0 **. c*ui0*ia BFS 607217 POLYVINYL CHLORIDE RESINS - CONTINUED United Kingdom ` '..v-.'-'"' -ST.;. Available statistics areas follows: V "...V:/' . Polyvinyl Chloride Resins - United Kingdom (Millions of Pounds) .* Production Imports Consumption Annual Capacity 1970 1971 1972 >727 ... 738 -- 172 -- -- 760 -- 782 (736) . (1,192)............ (1,309) flP Sources: (A) PCN, Volume 8, Number 44, November 2, 1970, p. 1 (Production datum for 1970). .. (B) ECN, February 19, 1971, p. 10 (Imports datum for 1970), and January 5, 1973, p. 4 (Consumption datum for 1972). (C) Brighton, C. A. loride Polymers (Intro* duction),' EncyclopdS jfr ~pf^Polymer Science and Technology, Vol New York ,<$.971, P] datufljf^or NyCf). Interscience Publishers, 306 and 307 (Consumption Age International, March 23, 1973, p. 9 oduction datum for 1971). CEH estimates based on information in trade publications (Annual Capacity estimates). BP Chemicals International Limited (a subsidiary of The British Petroleum Company Limited) 1. Baglan Bay, England. Capacity is 99 million pounds per year and an additional 99 million pounds per year is due on stream in 1973. Both plants are based on PechineySaint-Gobain's two-step bulk polymerization process (CW, October 6, 1971, p. 38, and February 14, 1973, p. 31). Vinyl chloride is produced on site. 2, Barry, South Wales. In early 1971, capacity was 440 million pounds per year (ECN, January 8, 1971, p. 10). Some vinyl chloride is supplied by the Baglan Bay facility. Bakelite Xylonite Limited (a subsidiary of Turner &. Newall Ltd.), Aycliffe, Durham, England. Capacity is 66 million pounds per year (ECN, January 12, 1973, p. 4). Vinyl chloride has been purchased from BP Chemicals International Limited (ECN, October 23, 1970, p. 18). Imperial Chemical Industries Limited (IC1) 1. Hillhouse, Lancashire, England. Capacity is 440 million pounds per year (ECN, November 5, 1971, p. 17). Vinyl chloride is produced on site. 2. Runcorn, Cheshire, England. Capacity is 154 million pounds per year (ECN, November 5, 1971, p. 17). Vinyl chloride is prtduced on site. o n BFS 007218 POLYVINYL CHLORIDE RESINS - CONTINUED `% ' - PLASTICS AND RESINS - ---------------------------------- tr 580.1384 O - SEPTEMBER t973 .' , . Vinafex Limited (a joint venture of Continental OH Company and Stavely Chemicals Ltd.), Stavely, Chesterfield, England. In 1969, capacity was 110 million pounds per year (99 million pounds per year were suspension grade and 11 million pounds per year were emulsion grade). Vinyl chloride was purchased from ICI (ECN, June 20, 1969, p. 12). Only about 70% of the product was expected to be marketed with the remainder being used captively for "polyvinyl chloride products (CA, October 30, 1970, p. 24). EASTERN EUROPE `. Bulgaria A 220 million pounds-per-year polyvinyl chloride resins plant is planned (ECN, April 20, 1973, p. 20). Karl Marx Chemical Plant, Reka Devnya. Capacity was 66 million pounds per year in 1969 (Chemische Industrie, XXI/Noveraber 1969, p. 762). A 331 million pounds-per-year vinyl chloride plant is to be built here by 1975 (ECN, April 20, 1973, p. 20). Czechoslovakia Total polyvinyl chloride resins capacity at year-end 1970 was estimated at 88 million pounds per year ("Petrochemicals and Their Raw Ma^ssials in Europe," Proceedings of the Fourth International Conference of the ugflpfla%-&hqjgrcal Marketing Research Association, Budapest, Hungary, October 13-15, 19 Novaky. Polyvinyl chlorid be expanded by 220 milldo p. 25). <3 capacity is 101 million pounds per year. Capacity is to per year in 1975 (Chimie Actualites, July 13, 1972, Spolana complex, Neratovice. A 110 million pounds-per-year polyvinyl chloride resins plant is scheduled for 1973 with an expansion to 264 million pounds per year planned for 1975 (Chimie Actualites, July 13, 1972, p. 25). Polyvinyl chloride resin plants are also located near Bratislava and/or Sala (ClI, 4/1970, p. 113). / n CHEMICAL ECONOMICS HANDBOOK S N> <5o SfSCAftCM t s11 turi .n^a mcmlo **, ctu'oaxii BFS 007219 580.188* P POLYVINYL CHLORIDE RESINS - CONTINUED East Germanv Total polyvinyl chloride resins capacity at year-end 1969 was 397 million pounds ("Petrochemicals and Their Kaw Materials in Europe," Proceedings of the Fourth Inter national Conference of the European Chemical Marketing Research Association, Budapest, Hungary, October 13-13, 1970, p. 103). In 1969, it was reported that all polyvinyl chloride resins production was to be concentrated at the VEB Chemische Werke Buna factory at Schkopau by 1975-1980 (CII, 2/1969, p. 55). Exports of polyvinyl chloride resins in 1970 and 1971 were 3 million pounds and 12 million pounds, respectively (Chemical Age International, October 13, 1972, p. 16). In March 1972, it was announced that a vinyl chloride plant and a 132 million pounds-peryear polyvinyl chloride resins plant were to be built at Schkopau (ECN, March 31, 1972, p. 14). Hungary Consumption of polyvinyl chloride resins in 1970 amounted to an estimated 88 million pounds (ECN, June 4, 1971, p. 16). Borsodi Vegyi Kombinat, Borsod. Capacity is 55 million pounds per year. A second plant with a capacity of 264 million pounds per year is to be built by 1980 (CII, 1/1973, p. 11). Poland In 1970, production of polyvinylich 18? million pounds, imports were 11 million pounds, exports wer<^9^m%liion pounds, and annual capacity was 298 million pounds per year (ECN, Jur September 10, 1971, p. 6; and July 3, 1970, p. 8). Felix DzierzynskiFactory, Tarnow. Capacity of this plant (which is based on the Hontecatini suspension process) is 88 million pounds per year (CII, 4/1968, p. 101). Oswiecim. Capacity is 115 million pounds per year (CfcEN, August 14, 1972, p. 14). o Wloclawek Nitrogen Works, Wloclawek. A 264 million pounds-per-year polyvinyl chloride resins plant is to be completed by 1977 (CAEN, August 14, 1972, p. 14). Rumania Polyvinyl chloride resins production was about 176 million pounds in 1970, and is expected to reach 52^ million pounds by 1975 (ECN, June 15, 1973, p. 22). Borzestl Chemical Combine, Borzesti. Capacity of this plant, which is based on suspension polymerization technology, is 79 million pounds per year (ECN, June 25, 1971, p. 18). o BFS 007220 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS . 580.1884 Q SEPTEMBER 1973 " Rlmnicu-Vilcea Chemical Combine, Rimnicu Vilcea. Capacity of this plant, which is based on suspension polymerization technology, is 88 million pounds per year, with another 309 million pounds-per-year plant under construction at this site, to^be completed In 1974 (ECN, June IS, 1973, pp. 22 and 24). .. .... .;v-' ^V Polyvinyl chloride resins are reportedly also produced at Tirnaveni and possibly at Iasi . and Turda (ECS, June 25, 1971, p. 18). In June 1972, plans were announced for a polyvinyl chloride resins plant of unknown capacity to be built at Constanta during the next five- year plan (ECN, Juno.23, 1972, p. 16). - -U.S.S.R. Production of polyvinyl chloride resins for 1970 was reported at 353 million pounds. The government is planning to increase production to 961 million pounds by 1975 (CA, June 2, 1972, p. 16). In 1970, an estimated 55 million pounds of polyvinyl chloride resins were supplied by Japan (OPD, October 26, 1970, p. 4). Capacity has been estimated at 661 million pounds per year for year-end 1970 ("Petrochemicals and Their Raw Materials in Europe," Proceedings of the Fourth International Conference of the European Chemical Marketing Research Association, Budapest, Hungary, October 13-15, 1970, p. 103). Kalush. A 132 million pounds-per-year polyvinyl chloride resins plant will be constructed in conjunction with a 440-550 million pounds-per-year vinyl chloride plant which is also planned for this site. Two other 132 million jpmunds-per-year polyvinyl chloride resins plants are also to be built nearby (ECN, 1971, p. 16). Navoi. A polyvinyl chloride re^nl) pla^fAs planned for this site (ECN, January 5, 1973, p. 12). Novomoskovsk. :iira Qp the plant is unknown, but reportedly is to be expanded by 128 million poundN)eai- (ECN, August 6, 1971, p. 14). Sterlitamak. A 132 million pounds-per-year polyvinyl chloride resins plant is planned along with a vinyl chloride plant (ECN, August 27, 1971, p. 10). Yugoslavia Estimated demand for polyvinyl chloride resins was projected at 66 million pounds for 1971 and 220-264 million pounds for 1975 (CII, 2/1972, p. 58). Heraijska Industrtja Pancevo (HIP), Pancevo (near Belgrade). An 88 million pounds-peryear plant is under construction, based on Stauffer Chemical Company technology. Completion of the plant is expected in early 1975. A 220 million pounds-per-year vinyl chloride plant is also planned for this site (ECN, September 10, 1971, p. 14). IMA Consortium, Prgansko tfemtjska Industrija Skopje, and Jugovinil, Rijeka. In 1971, plans for a 220 million pounds-per-year plant were under consideration (CW, November 17, 1971, p. 35). CMCMICftL fCONOMfCS HANrROOh *FSf*CM INSTITUTE mww0 , ourooit BFS 007221 POLYVINYL CHLORIDE RESINS - CONTINUED : Jugovinll, near-.split. Capacity is 55 million pounds per year. The vinyl chloride used /.. for the polymer is made from acetylene feedstock (CE, July 27f 1970, p. 94). ; V.;-' Jugovinll fS.y) and Montecatini Edison SpA t Italy] (45^), Kastel Sucarac (near Split), - In late 1971, a 176 million pounds-per-year plant was planned for late 1973, Plans " include exporting 30.1 of the-polyvinyl chloride resins to Italy (CW, November 17, 1971, . p, 38). Organsko iiemt/jska Industtija Skopje (PHIS), Skopje. year (ECN, April 7, 1972, p, 18). Capacity is 26 million pounds per Organsko Kemijska Industri.ja Skopje (PHIS) [87.5^] and Rhone-Poulenc SA (France) [12.5`>1, Skopje. A 106 million pounds-per-year plant is planned which will use Pechiney-SaintGobain technology (CW, November 17, 1971, p. 35). Vlnilpiastlka, Zadar.- In June 1973, a 44 million pounds-per-year plant, using PechineySaint-Gobain technology and imported vinyl chloride, was nearly completed (HP, Section 2, June 1973, p. 26). ASIA China (Mainland) Total PVC capacity is estimated lp5 mfXlcon pounds per year, distributed among four plants (Apte, G. S., "Develoffifent the Petrochemical Industry in the ESCAFE Region," ID/WG.34/5, InterregigQg.^^e^5^hemical Symposium on the Development of the Petrochemical Industries in Pe Industrial Devel tries, Baku, U.S.S.R., October 20-31, 1969, United Nations rganization, p. 49). India Available statistics are as follows: Polyvinyl Chloride Resins - India (Millions of Pounds) Production Consumption Annual Capacity 1970 1971 1972 85 95 103 110 -- 96 99 -- Sources: (A) (B) (C) Indian Petroleum & Chemicals Statistics, Jan-Dec 1972, Government of India (Production data). CA, October 1, 1971, p. 20 (Consumption datum for 1970). Chemical Industry News-Indla, December 1972, p. 688 (Annual Capacity data). o o BFS 007222 POLYVINYL CHLORIDE RESINS - CONTINUED , - PLASTICS ANO RESINS 580.1584 S SEPTEMBER 1973 The Ahnedabad Manufacturing & Calico Printing Co.,, Limited, Bombay* Maharashtra, In 1970, capacity was 15 million pounds per year and was to be expanded to 44 million pounds per year using a Pechiney-Saiat-Gobain license (Chemicals, U.S. Department of Commerce, Business and Defense Services Administration, March 1970, p. 33, and Petrochemical Directory 1971, The Petroleum Publishing Company, Tulsa, Oklahoma, 1970, p. 18). Chemicals k Plastics India Limited (Chomplast) (jointly owned by The 8. F. Goodrich Company and Indian investors), Madras, Tamil Nadu.. In 1969, capacity was 13 million pounds per year. The capacity was to have been expanded to 30 million pounds per year in 1970 using Kureha Chemical Industry Company Ltd. technology. A further expansion to 44 million pounds per year was planned (Chemical Industry News-India, October 1969, p. 441). The Delhi Cloth &. General Mills Co., Ltd,, Shriram Vinyl and Chemical Industries Division, Kota, Rajasthan. In 1970, capacity was 24 million pounds per year (Chemicals, U.S. Department of Commerce, Business and Defense Services Administration, March 1970, p. 33). In 1971, the capacity was being expanded to 44 million pounds per year (Petrochemical Directory 1971, The Petroleum Publishing Company, Tulsa, Oklahoma, 1970, p. 19). National Organic Chemical Industries Limited (NOCIL) (owned 33.3% by the Royal Dutch/Shell Group [The Netherlands], 28.3% by Indian Mafatlal Group, and 38.3% by the public), Thana, Bombay. Capacity is 44 million pounds per year and plans are under consideration for increasing capacity by another 44 million pounds per year (C_II, 2/1972, p. 44). Indonesia Nusantour Duta Development and Industries Co., Ltd,, near Djakarta. A 33 million pounds-per-year lantNis scheduled to be built and completed by the end of 1973 (CW, January 1( . 46). Iran Abadan Petrochemical Company, Ltd, (owned 74% by National Iranian Oil Company and 26% by The B. F. Goodrich Company), Tehran. In 1970, capacity was only 44 million pounds per year, although the plant does have expansion capability up to 88 million pounds per year. Capacity is to be tripled by multi-phase expansions. Feedstocks for the vinyl chloride are based on natural- gas (IC, May-June 1970, p. 38, and Adhesives Age, April 1973, p. 58). Israel Electrochemical Industries (Frutarom) Ltd., Acre (near Haifa). -This plant, which is based on Monsanto Company technology, has a capacity of 26 million pounds per year. In late 1971, an additional 29-35 million pounds per year was expected on stream (CW, November 24, 1971, p. 21). CHEMICAL ECONOMICS HANOBOOK issiu S'*HrosQ IMSIllulf "into PMR, CHOOillt BFS 007223 580.1384 T POLYVINYL CHLORIDE RESINS - CONTINUED Japan Salient statistics are as follows Production 1970 1971 1972 2,561 2,246 2,379 Polyvinyl Chloride Resins (Millions of Pounds) Consumption Exporta Japan Annual Capacity 2,213 2,023 2,164... 294 321 316 (3,636) (3,636) ( 3,5 26 ) a a. Some of the older plants were scrapped because of depressed market conditions and modernization of other plants during this year. It is not known which plants were shut down. Sources: (A) JCW, February 11, 1971, p. 1 (Production, Consumption, and Exports data for 1970), and February 24, 1972, p. 8 (Production, Consumption, and Exports data for 1971). (B) CEH estimates based on information in trade publications (Annual Capacity estimates for 1970 and 1971). (C) PIN, March 1973, pp. 40 and 41, and April 1973, p. 54 data for 1972, and information footnote a). (all Most of the company information in this s&t44o)&is'5!tfased on the following reference (unless otherwise noted), Oikawa, fteniyuky^Yasuhiro Uchida, and Susumu Imaizumi, 'Growing Petrochemical IndjrSfcjlqfe^nd Polyvinyl Chloride Industry," CEER, May 1971, pp. 11-22. Asahi Glass Compa of the polyvinyl chloride resins produced by Asahi Glass are used for a spe^iift fiber glass-reinforced PVC plastic product (PIN, October 1969, pp. 122-124). 1. Goi, Chiba Prefecture. In 1969, capacity was 9 million pounds per year. The vinyl chloride was supplied by Asahi-Penn Chemical Company, Ltd. (owned by Asahi Glass Company, Ltd. and PPG Industries, Inc.) (PIN, October 1969, pp. 122-124). 2. Kashima, Ibarki Prefecture, In 1971, capacity was 5 million pounds per year. The vinyl chloride is supplied by pipeline from the Kashima Vinyl Chloride Monomer Co., plant at Kashima, Ibarki Prefecture. Central Chemical Company, Ltd, (joint venture of Central Glass Co., Ltd, and Toa Nenryo Kogyo KK), Kawasaki, Kanagawa. Plans to build a 53 million pounds-per-year plant by early 1974 have received government approval (JOT, July 19, 1973, p. 3). BFS 00? POLYVINYL CHLORIDE RESINS - CONTINUED ------- PLASTICS AND RESINS 580.1884 U SEPTEMBER 1973 1. Goi, Chiba Prefecture. In 1970, capacity was 70 million pounds per year (Pllf, September 1970, pp. 121-123). Vinyl chloride is supplied by pipeline from Aaahi-Penn . Chemical Company, Ltd., Goi, Chiba Prefecture (capacity is 110 million pounds per-year). - 2. Minamata, Kumamoto Prefecture. In. 1970, capacity was 122 million pounds per year (PI?f, September 1970, pp. 121-123). Vinyl chloride is produced on site by a 132 million pounds-per-year plant owned by Chisso Corporation. . . 3. Mizushima, Okayama Prefecture. In 1970, one source estimated capacity at 66 million -, pounds per year (PIN, September 1970, pp. 121-123). In 1971, another source estimated capacity at 79 million pounds per year. Vinyl chloride is supplied by pipeline from the Sanyo Monomer Company, Ltd., which has a vinyl chloride plant at Mizushima with a capacity of 264 million pounds per year. Denki Kagaku Kogyo KK (DENKA) 1. Goi, Chiba Prefecture. In 1971, capacity was 77 million pounds per year. Vinyl chloride is supplied by pipeline from the 353 million pounds-per-year vinyl chloride plant of Chiba VCM Company, Limited, Anega.saki, Chiba Prefecture. 2. Oral, Niigata Prefecture. Capacity was 110 million pounds per year in 1970. Some of this capacity may have been scrapped to government restrictions when the plant at Goi came on stream In late 1970 or earjk^A sSXl. Vinyl chloride is supplied by lorry transport from Nissan PetrochemicaiflrUJfcB; ,^3oi, Chiba Prefecture (capacity is 110 million pounds per year). Gunma Kagaku KK, subsicft^ry, Sftibukawa, Gunma Prefecture. Capacity was 119 million pounds per year In jagO^/Some of this capacity may have been scrapped to meet government rgstticm>gp when the plant of Denki at Goi came on stream in late 1970 or early l$l2'^Sh4 vinyl chloride is supplied by lorry transport by the companies that supply yhe parent company at 0ml, Kanegafuchi Chemical Industry Company Limited 1. Kashima, Ibarki Prefecture. In 1971, capacity of this plant, which is based on a self-developed process, was 110 million pounds per year. Vinyl chloride is supplied by Kashima Vinyl Chloride Monomer Co., which has a 485 million pounds-per-year vinyl chloride plant at Kashima. 2. Osaka, Osaka Prefecture and Takasago, Hyogo Prefecture. In 1971, combined capacity of these plants, which are based on Stauffer technology, was 253 million pounds per year. Seme of the capacity at Osaka may have been scrapped when the plant at Kashima came on stream. Vinyl chloride is supplied by pipeline from Kanegafuchi Chemical's monomer plant at Takasago which has a capacity of 264 million pounds per year. Kureha Chemical Industry Co., Ltd., Nishiki, Fukushima Prefecture. In 1971, capacity was 272 million pounds per year. Vinyl chloride is supplied by a plant at the same location which has a capacity of 309 million pounds per year. O CHEMICAL ECONOMICS MAN0B00K (KMl) ^r***owc acsf*e msmu'i, amo mdi, califo**)* BFS 007225 iA-, -XL- S8olt8S4 v ' POLYVINYL CHLORIDE RESINS - CONTINUED ; Mltsubishi-Monaanto Chemical Company (a joint venture of Mitsubishi Chemical Industries Limited and Monsanto Company), Yokkaichi, Mie Prefecture. In 1970, capacity was 238 . million pounds per year. All of the vinyl chloride produced on site by MitsubishiMonsanto from a 132 million pounds-per-year plant is used. Additional quantities are 'purchased from Ryo-Nichi Co., Ltd., at Mizushima (PIN, September 1970, pp. 121-123). Mitsui Toatsu Chemicals, Incorporated (merger of Mitsui Chemical Industry Co., Ltd., and Toyo Koatsu Industries, Inc.), Nagoya, Aichi Prefecture. In 1971, capacity was 185 million pounds per year. Plans to decrease capacity at this plant and to increase capacity at Mitsui Senboku Petrochemicals, Inc., were under consideration. Vinyl chloride is supplied by sea transport from Mitsui Senboku Petrochemicals, Inc., Senboku, Osaka Prefecture. Mitsui Senboku Petrochemicals, Inc., subsidiary, Senboku, Osaka Prefecture. In 1971, capacity was 66 million pounds per year. Plans to increase capacity at this plant and to decrease capacity at the parent company's Nagoya plant were under consideration. Vinyl chloride is supplied by a 264 million pounds-per-year plant on site. Nippon Carbide Industries Company, Inc. 1. Uozu, Toyama Prefecture. In 1971, capacity was 147 million pounds per year. Vinyl chloride is supplied by sea transport from Ryo-Nichi Co., Ltd., Mizushima, Okayama Prefecture (capacity is 440 million pounds per year). 2. Hayatsuki, Toyama Prefecture. Asahi Glass Company has invested in the existing plant which has a capacity of 13 million poyfts- per year for specialty polyvinyl chloride copolymer resins (JCVf, April 5, 191 Ryo-Nichi Co., Ltd., (jo^tlfe owdjM*' by Nippon Carbide Industries Company, Inc., and Mitsubishi Chemical Ipjiustr^ks0Limited), Mizushima, Okayama Prefecture. In 1971, capacity was 127 ra^l-Kfccm pounds per year. The vinyl chloride is supplied by pipeline from Ryo-Nich^-^vy^heK, Mizushima, Okayama Prefecture (capacity is 440 million pounds per year) Nippon Zeo To,, Ltd, (partly owned by Asahi Chemical Industry Co., Ltd.) 1. Mizushima, Okayama Prefecture. In 1971, capacity was 128 million pounds per year. Vinyl chloride is supplied by pipeline from the Sanyo Monomer Company, Ltd., which has a vinyl chloride plant with a capacity of 264 million pounds per year. 2. Takaoka, Toyama Prefecture. In 1971, the capacity of this plant, which uses B. F. Goodrich technology, was 242 million pounds per year. Vinyl chloride is supplied by pipeline from Nippon Zeon's 286 million pounds-per-year plant at Takaoka. Shin-Etsu Chemical Industry Co., Ltd. 1. Kashima, Ibarki Prefecture. In 1971, capacity of this plant, which is based on the company's own new technology, was 331 million pounds per year. Vinyl chloride is supplied by pipeline from the Kashima Vinyl Chloride Monomer Co., Ltd., vinyl chloride plant at Kashima, which had a capacity of 485 million pounds per year. 2. Nanyo, Yamaguchi Prefecture. In 1970, capacity was 66 million pounds per year (PIN, September 1970, pp. 121-123). Vinyl chloride is supplied by pipeline from the Toyo Soda Manufacturing Co., Ltd., plant at Tokuyama, Yamaguchi Prefecture. o f BFS 00722 POLYVINYL CHLORIOE RESINS - CONTINUED ~ mastics ano resins 580.1884 W SEPTEMBER 1973 3 Naoetsu,. Niigata Prefecture. la 1970, capacity was 132 million pounds per year, v. ; However, after the Kashina plant was built, the capacity of the Naoetsu plant was -to v bereduced substantially (PHT, September 1970, pp. 121-123). ;. Hissin Chemical Industry Co., Ltd., subsidiary, Takefu, Fukui Prefecture. 'Capacity in 1970 was 127 million pounds per year. The Japanese government has approved an expansion by 50 million pound* per year of capacity, but this had not yet been utilized in 1971 (Japan Chemical Review 1971, p. 98). Sumitomo Chemical Co., Ltd. 1. Anegasaki, Chiba Prefecture. In 1970, capacity was 53 million pounds per year (PIN, September 1970, pp. 121-123). 2. Niihama, Ehirae Prefecture. In 1971, capacity was 110 million pounds per year. Vinyl chloride is supplied by pipeline from the Chiba VCM Company, Limited, at Sodegaura, Chiba Prefecture, which has a vinyl chloride capacity of 110 million pounds per year. An additional 61 million pounds per year of polyvinyl chloride resins capacity had been approved by the Japanese government but had not yet been utilized in 1971 (Japan Chemical Review 1971, p. 98). Sun Arrow Chemical Company, Ltd, (owned by Tokuyama Soda Co., Ltd., Tekkosha Co., Ltd., and Daicel Ltd.), Tokuyama, Yamaguchi Prefecture. In 1971, capacity was 132 million pounds per year. Vinyl chloride was supplied by a 242 million pounds-per-year plant on site. Toagosei Chemical Industry Co., Ltd., Tokushima, Tokushima Prefecture. In 1971, capacity was 126 million pounds per year. Of , 29 million pounds per year is based on Pechiney-Saint-Goba in technology. Ajjoiwd^. been given by the Japanese government for an additional 44 million pounds per'^uiQr^but this had not yet been realized in 1971. Vinyl chloride was supplied twjrat 106 jpiTlion pounds-per-year vinyl chloride plant on site and was supplemented by OMacchasWf from outside (ECS, April 3, 1970, p. 14; Japan Chemical Review 1971, p. 98; apfr* P73F?) September 1970, pp. 121-123). Kawasaki 1971, cap from Centr emical Co., Ltd., subsidiary, Kawasaki, Kanagawa Prefecture. In was 66 million pounds per year. Vinyl chloride is supplied by pipeline Chemical Company, Ltd., at Kawasaki. Tokuyama Sekisui Industry Company, Ltd, (a subsidiary of Sekisui Chemical Co., Ltd.), Nanyo, Yamaguchi Prefecture. In 1971, capacity was 68 million pounds per year. An addi tional 27 million pounds per year has been approved by the Japanese government but had not yet been realized in 1971 (Japan Chemical Review 1971, p. 98). Vinyl chloride is supplied by pipeline from the Toyo Soda Manufacturing Co., Ltd., vinyl chloride plant at Tokuyama, Yamaguchi Prefecture, which has a capacity of 331 million pounds per year. Toyo Soda Manufacturing Co., Ltd., Shin-Nanyo, Yamaguchi Prefecture. Plans to build a S3 million pounds-per-year plant by early 1974 have received government approval (JOT, July 19, 1973, p. 3). CHEMICAL ECONOMICS HANDBOOK *> ? 0 D RESEARCH i nst i ru' r mcnlo ***, emconnu BFS 580.1884 X POLYVINYL CHLORIDE RESINS - CONTINUED o ' Yokkalchi Tekkosha Co., Ltd, (a wholly owned subsidiary of Tekkosha Company, Ltd.), Yokkaichi, Mie Prefecture. In 1071, capacity of this plant, which is based on a Tekkosha process, was 79 million pounds por year. Vinyl chloride is supplied by the Toyo Soda Manufacturing Co,, l.td.fc plant at YokkaichL which.has a capacity of 200 million pounds per year. Tn late 1971, it was reported that Toyo Soda Manufacturing Co., Ltd., was planning to take an equity interest in Yokkaichi Tekkosha (OPD, December 6, 1971, p. 7). Korea, North *\ > . A 4 million pounds-per-vear polyvinyl chlor.ide plant, is operational (JCW, January 18, 1973, p. 3). Korea, Republic of Daehan Plastics Ltd., location unspecified. year (Japan Chemical Review 1971, p. 8). In 1971, capacity was 15 million pounds per Kongvong Chemical Co., Ulsan. In 1967, capacity was 15 million pounds per year (Soo Suh, Jin, Editor, Review of Korean Economy in 19G7, The Bank of Korea, Seoul, Korea, July 20, 1968, p. 104). Korea Chemical Industry Co., loca per year (Shik Chuh, Eun, Edi Korea, August 15, 1969 unstteOjLfled. In 1968, capacity was 33 million pounds kiow of Korean Economy 1968, The Bank of Korea, Seoul, o Upung Chemical C Eun, Editor, Kevi 1970, p. 100). In 1969, capacity was 22 million pounds per year (Shik Chuh, of Korean Economy 1969, The Bank of Korea, Seoul, Korea, August 31, Malaysia Petrochemicals Malaysia Sdn. Uhd. (owned by Sumitomo Sho.ji Kaisha, Ltd. [Japan] [a member of the Sumitomo group] and 49*"-, by Idemitsu Petrochemical Co., Ltd. [Japan]), location unspecified. A 13 million pounds-per-year plant is under construction which will use Sumitomo technology. Completion is expected in October 1973 (JCW, November 16, 1972, p. 1). Pakistan Arokey Chemicals, location unspecified. Polyvinyl chloride resins capacity is 12 million pounds per year (JCW, February 8, 1973, p. 15). Fau.tl Foundation (government pension fund for officers), near Karachi. In early 1971, plans were in progress to build a 48 million pounds-per-year plant using ICI technology. The plant was expected to be completed by 1974 (ECN, February 12, 1971, p. 12). o BFS 00722 POLYVINYL CHLORIDE RESINS - CONTINUED ....... PLASTICS AND RESINS 580.1884 V SEPTEMBER 1973 Philippines T Mabuhay Vinyl Corporation, Iligan. Capacity is 22 million pounds per yeax-CU-S. Depart- went of State Airgraro, January 24, 1973, DIB 73 03 133). . Philippine Vinyl Consortium, Inc. (The B. F. Goodrich Company is a minor 'shareholder), near Manila. In May 1972, plans to build a 44 million pounds-per-year plant using B. F. Goodrich Company technology were under consideration. The plajrt. is expected to be completed in 1974 and will use imported vinyl chloride (CMR, May 22, 1972, p.'5). Singapore Camel Chemical, Singapore. In 1969, a 22 million pounds-per-year plant was under construc tion, and was to have come on stream in the fall of 1970 (CIV, July 5, 1969, p. 34). Taiwan Total polyvinyl chloride resins capacity in Ta and 298 million pounds per year in e cations). million pounds per year in 1970 feed on information in trade publi- Cathay Plastic Industi&.^fee., Ltd., location unspecified. In 1969, capacity of this plant, which is based on Sumitomo technology, was 26 million pounds per year (CII, 1/1969, p. 7). China-Gulf Plastics Corporation (owned 63% by Gulf Oil Corporation and 37% by the Chinese Petroleum Corporation [which is government-owned]), location unspecified. In 1969, capacity was 89 million pounds per year (CII, 1/1969, p. 7). Formosa Plastics Corporation, location unspecified. In early 1970, capacity was estimated at approximately 77 million pounds per year (CLEW, April 13, 1970, pp. 16-19). Another plant is under construction with 7 million pounds per year of capacity already on stream and an additional 7 million pounds per year scheduled for June 1973 and December 1974 <CW, October 18, 1972, p. 17). I Fan Plastics Corporation, location unspecified. per year (CII, 1/1969, p. 7). In 1969, capacity was 18 million pounds Taiwan VCM Corporation (a joint venture of all four of the above polyvinyl chloride produ cers, Chinese Petroleum Corporation (which is government-owned), and Taiwan Alkali Company (also government-owned) 1. Kaohsiung. In early 1970, a new 88 million pounds-per-year vinyl chloride plant was scheduled to start up at the end at 1971 and an additional 88 million pounds per year was already planned (CLEW, April 13, 1970, pp. 16-19). 2. Toufen. In early 1970, a 132 million pounds-per-year vinyl chloride plant was planned (CLEW, April 13, 1970, pp. 16-19). CHEMICAL ECONOMICS HANDBOOK 5 r **r 00 *HUCH INSTMUTC, MCNIO ***, CALirOAftl* BF5 00 7*22 9 530.1884 Z POLYVINYL CHLORIDE RESINS - CONTINUED Thailand Mitsui Toatsu Chemicals, Inc. [Japan], and Thai investors, location unspecified. In 1971, it was reported that thex'e were plans to build a polyvinyl chloride resins plant in July 1976, using Mitsui Toatsu technology (ECS, September 24, 1971, p. 4). Thai Plastic and Chemical Company (owned 337c by Mitsui L Co., Ltd. CJapan1 and .Mitsui Toatsu Chemicals, Incorporated [Japan]; and 337. by Thai Asahi Caustic Soda Company), near Bangkok. Capacity is 22 million pounds per year and may be expanded to 44-66 million pounds per year (CUR, November 6, 1972, p. 32). Vinyl chloride was to be supplied from Japan. Turkey Petkira Petrokimva AS (a subsidiary of Turkish Petroleum Corporation) 1. Aliaga. A 57 million pounds-per-year polyvinyl chloride resins plant is under construction (ClI, 4/1972, p. 122). 2. Yarmca. In late 1971, the capacity of this plant, which is based on ICI and Solvay St Cie technology, was 57 million pounds per year (QPD, November 15, 1971, p. 9). Vinyl chloride was supplied by a 60 million pounds-per-year plant on site (QPD, September 15, 1969, pp. 7 and 35). It was expected that the vinyl chloride and poly vinyl chloride resin capacities would be doubled (ECN, July 4, 1969, p. 10). AUSTRALIA In 1970, total Australian consumpt ioiwof ap4sm|iyfchloride resins was estimated to reach 88 million pounds by 1970 and 154 i&ljtionpounds by 1975 (CII, 2 1970, p. 56). Total polyvinyl chlori ' ae^Ltv irS 1%69-1971 is estimated to have been 92 million pounds per year Abased on information in trade publications). B. F. Goodrich Chiforeal Limited (owned 80% by The B. F. Goodrich Company), Altona (near Melbourne), Victoria. In 1969, capacity was estimated at 15 million pounds per year (McKern, R. B., ''Recent Development in the Australian Petrochemical Industry," ID.AVG.34 69, Interregional Petrochemical Symposium on the Development of the Petrochemical Industries in Developing Countries, Baku, U.S.S.R., October 20-31, 1969, United Nations Industrial Development Organization, p. 12). ICI Australia Limited (owned 62.5% by Imperial Chemical Industries Limited [United Kingdom]), Botany (near Sydney). Capacity in 1969 is estimated to have been 77 million pounds per year (CEH estimate based on McKern, R. B., ''Recent Development in the Australian Petrochemical Industry," ID/WG.34/69, Interregional Petrochemical Symposium on the Development of the Petrochemical Industries in Developing Countries, Baku, U.S.S.R., October 20-31, 1969', United Nations Industrial Development Organization, p. 13). BFS 007 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS '580.1885 A SEPTEMBER 1973 AFRICA Algeria SONATRACH (Societe Rationale pour la Recherche, la Production, le Transport, la Transform ation et la Commercialixation des Hydrocarbures>, Skikda. In May 1972, plans were under consideration to build an 88 million pounds-per-year vinyl chloride plant and a 77 million pounds-per-year polyvinyl chloride resins plant based on Mitsui Toatsu technology. The plants are expected to come on stream ^n 1975 (CMR,. May 22, 1972, p. 5). Nigeria In early 1971, plans were under consideration to build a 66 million pounds-per-year poly vinyl chloride resins plant in conjunction with a new petrochemical complex at a site not yet determined (CII, 1/1971, p. 25). South Africa, Republic of Consumption of polyvinyl chloride resins in 1970 amounted to an estimated 110 million pounds (ECN, October 1, 1971, p. 16). In 1971, consumption was above 110 million pounds with large amounts of polyvinyl chloride resins having been imported to meet demand (CII, 1/1972, pp. 13 and 14). AA Plastics and Chemicals, Benoni. unspecified capacity was started (ECN, October 31, 1969,^^^)^ ---j ^ Igsinyl chloride resins plant of was to have come on stream in 1970 AEfcCI Ltd, (owned 42.5% ^y imperial Chemical Industries Limited [United Kingdom]). 1. Midland, Orange Free State. Polyvinyl chloride capacity is 64 million pounds per year (ECN, September 22, 1972, p. 10). 2. Umbogintwini (near Durban). Capacity is 20 million pounds per year. Plans are under consideration to build a second plant (CII, 1/1972, pp. 13 and 14). Sentrachem Limited (owned by Federale Volks Beleggings, Industrial Development Corporation of South Africa, and BP Chemicals International Limited), unknown location. A polyvinyl chloride resins plant is being considered (ECN, January 19, 1973, p. 12). CHEMICAL ECONOMICS HANDBOOK fe!! S'cxrono BtSE*BCH IMMIIIII, MtNlO ***, CHIFODNU BFS 007231 580,1685 B POLYVINYL CHLORIDE RESINS - CONTINUED B'lBLrdGRAPHY The* following is a listing of pertinent references for supplemental reading. Allen, Dr. G. D,, Dr. P. A. Arias-Soto, and Dr. T. M. Gallub, "The Plastics Industry: Some International Comparisons-USA V EEC V Japan," paper presented at the Chemical Marketing Research Association meeting, New Orleans, Louisiana, February 1973. Brighton, C. A., "Vinyl Chloride Polymers, Compounding and Fabricating," Encyclopedia of Polymer Science and Technology, Volume 14, Interscience Publishers, New York, 1971, pp. 394-452. , "Vinyl Chloride Polymers, Polymerization and Copolymers," Encyclopedia of Polymer Science and Technology, Volume 14, Interscience Publishers, New York, 1971, pp. 320-358. Bucsko, R. T., "Future Markets for Vinyl Dispersion Resins," paper presented before the 13th Film, Sheeting and Coated Fabrics Conference, The Society of the Plastics Industry, Inc., New York, November 1971. "CHLOrine + Ethylene = CHLOE," Informations Chimie, May-June 1971, pp. 37-47. "Crosslinked PVC Foams Aim for High Performance Jobs," Modem Plastics, September 1968 p. 53. 'Europe offers viable technology for chlorinated Chemical Age International, 13, job waste recovery processes, n. Huels PVC Batch Proces 16, 1968, pp. 78-81 launder Computer Control," Oil and Gas Journal, December Hurard, Henry, "The European Market of PVC," Proceedings of the 4th International Conference of the European Chemical Marketing Research Association, Budapest, Hungary, October 1970. ` Mazzolini, C., L. Patron, A. Moretti and M. Campanelli, li^EC Product Research and Development, December 1970, pp. 504-511. McKelvey, J. M., "Polymer Processing/' John Wiley & Sons, Inc., New York, 1962. "New Route to Vinyl Chloride," Oil and Gas Journal, November 8, 1971, pp. 64 and 65. "Plastic-Bottle Future: pp. 78-83. Grafted to Proliferating Molecules," Modern Packaging, May 1969, "Polyvinyl Chloride," ECN Process Survey, European Chemical News, January 29, 1971. Sarvetnick, Harold A., Polyvinyl Chloride, Van Nostrand Reinhold Company, New York, 1969, o BF5 007232 POLYVINYL CHLORIDE RESINS - CONTINUED PLASTICS AND RESINS ------------------------------------ 580.1885 C SEPTEMBER t973 Schroeter, G., Kunststoffe, June 1970, pp. 363-366. Shelley, P. G. and E. J. Sills, "Honomer Storage and Protection/' Chemical Engineering Progress.. April 1969, pp. 29--36, Skiest, E. N., "Blending'Dispersion Resin. InteractionsModem Plastics, October 1970, pp. 132; 133. and 136. Stinson, Stephen C.f "Developments Are Breaking Fast on the Red-Hot Foams Front," Plastics Technology, September 1972, pp. 33-36. Thomas, J. C., "New Improved Bulk PVC Process," Hydrocarbon Processing. November 1968, pp. 192-196, Waechter, C. J., "What's Happening in PVC Blow Molding," SPE Journal. July 1971, pp. 43-47. o LEGENO - PERIODICALS ABBREVIATIONS AC APJ CA CCP CE C&EN CEER CEH CEP Cti CMR <0P0> CPE cw OS ECN PC HP 1C Agricultural Chemicals American Paint Journal Chemical Age Canadian Chemical Processing Chemical Engineering Chemical & Engineering News Chemical Economy & Engineering Review Chemical Economics Handbook Chemical Engineering Progress Chemisehe Industrie international Chemical Marketing Reporter Chemical & Ptocess EnpAeermg Chemical Week Detergents and Specialties European Chemical News Farm Chemicals Hydrocarbon Processing Informations Chimie International t&EC JCA JCW ME MP Ni O&GJ PCN PIN P&P PVP PW RA RW sees (SACS) su TO industrial and Engineering Chemistry Japan Chemical Annual Japan Chemical Week Materials Engineering Modern Plastics Nitrogen Oil and Gas Journal Petrochemical News Plastics Industry News Phosphorus A Potassium Paint and Varnish Production Plastics World Rubber Age Rubber World Soap/Cosmetics/Chermcal Specialties Sulphur Textile Organon <*HCMICAI ECONOMICS HANOOOCK 5 r * v t a * e at st**c MINLO PAH*, CAUrOtlll BFS 907233