Polyvinyl chloride (PVC) is a ubiquitous material found in countless everyday items, from medical tubing to backyard decking. This versatile material starts with two simple ingredients: salt and oil.
From Salt and Oil to PVC
The journey of PVC begins with ethylene, derived from natural gas, which is obtained through a process known as thermal cracking.
In this process, liquid petroleum is heated in steam furnaces under extreme pressure, altering the molecular weights of chemicals in the petroleum feedstock.
This modification allows ethylene to be separated, captured, and cooled back into a liquid state.
Concurrently, chlorine is extracted from sea salt—a process that involves the electrolysis of a saltwater solution. A strong electrical current alters the molecular structure of the solution, facilitating the extraction of chlorine.
These two substances—ethylene and chlorine—react to form ethylene dichloride (EDC). ethylene dichloride undergoes further thermal cracking to produce vinyl chloride monomer (VCM), the fundamental building block of polyvinyl chloride (PVC).
Creating the Polyvinyl Chloride Resin
The core of polyvinyl chloride production is the polymerization process, where vinyl chloride monomer (VCM) is transformed into PVC. This occurs in reactors containing catalysts that prompt the vinyl chloride monomer molecules to link together, forming long chains known as polyvinyl chloride resin.
This resin forms the basis of all vinyl compounds, renowned for their inherent fire retardant and chemical resistant properties.
To achieve specific characteristics like UV resistance or colour, PVC resin is mixed with various plasticizers, stabilisers, and modifiers.
This formulation process is both an art and a science, perfected by research and development (R&D) teams over decades to meet increasingly challenging requirements.
Manufacturing Processes
The most common method of producing polyvinyl chloride is suspension polymerization. Here, vinyl chloride monomer (VCM) is liquefied, introduced into a polymerization reactor pre-filled with water and suspending agents, and agitated to form small droplets.
An initiator is then added, and the reaction proceeds at moderate temperatures to form polyvinyl chloride. This process results in PVC suspended in water as tiny particles, which are later dried to produce a white powdery substance.
Less commonly, emulsion polymerization is used to produce finer, smaller particles of resin, known as “paste” PVC, which are necessary for specific applications.
Eco-friendly Considerations
In producing polyvinyl chloride, a significant focus is placed on sustainability. Unreacted vinyl chloride monomer is recovered and recycled, reducing waste and environmental impact.
Innovations continue to emerge in the vinyl compound sector, driven by a commitment to finding new, creative solutions that meet both customer needs and environmental standards.
For instance, using materials like foamex, which offers enhanced durability and versatility, is an example of how industry preferences are shifting towards more sustainable and practical alternatives in manufacturing and design applications.
The Versatile and Durable Polymer
Lastly, PVC’s chemistry might seem complex, but it is the backbone of many products we use daily.
Through continuous innovation and adherence to rigorous safety and environmental standards, the PVC industry remains a vital part of the global manufacturing landscape, constantly adapting to meet the challenges of modern applications.
Makki Seo 
Alex