This document discusses research proposals for the production of polyvinyl acetate (PVAc) emulsions. It aims to analyze the composition of Mowilith resins, how they are made, production processes and costs. The document outlines the polymerization of PVAc and economic analysis. It also provides details on the emulsion polymerization process, raw material requirements, production cost estimates and a project cash flow analysis for a proposed PVAc plant with an initial capacity of 20,000 tons per year and investment of 10 million euros.

1. In this research are described answers on following questions: - What is the composition of the Mowilith resins? - How are they made? - What is process? - What are costs of the materials? - What are costs of production? - Business plan for production.

2. The aim is by research proposals as: - literature research/patent inventory polymerisations of the PVAc(with attention points on Mowilith dispersions in PVa as stabilization: Mowilith D ca.50 %, Mowilith DHS S1, Mowilith LD 167 and Mowilith SDM 4230 KL), - Economic perspective - researches and - Lab. tests possible polymerisation routes, determinate the possibilities for production with possible commitment (use) present equipment at "Paramelt”.

3. polyvinyl acetate (PVAc) Emulsion Polymerisation

4. Monomer Addition radical attacks double bond of monomer new radical forms that is one monomer unit longer chain reaction The polymer chain grows by addition of monomer units: chain has propagated called free radical polymerisation

5. Initiation From where does the first unpaired electron come? Generated by an initiator e.g. hydrogen peroxide (H 2 O 2 ) has O–O bond (easy to break) generates 2 OH • radicals usually don’t use H 2 O 2 but other peroxides, e.g.: potassium persulfate persulfate ion is: [O 3 S–O–O–SO 3 ] 2– O–O- bond breaks readily at 60 o C to initiate reaction

6. poly(vinyl acetate) (PVAc)

7. Polymer Colloids Polymers often prepared in colloidal form Polymer Colloids in water Called a latex Why? More environmentally friendly than organic solvents Easier to process and transport than polymer solutions Easier to get greater efficiency in process Can get up to 50/50 polymer/water

8. What is a Colloid? Small blobs suspended in water, e.g. paint, glue polymer in water latex ink pigment in water dispersion muddy pond clay in water dispersion milk fat or oil in water emulsion

9. Colloid Stability What stops colloidal particles joining together and settling out? Brownian Motion Surfactants

10. About Surfactants Surfactants (soaps/detergents) Structure of a typical surfactant long hydrocarbon chain (water-hating or hydrophobic ) ionic head group (water-loving or hydrophilic ) e.g. sodium dodecyl sulfate (SDS) household detergent, soap, shampoo

11. Colloid Stability: Surfactants Surfactants (soaps) stop particles joining together like dissolves like water-hating tails go into water-hating polymer water-loving heads go into water charge repulsion of ionic head groups stops coalescence form a stabilised latex e.g. with SDS, latex surface covered in negatively charged surfactant head groups

12. Theory into Practice Making a polyvinyl acetate: chemicals required dispersion medium water monomer vinyl acetate initiator potassium persulfate soap AMA, AOT preparation ( emulsion polymerisation ) mix all chemicals warm in water bath (60 o C) stir for several hours (overnight)

13. Emulsion Polymerisation Emulsion Polymerisation monomer (oil) droplets: (stabilised by soap) in water polymer colloids: (stabilised by soap) in water Water Polymer Water Oil

14. * actual polymerisation process very complex - area of lots of research

15. Project Cash Flow Project cost money, the spending of which usually has to be justified in terms of receiving a return or making profit.

16. Project Cash Flow Analysis- the Manufacture of PVAc emulsion The Initial Information Initial design capacity 20.000 t/year Investment (plant costs) 10.000.000 € Building costs 5% of Investment Working capital 14% of Investment For plant construction would take two years from the investment decision. The plant and building costs would be spend in two years and the working capital all in in second year . Working capital is fully recovered at the end of the plant’s productive life.

17. Production costs estimates Comprise the annual : - fixed costs - variable costs

18. Fixed Production Costs for PVAc Plant FIXED COSTS of PVAc Capacity(ton/year) design 20.000 20.000 Capex(€) 10.000.000 Operating cost 3 60000 9 Other staff 0,5 10000 0,3 Maintenance 2% 2% 10 General 65% of Op.,Ot +Ma. 13 TOTAL FIXED COSTS of PVA c (55%) 32

19. TOTAL VARIABLE COSTS GENERAL RECIPT(large-particle size)(CELANESE) PVAc (55%) Cost item Yield kg/t Cost €/t Cost €/t emul. Water 427,5 20 9 Vinyl Acetate 550,0 400 220 Hydroxyethylcellulose or Polyvinylalcohol 20,0 1500 30 Soap (Tergitol NPXl)-Polyoxyethylene nonylphenol 0,5 2500 1 K2S2O8 (Potassiumperoxydisulfate) 0,5 3038 2 NaHCO3 1,5 557 1 Enrgy 100 Utilities 50 TOTAL VARIABLE COSTS of PVAc 412

20. The producion - can be increased gradually to 106-120%without requiring increased capital investment 1th year of production 10.000 t/year 2 th year of production 20.000 t/year 3 th year of production 21.250 t/year 3-14th year of production 21.250 t/ year

21. ? V A c -monomer price 400-1200 €/t

22. Price of polimer PVAc emulsion(~55%) 610-700 €/t emul.

23. CHASH FLOWS FOR SIMPLE PLANT PVAc

24. Payback Time= 4,5 Years % ROI (ex.dep) = 24 %ROI (inc.dep.) = 17