Design, build, and commission of plant presented considerable engineering challenges, not least because of the nature of the vinyl chloride monomer and the polymerisation reaction
Strata Technology has designed, built and commissioned an automated PVC pilot plant for Synthomer, part of the polymers division of Yule Catto, a supplier of synthetic polymers.
With all of the complexity of a full-scale design, including the risk elements, the engineering challenges posed by the pilot plant were considerable - not least because of the highly toxic and flammable nature of vinyl chloride monomer and the exothermic nature of the vinyl chloride polymerisation reaction. Synthomer's pilot plant can mimic conditions in a full-scale commercial reactor, and it can be tuned to match the technology of any PVC producer worldwide.
It incorporates a PC-based control system, with efficient VCM containment in the reactor, and essential safety and fail-safe alarm systems to avoid reactor temperature and pressure excursion.
Safety features include dedicated VCM mass metering, with a venting and extraction capability for the entire plant area, and VOC destruction to >99.99% for gases released to the environment.
The Strata Technology design incorporates a dual, interchangeable reactor system, with 10 litre capacity bodies, and geometries to match the two principal current technologies - a short squat reactor, and a tall and thin reactor.
3D modelling was used extensively in the development of the reactors and other key components to ensure that client requirements were met.
The reactors are designed for pressure containment up to 18 barg and a maximum operating temperature of 80C.
The design was developed using the latest instrumentation and control system for precise process and parameter monitoring during runs, with automated shutdown features.
Double automated valves were an absolute necessity for process containment and were a specific customer safety requirement.
The pilot plant has a dedicated PC-based automation and control system, interfaced with VOC detection for added safety.
Strata also developed the user-friendly, dedicated software that enables sophisticated process trending, data recording, alarm recognition, and parameter monitoring to be carried out.
"It's been a very good project, delivered in cost and on time," comments Synthomer's technical manager, Peter Shaw.
"Strata is technically excellent and brought skills that we don1t have internally.
We certainly learned from each other as the project developed, but Strata was the only company that could offer the appropriate fast track design, project management, and construction."
