PVC PIPES MANUFACTURING PLANT
[EIRI/EDPR/1623] J.C.: 426, 9997INR
INTRODUCTION
PVC (unplasticized polyvinylchloride) pipes and fittings exhibit excellent resistance to aggressive environments both naturally occurring and as a result of industrial activity. They are resistant to almost all types of corrosion, either chemical or electrochemical in nature. Since PVC is a non-conductor, galvanic and electro chemical effects do not occur in PVC pipes.
PVC Pipes and fittings a often used in the following circumstances:
• For drinking water pipe distribution systems, both main and supply lines
• Sewer and discharge pipe systems
Due to its non-metallic nature, the material used is totally resistant to all forms of metallic corrosion.
Aggressive water resulting from high sulphate soils and low hardness water will not attack PVC pipes.
Our pipes are therefore resistant to a wide range of industrial waters and chemicals and offer an advantage in long-term systems life and manufacture costs.
For more information on the resistance of PVC for specific chemical(s), do not hesitate to let Interplast know. We inform you of the suitable pipe solution necessary.
Being made of a tasteless and odorless material, PVC pipes remain neutral to all transported fluids.
PVC is completely inert and is widely used for transporting liquids made for human consumption.
Because of their mirror-smooth inside surface, PVC pipes have minimum flow head loss. There is also no buildup of inside deposits, a particular advantage in the construction of sewerage systems.
The physical properties of PVC pipes are not affected by neither direct sunshine, nor wind or rain.
However, to avoid surface browning due to long exposure to direct sunlight, it is recommended that the pipes are kept protected from direct sunlight.
Rigid PVC is not conductive to combustion. In the event of a fire, flames are unable to travel on PVC pipes. They therefore offer added safety when used for electrical installations, both domestic and industrial.
PVC pipes are relatively light. Their specific weight 1.43 is one- fifth that of steel pipes. This cuts down transportation costs and facilitates installation when in difficult and remote places. Installation is quick and easy with a complete line of fittings either with the solvent glue weld sockets or the rubber seal socket joints. In either case, a leak-proof joint is assured. Subsequent maintenance work is also carried out with a minimum of complication and cost.
PVC pipe which is made from polymerized vinyl chloride, a synthetic resin, which when plasticized or softened with other chemicals has some rubber-like properties. Derived from acetylene and anhydrous hydrochloric acid. PVC pipe has nominal sizes that are to be used with PVC socket fittings (schedule 40) and PVC socket or threaded fittings (schedule 80).
PVC Pipe and Fittings have got tremendous demand in India as well as in abroad. To manufacture this, all the machinery and raw materials are available indigenously.
A polyvinyl chloride (PVC) pipe is made from a plastic and vinyl combination material. The pipes are durable, hard to damage, and long lasting. A PVC pipe does not rust, rot, or wear over time. For that reason, PVC piping is most commonly used in water systems, underground wiring, and sewer lines.
PVC was first developed in 1925 when a BF Goodrich employee, Dr. Waldo Semon, attempted to invent a method for bonding metal and rubber. After blending materials together to create a strong and flexible material, Semon discovered PVC. Nonetheless, the product remained virtually useless for another decade. In the late 1930's, PVC was found to have great shock absorbing abilities. This discovery led to the creation of long lasting PVC tire treads, which were created with flexible forms of PVC.
Two decades later, PVC pipe was invented. By heating the PVC material, a special machine called an extruder could be used to push the PVC into hollow pipes. This PVC pipe was extremely solid and virtually indestructible. Using PVC pipes for irrigation systems proved to be effective. PVC pipe has since been considered an affordable and reliable means for water piping.
Due to the ability of PVC pipe to withstand extreme movement and bending, it is also increasingly used in earthquake prone areas. PVC pipe can withstand the rigorous shaking of the earth without experiencing any damage. The smooth surface of the PVC pipe is also resistant to bacterial contamination, such as E. coli. Therefore, many water companies rely on PVC pipe in their systems in order to keep them free of contamination.
Unfortunately, the material used in PVC pipe appears to be detrimental to a person's health and safety. Reported cases of PVC pipe shattering when used with high-pressured gases have increased drastically. The Federal Government has issued safety warnings, which strongly recommend using alternative piping material. In addition, the heavy metals used to create PVC pipe can leach out when heated. The vapors emitted from the heated PVC pipe are now being linked to certain forms of cancer, especially lung cancer.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (10,000 sq.mt.) Rs. 14.17 Cr
Plant & Machinery Rs. 1.77 Cr
Working Capital for 2 Months Rs. 4.55 Cr
Total Capital Investment Rs. 20.96 Cr
Rate of Return 13%
Break Even Point 64%
CONTENTS
INTRODUCTION
PVC PIPES AND FITTINGS A OFTEN USED IN THE FOLLOWING CIRCUMSTANCES:
PROPERTIES OF PVC PIPES & FITTINGS
ADVANTAGES & LIMITATIONS
HANDLING & STORAGE:-
BUREAU OF INDIAN STANDARDS SPECIFICATIONS PLASTIC PIPES & FITTINGS
PRESSURE PIPES FOR WATER SUPPLY & IRRIGATION
PLUMBING PIPES
APPLICATIONS OF PVC PIPES & FITTINGS
THE MAIN APPLICATION OF RIGID PVC PIPES & FITTINGS ARE:-
1. FOR TRANSPORTATION OF WATER:
2. TUBE WELLS:-
3. CHEMICAL PROCESSING PLANTS:-
4. DUCTING FOR POWER AND COMMUNICATION CABLES:
FOR TRANSPORTATION OF PULVERIZED MATERIALS
ADVANTAGES OF USING PVC PIPES
1. IT IS ECONOMICAL:
2. IT RESISTS CORROSION:
3. NON-ENRUSTATION:
4. LIGHT WEIGHT:
5. EASE OF INSTALLATION:
MARKET SURVEY
PRESENT CONSUMPTION PATTERN OF P.V.C. RIGID PIPES
PVC PIPES OFFERS THE FOLLOWING ADVANTAGES:-
APPARENT CONSUMPTION (IN TONS)
TREND IN INCREASE IN DEMAND
TREND GROWTH RATE IN INCREASE OF DEMAND = 15%
ENHANCED RECYCLING PROPERTIES FOR PVC PIPES
MANUFACTURERS/EXPORTERS OF PVC PIPES
PVC PIPE MANUFACTURERS/EXPORTERS RAW MATERIAL SECTION
PVC RESIN:
FORMULATION FOR PVC RIGID PIPES
FORMULATION -I
PVC FLEXIBLE PIPES
FORMULATIONS
PROCESS OF MANUFACTURE
PLUMBING PIPES
USES & APPLICABILITY OF PVC COMPOUNDS
BUILDING AND CONSTRUCTION:
PACKAGING:
MISCELLANEOUS:-
PROCESS OF MANUFACTURE OF RIGID PIPES
TWIN SCREW EXTRUDERS
EXTRUSION DIES
EXTRUSION LINES:-
PVC PIPE FITTINGS:-
PLASTICIZER OF PVC
FILLERS OF PVC
STABILIZERS
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC PIPES
PROCESS FLOW SHEET FOR THE MANUFACTURE OF PVC FITTINGS
PLANT LAYOUT
THE NEW GENERATION OF PVC-O PIPES
MOLECULAR ORIENTATION, A REVOLUTION IN PVC TECHNOLOGY
A PLASTIC WITH UNBEATABLE PROPERTIES
CUTTING-EDGE TECHNOLOGY FOR WATER
MAXIMUM RELIABILITY AND SECURITY
HIGH SHORT AND LONG TERM HYDROSTATIC RESISTANCE
EXCELLENT RESPONSE TO WATER HAMMER
INCREASE HYDRAULIC CAPACITY
MAXIMUM FLEXIBILITY
COMPLETE CORROSION RESISTANCE
TOTAL WATER QUALITY
COMPLETELY WATER TIGHT
LOWER COST AND EASIER INSTALLATION
THE MOST ECO-FRIENDLY PIPES ON THE MARKET
ENERGY EFFICIENT
OPTIMAL USE OF WATER RESOURCES
100% RECYCLABLE
THE BEST MECHANICAL PROPERTIES
TENSILE RESISTANCE
LONG TERM HYDROSTATIC RESISTANCE
PIPING AND MATERIAL MECHANICAL PROPERTIES
OTHER MATERIAL CHARACTERISTICS
UNBEATABLE HYDRAULIC PROPERTIES
HYDRAULIC CAPACITY
WATER HAMMER
A RANGE FOR ALL KINDS OF APPLICATIONS
DIMENTIONS
PACKAGING
JOINTS AND WATER TIGHT SEALS
FITTINGS
TAPPING SADDLES
FLANGE WITH ANTI-TRACTION SYSTEM
FITTINGS WITH PLUGS EURO TYPE
APPLICATIONS
OTHER APPLICATIONS
PRODUCTION OF PVC IRRIGATION PIPE
FIG. 1 ILLUSTRATES THE PROCESS OF THE PRESENT METHOD.
EXAMPLE 1
EXAMPLE 2 (COMPARATIVE)
EXAMPLE 3 (COMPARATIVE)
EXAMPLE 4 (COMPARATIVE)
EXAMPLE 5
EXAMPLE 6 (COMPARATIVE)
TAPPING TOOL FOR PVC PIPES AND FITTINGS
JOINING MECHANISM FOR PVC PIPE
REPAIR PIPE FITTINGS
SUPPLIERS OF PLANT AND MACHINERY OF PVC PIPES
HIGH SPEED MIXER
EXTRUDER
PLASTIC SCRAP GRINDER MACHINE
PLASTIC INJECTION MOULDING MACHINE
STEAM BOILERS
GENERATOR SET
SUPPLIERS OF RAW MATERIALS
PVC RESIN
CALCIUM STEARATE
LEAD STEARATE
PRECIPITATED CALCIUM CARBONATE
PIGMENT DYE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
