PVC SOLVENT CEMENTS MANUFACTURE WITH PROCESS AND FORMULA (UPVC & CPVC) [3594]
The operation of solvent cement may be broadly defined as the formation of a Joint where in a self bond between two polymeric component is promoted by the presence of a solvent in temporarily high concentration. The onion between two parts of a Joint is brought with the aid of solvents, solvent cement or adhesives. The type of joint best suited to solvent bonding is a lap joint. The nutuod in not normally used for but. Joint where these are likely to experience significant stresses. The essential features of bond formation in this method are the intes diffusion of polymer molecules across the original interface between the two components of the joint, and the promotion and acceleration of this process by the swelling of the polymer of the joint components at the clubface, caused by sorption of the solvent. The solvent concentration in the polymer, originally high, is ultimately reduced to a lord constant value mainly the further penetration inwards and also by evaporation from the edges of the bond zone. PVC or poly vinyl chloride is insoluble in common cow cost solvents, but is soluble in cyclohexane, tetra hydrofuram nitrohenzene and a value of others. In solvent of this type it can be used for bonding rigid PVC pipe work since the solvents soften the santenial of the pipes and as form of solvent weld in produced. It is sometimes tenght that by virtue of its polymer content, a solvent cement is gap-filling. This is not the case with solvent cements for PVC card indeed not with most such cements formulated for other plastics. Mainly because the amount of polymer they contain is proportionately low. It is therefore essential for good results that the surfaces of parts to be joined should fit closely tog ether with no gaps. The polymeric components of PVC solutions used as solvent cements for bonding pipes, pipe fittings and certain other PVC products may be homo polymers, co polymers, standard PVC compounds or the actual compositions of the moldings etc. to be bonded. By defination, the two essential components of a PVC solution must be PVC polymer (S) and solvent. The solvation so obtained is used for some practical application (e.g. some solvent cements, film casting salvations) are just such simple systems. Most PVC applications, i.e. the ones they are designed for, do not require very critical procedure for joining pieces together, because most of the time the fluid going through them is not under pressure. However, certain high-strain applications, such as Spud Gunning, require that the joints are strong and airtight. The way to achieve that is proper solvent welding. The stuff that you get at the store to put together pieces of PVC is labeled "Cement." This is a misnomer. The “cement" class of adhesives, such as contact cement, rubber cement, etc, all are used to bond two, usually dissimilar, materials together. PVC cement is actually a solvent. Welding involves melding two pieces of the same material into one. When you solvent weld PVC, you are actually turning the two sides that you are joining into PVC mush, the molecules all blend together, and what you are left with is essentially one single piece of PVC. The Solvent cement is used for jointing PVC pipes & Fittings. Proper care is always taken to ensure stringent quality checks on the product at al I stages, without compromising on the quality. This is a simple process for jointing Rigid PVC Pipes with molded or fabricated fittings. The tools required are a hacksaw with fine teeth, sandpaper, cotton waste, a soft brush, a knife and solvent cement.
COST ESTIMATION
Plant Capacity 2 Ton/Day
Land & Building (800 sq.mt) Rs. 1.06 Cr
Plant & Machinery Rs. 45 Lac
Working Capital for 1 Month Rs. 72 Lac
Total Capital Investment Rs. 2.30 Cr
Rate of Return 33%
Break Even Point 50%
INTRODUCTION
HOW TO SOLVENT WELD PVC PIPE AND FITTINGS
SOLVENT CEMENT
THE JOINTING PROCEDURE IS AS UNDER
APPLICATIONS
AVAILABLE SIZES
MECHANISM OF THE SOLVENT CEMENT OPERATION
PROPERTIES AND CHARACTERISTICS OF PVC SOLVENT CEMENT
USES & APPLICATION
INSTALL NEW PLUMBING PIPES IN YOUR HOME
REPAIR SMALL HAIRLINE CRACKS IN PVC PIPE
MARKET OVERVIEW
FUTURE DEMAND
EXPORT DATA
DETAILED IMPORT DATA OF PVC SOLVENT CEMENT
OVERVIEW OF PVC AND CPVC PIPES
PVC PIPING SEGMENT
OPPORTUNITIES AHEAD:
AGRICULTURE/RIGID PIPE SEGMENT –OPPORTUNITY CONTINUES
THE RECENT INITIATIVES BY THE NDA GOVERNMENT:
PLUMBING PIPES –A FUTURE LIES HERE
KEY GROWTH DRIVERS:
CPVC PIPE –GAINING POPULARITY DAY BY DAY
HOW CPVC PIPES HAVE EVOLVED IN INDIA?
FEATURES OF CPVC PIPE
CPVC PIPE MARKET IN INDIA
PRODUCTION OF PVC AND CPVC PIPES FROM 2007 TO 2016
TREND IN INCREASE IN DEMAND
ENHANCED RECYCLING PROPERTIES FOR PVC PIPES
OVERVIEW OF PVC IN INDIA
INDIAN SCENARIO
FIGURE: PVC PRODUCTION AND IMPORTS IN INDIA
FIGURE: PVC DEMAND IN INDIA - HISTORY
FIGURE: APPLICATION BREAK-UP OF PVC – INDIA
FIGURE: APPLICATION BREAK-UP OF PVC – GLOBAL
FIGURE: PVC CONSUMPTION IN INDIA (2001-2015)
FIGURE: DOMESTIC MANUFACTURERS AND CAPACITIES (KT)
PRESENT MANUFACTURERS/SUPPLIER OF PVC SOLVENT CEMENT
SPECIFICATION OF CPVC RESIN
REQUIREMENT OF PVC SOLVENT CEMENT
REFERENCED DOCUMENTS
ASTM STANDARDS:
TERMINOLOGY
MATERIALS AND MANUFACTURE
TECHNICAL SPECIFICATION OF LOW
VOC PVC SOLVENT CEMENT
GENERAL PRODUCT SPECIFICATIONS:
CONFORMANCE STANDARDS AND APPROVALS:
PACKAGING, SHIPPING & TRANSPORTATION INFORMATION:
THE FOLLOWING IS GENERAL INFORMATION FOR GROUND SHIPPING,
SEE SDS PVC37-6 FOR ADDITIONAL DETAIL.
SAFETY & USE PRECAUTIONS:
FIRST AID
INSTALLATION & INSTALLER TRAINING
AVOID USE AROUND DRY GRANULATED CALCIUM HYPOCHLORITE
FORMULATIONS OF PVC SOLVENT
FORMULATION -1
UPVC SOLVENT CEMENT
FORMULATION -2
CPVC SOLVENT CEMENT
FORMULATION -3
CPVC SOLVENT CEMENT (HEAVY DUTY)
MANUFACTURING PROCESS OF PVC SOLVENT CEMENT
PROCESS FLOW DIAGRAM
DETAILS OF UNIVERSAL SOLVENT CEMENT
ACRYLIC RESIN
SOLVENT
ADDITIONAL RESINS
OTHER INGREDIENTS
VISCOSITY
UNIVERSAL SOLVENT CEMENT
FORMULATION
TESTING, MARKING AND HANDLING OF PVC SOLVENT CEMENT
TEST METHODS
BOND STRENGTH:
LAP SHEAR STRENGTH:
HYDROSTATIC BURST STRENGTH:
RETEST AND REJECTION
QUALITY ASSURANCE
GUIDE OF PVC SOLVENT CEMENT SELECTION
TABLE PVC CEMENTS FOR SCHEDULE 40 AND INTERFERENCE FIT
TABLE PVC CEMENTS FOR SCHEDULE 80 AND NONINTERFERENCE FITS
WORKING METHOD WITH SOLVENT CEMENT
STORING
SOLVENT CEMENTING WITH A PRIMER
STEP 1 CUT
STEP 2 DEBURR
STEP 3 CLEAN
STEP 4 CUT
STEP 5 CHOOSE APPLICATOR
STEP 6 PRIMING
STEP 7 CEMENTING
DO NOT TEST WITH AIR.
THINGS TO REMEMBER WHEN SOLVENT CEMENTING IN COLD WEATHER:
PRECAUTIONS
READ ALL INFORMATION CAREFULLY BEFORE USING THIS PRODUCT
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF RAW MATERIALS
PVC RESIN
SOLVENT
PVC STABILIZER
SUPPLIERS OF PLANT AND MACHINERIES
REACTION VESSELS
STORAGE VESSEL
D.G. SETS (DIESEL GENERATOR)
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
CONSULTANT AND TECHNOLOGY PROVIDER FOR PVC SOLVENT CEMENTS
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)
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