Influence of Water Regeneration on Chemical and Process Indices in an Energy-Integrated PVC Production Process.

Water regeneration in PVC production is a key issue to consider, given the high freshwater consumption rate of the process. This research evaluates the inherent safety of poly(vinyl chloride) (PVC) production via suspension polymerization by implementing mass and energy integration strategies in combination with wastewater regeneration under a zero-liquid-discharge (ZLD) approach. The impact of these integrations on process safety was examined by considering the risks associated with the handling of hazardous materials and critical operations, as well as the reduction in waste generation. To this end, the Inherent Safety Index (ISI) methodology was employed, which quantifies hazards based on factors such as toxicity and flammability, enabling the identification of risks arising from system condition changes due to the implementation of sustainable water treatment technologies. Although the ISI methodology has been applied to various chemical processes, there are few documented cases of its specific application in PVC plants that adopt circular production strategies and water resource sustainability. Therefore, in this study, ISI was used to thoroughly evaluate each stage of the process, providing a comprehensive picture of the safety risks associated with the use of sustainable technologies. The assessment was carried out using simulation software, computer-aided process engineering (CAPE) methodologies, and information obtained from safety repositories and expert publications. Specifically, the Chemical Safety Index score was 22 points, with the highest risk associated with flammability, which scored 4 points, followed by toxicity (5 points), explosiveness (2 points), and chemical interactions, with 4 points attributed to vinyl chloride monomer (VCM). In the toxicity sub-index, both VCM and PVC received 5 points, while substances such as sodium hydroxide (NaOH) and sodium chloride (NaCl) scored 4 points. In the heat of reaction sub-index, the main reaction scored 3 points due to its high heat of reaction (-1600 kJ/kg), while the secondary reactions from PVA biodegradation scored 0 points for the anoxic reaction (-156.5 kJ/kg) and 3 points for the aerobic reaction (-2304 kJ/kg), significantly increasing the total index. The Process Safety Index scored 15 points, with the highest risk found in the inventory of hazardous substances within the inside battery limits (ISBL) of the plant, where a flow rate of 3241.75 t/h was reported (5 points). The safe equipment sub-index received 4 points due to the presence of boilers, burners, compressors, and reactors. The process structure scored 3 points, temperature 2, and pressure 1, reflecting the criticality of certain operating conditions. Despite sustainability improvements, the process still presented significant chemical and operational risks. However, the implementation of control strategies and safety measures could optimize the process, balancing sustainability and safety without compromising system viability.