Huge Market Potential of New PVA Fiber Varieties

By Li Feng, Beijing Sujia Huifeng Chemical Technology Consulting Co., Ltd.

Slack Market and Fierce Competition

PVA fiber (polyvinyl alcohol fiber) is one of the important members in the family of formaldehyde downstream products. The development of PVA fiber in China can be roughly divided into eight periods:
(1) In 1962, China constructed its first 1.0 kt/a PVA and PVA fiber unit, with design, installation and equipment manufacturing all done by China itself. The curtain was raised on the commercial production of PVA fiber in China.
(2) In the early 1970s, by using imported equipment, China constructed nine more PVA and PVA fiber units, each with a capacity of over 10.0 kt/a, and using calcium carbide acetylene as raw material. China also introduced a 45.0 kt/a PVA and PVA fiber unit with technology from Japan using natural gas acetylene as raw material and a 33.0 kt/a PVA and PVA fiber unit with technology from France using petroleum ethylene as raw material. In this stage, China’s PVA and PVA fiber capacities reached 193.0 kt/a and 165.0kt/a, respectively. A solid foundation was laid for the development of the PVA fiber sector in China.
(3) Starting from the 1980s, due to the poor durability of PVA fiber, the availability of alternative synthetic fibers and the rapid development of non-fiber uses for PVA, the PVA fiber market in China shrank.
(4) In 2003, the output of PVA fiber in China was already reduced from 103.0kt in the peak period to 33.4kt.
(5) In 2008, the PVA fiber sector in China was faced with numerous problems. In the second half of the year, in particular, PVA fiber prices fell sharply, the market was slack, demand was soft and producers had a hard time.
(6) In 2010, with the gradual passing of negative factors such as the global economic crisis the PVA fiber sector managed to recover.
(7) In 2011, due to the sustained influence of the global financial crisis, the prices of energy and raw materials increased constantly, and market competition was fierce.
(8) In 2012, the PVA fiber sector in China was becalmed. Capacity was 90.2 kt/a. During 2008-2012, the average annual growth of capacity had been 8.87 %. In the same period, the average annual growth of PVA fiber output was 2.06. Table 1 shows the development of the PVA fiber sector in China during 2008-2012.
Now, Ningxia Dadi Chemical Industry Co., Ltd. is reportedly constructing a 56.0 kt/a high-strength and -modulus PVA fiber plant, which is planned to start production in 2015. The capacity of PVA fiber in China will reach 146.2 kt/a at that time, and market competition will probably be white hot. During 2012-2015, the average annual growth of PVA fiber capacity in China will be 17.47%.

Table 1   Production of PVA Fiber in China, 2008-2012  ( kt)

Year    Capacity    Output    Operating rate (%)
2008    64.2        48.1    74.96
2009    64.2        36.2    56.37
2010    64.2        44.2    68.82
2011    64.2        46.7    72.78
2012    90.2        52.2    57.89
YoY Growth 2008~2012 (%)    8.87    2.06    -6.26


Table 2    Output of PVA Fiber in China

PVA fiber family    Output  (ton)                    YoY growth 2008-2012 (%)
                    2008      2010     2011        2012    
PVA staple fiber    6743.71     3629.19 2755.05    3573.00      -14.68
PVA filament fiber    2538.84     2532.80 2189.00    1684.00      -9.75
High-strength
and -modulus fiber    25567.81 22583.45 22368.00    22210.00    -3.46
Intermediate-strength
and -modulus fiber    2589.64       0       0           0          0
Water-soluble fiber    9938.00    15263.47  18753.45    22973.43    23.31
Others                743.62    173.44      656.56    1778.00        24.35


Extensive development space of new fiber varieties

The output of PVA fiber in China was 52.2kt in 2012 – 44% for water-soluble fiber, 42.5% for high-strength and -modulus fiber, 6.8% for PVA staple fiber, 3.2% for PVA filament fiber. See Table 2 for details.
PVA fiber units in China are mainly situated in Anhui (38.8%), Chongqing (19.96%), Hunan (14.63%), Fujian (13.3%), Gansu (6.65%) and Inner Mongolia (6.65%). Table 3 shows the major producers of PVA fiber in China.
Certain properties of PVA molecules – water solubility, porosity, chelation and chemical cross-linking – can be used to develop fiber varieties with special features. The varieties currently made in China mainly include filament fiber, wool-like fiber, medium length fiber, strong fiber, high-strength and -modulus fiber, intermediate-strength and -modulus fiber and water-soluble fiber. Judging from the overall trend, conventional varieties (such as staple fiber, filament fiber and draft-cut fiber) will see little market growth, whereas new varieties have extensive development opportunities in water-soluble non-woven fabrics, carrier yarns, paper making, and cement products, and in the concrete and battery sectors. The main up-and-coming PVA fiber varieties in China today are water-soluble fibers, high-strength and -modulus fibers and composite fibers. Looking forward, varieties that could reach commercial production in China include flame retardant fibers, colored fibers and medium length fibers.
In 2010 Donghua University used low-temperature PVA fiber as raw material and maleic anhydride as a cross-linking agent to form a PVA fiber network structure, producing super absorbent fiber (SAF).
PVA fiber was initially used in industry because it had some better properties than cotton. Its strength, abrasion resistance, sunlight resistance and corrosion resistance were better, its specific gravity was smaller and its hydroscopicity was nearly as good. PVA fibers modified through new processes have won high praise recently. Researchers have successfully developed a group of high-performance varieties such as flame retardant fibers, high-strength and -modulus fibers, and water-soluble fibers. The usefulness of PVA fiber in reinforcing other materials, and in the fishery and packaging sectors is therefore greatly upgraded, and applications in medical care and ion exchange adsorption are also opened up. PVA fiber has bright development prospects.
1. High-strength and -modulus PVA fiber
Owing to its excellent hydrophilicity, adhesion and impact resistance, and its good dispersion, high strength and high modulus, PVA fiber has extensive development potential in industrial and construction sectors.
High-strength and -modulus PVA fiber can be used in reinforcing concrete, with many advantages:  (a) Good mechanical property: It can increase the toughness and impact resistance of construction materials. (b) Good acid/alkali resistance: It is suitable for use in various grades of concrete. (c) Good dispersion: The surface of construction materials can be kept smooth for a long time with no peeling. (d) Small consumption: The consumption is only 1/5 of that of asbestos. The unit weight of products can therefore be effectively reduced and the operating conditions can be remarkably improved. (e) Low air permeability of concrete: The corrosion of steel rebar can be prevented. Such concrete weathers comparatively well in any climate.
High-strength and -modulus PVA fiber can also be used to replace glass fiber. It can also be used in rubber reinforcing materials and tire cord yarns. Owing to its high tensile strength and corrosion resistance, it can be used to produce fishing nets, ropes, canvas and conveyor belts.
2. Water-soluble PVA fiber
Water-soluble PVA fiber is a functional differential fiber with high value. It has two categories – filament fiber and staple fiber. PVA filament fiber is an ideal water-soluble fiber with special features. The water-soluble temperature is 0-100℃. Water-soluble PVA fiber also has tensile elongation as well as good resistance to acids, alkalis and dry heat. It has no odor and no toxicity after being dissolved in water, and the aqueous solution is colorless and transparent. It biodegrades naturally and quickly. Water-soluble PVA fiber can be used to produce high-grade twist-free towels, silk stockings, fishing nets, fine narrow lace fabrics and wool facing fabrics. The weaving performance of flax and ramie yarns can be improved. Water-soluble PVA fiber used as raw material for knitted fabrics is suitable to knit facing fabrics of various structures. It can also be used in lithographic printing, tight (rubber, canvas) cloth covers, weftless felts and embroidery.
3. Flame retardant PVA fiber
For flame retardant PVA fiber, the LOI can increase from 19% to over 30%. It also has advantages of droplet-free combustion, high strength, mildew resistance and moth resistance. It is used in underground conveyor belts of coal mines and in air ducts, tarpaulins, tents, firefighting clothes, welding clothes, gloves, shoes, caps, ropes, meshes, filter fabrics, filter felts, various heat-resistant filters, insulating layers and electric appliance insulating materials.
With the constant upgrading of the research level and the vigorous expansion of applications – especially in the construction material and packaging material sectors – PVA fiber has bright application prospects in China. PVA fiber varieties with high performance and high added value should be developed in accord with market demand. In this way the PVA fiber market in China will soon have another glorious period.     

Table 3    Major Producers of PVA Fiber in China  (kt)

Producer    Capacity    PVA fiber Product                 Output
           2008      2012                        2008    2009    2010    2011    2012
Sinopec Sichuan
Vinylon Works    18.0    18.0                14.8    12.5    12.9    15.4    14.2
                         PVA staple fiber    5.2          -         2.1    1.9         3.1
                         PVA filament fiber    2.0          -         2.4    2.1         1.7
                         high-strength and -modulus fiber     2.9     -    3.0    4.2    0.5
                         intermediate-strength
                         and -modulus fiber 1.1           -      0         0          0
                         water-soluble fiber 3.4       -     5.3    6.9         7.3
                         others                 0.2       -     0.1    0.4         1.6
Anhui Wanwei Updated 15.0    35.0
　　　　15.0    35.0   High-tech Material Co., Ltd. 16.4 10.8 16.0 17.8    17.6
        
　　　　　　　　　　high-strength and -modulus fiber16.4 10.8 16.0    17.8 17.6
Hunan Xiangwei Co., Ltd.     13.2    13.2            4.8     3.3  4.1    5.5    6.1
                    PVA staple fiber                 0      -      0.4    0.5    0.2
                    PVA filament fiber                0.2      -      0         0    0
                    high-strength and -modulus fiber    0.5    -    0    0    0
                    water-soluble fiber                3.6      -      3.7     4.9 5.8
                    others                            0.5      -      0.1    0.2     0.2
Lanzhou Lanwei Material Co., Ltd.     6.0    6.0            7.0     3.5  3.6    0     0
                    high-strength and -modulus fiber 5.5  -      3.6    0    0
                intermediate-strength and -modulus fiber 1.5    -    0    0    0
Fujian Fuwei Co., Ltd.     12.0    12.0                   5.2    6.0    7.5    8.1    10.2
                    PVA staple fiber                   1.6     -    1.1    0.5     0.3
                    PVA filament fiber                   0.4     -    0.2    0.1     0
                    high-strength and -modulus fiber   0.3    -    0    0.4     0
                    water-soluble fiber                   3.0    -    6.2    7.0    9.9
Inner Mongolia Shuangxi
Environment-friendly
Material Co., Ltd.      0      6.0                           0    0    0    0    4.1
                     0      6.high-strength and -modulus fiber 0    0    0    0    4.1