Process Diagram for Production of Elastic Ppu

The process flow chart of the unit SGP production consists of the following process operations: a) raw material preparation; b) preparation of activator mixture and component A; c) foaming of components, obtaining SGP units; d) ripening of blocks; e) cutting blocks into sheets, packing. 1.4.1 Tempering of polyester components. Polyester Isonol 3300 or component A Isolan 50/1 entering the compartment in barrels is kept in a warm room (cold season) at a temperature of not less than + 18 ° C for not less than 2 days or heated to this temperature, but not higher than + 22 ° C. Polyester Isonol 3300 or component A Isolan 50/1 (depending on the grade of the SGP to be produced) is pumped into the working tank pos. Z (volume of 900 l). 1.4.2 Temperature of toluylenediisocyanate or component B EL- 50/1. Toluylenediisocyanate T 80 or component B EL-50/1 coming from storage in barrels shall be kept in a warm room at temperature not less than + 20 ° С for at least a day. At a temperature lower than + 15 ° C, the TDI may be completely or partially crystallized. In this case, before use, the TDI is necessarily heated until the crystals are completely dissolved and stirred by rolling the barrel. Heating temperature of TDI 80 must not be higher than + 50 ° С. Catalysts, Isostab 1800 foam stabilizer and K 46 modifier entering the compartment in canisters or barrels are kept in a warm room at a temperature of at least + 18 ° C for at least a day. 1.4.3 Preparation of component A for production of EL50/1 polyurethane foam. Preparation of component A consisting of polyester Isonol 3300, surfactant Isostab 1800, catalyst Vicat 33, modifier K 46 is carried out in a working vessel (pos. H) in the following sequence. Based on the amount of polyester Isonol 3300 pumped into the container pos. H in the following sequence: a pure container made of polyethylene or stainless steel (pos. 1), installed on the scales and with an error of ± 10 g, is poured with a calculated amount of distilled water (condensate) with a temperature not higher than + 25 ° С. It is allowed to use service water purified from impurities by passing through a filter with activated carbon (for example, of the type "Rodnichok"). The catalyst Vicat-33, surfactant IS 1800, modifier K-46 is then added thereto in the above sequence. The finished mixture is mixed for 15-20 minutes with a wooden blade. The mixture is ready for use in 10 minutes. The finished activator mixture is pumped by pump or manually through the hatch to the working tank pos. H, where polyester Isonol 3300 is already located. The resulting mixture is mixed with a mixer for 20-30 minutes. Simultaneously with stirring, the mixture is brought to an operating temperature of 20 ± 2 ° C by supplying the container with pos. Cold or hot water. After mixing, the component settles for at least 1 hour to remove excess air from the mixture. It is recommended to process the finished component A within three days from the time of preparation. 1.4.4 Catalyst preparation - tin octoate. The tin octoate catalyst is supplied in polyethylene canisters, kept in a warm room for at least a day, and then poured into the consumption tank of the foaming machine pos.6. When adding a 200 ml tin octoate catalyst from a syringe to a container, water must be avoided because the tin is hydrolyzed and loses catalytic activity. In any case, the catalyst is not subject to reprocessing. 1.4.5 Foaming of components, production of blocks. The production of elastic SGP units is carried out on a periodic machine "Blockmatic 120" of Cannon, Italy, having a mixer volume of 120 l. When pouring the units, the temperature of the room should be maintained at 20 ± 2 ° C, for stable process management. The blocks are filled in the following sequence. On the control panel of the foaming machine, the ratio of components according to the selected recipe is set. In addition, the following parameters are specified: a) the first mixing rate of component A with cat.Tin octoate is accepted 450-600 rpm b) the second mixing rate of component A with T 80 is 1000 rpm c) the first mixing time of component A with cathode. Tin octoate 4-6 s g) the second mixing time of component A with T 80, 4-6 s. A mold pre-lubricated with a separation lubricant (for example, solidol) is fed under the mixing cylinder to prevent sticking of the finished foam. According to the program specified on the panel, component A from the tank pos. The metering pump pos. (item) 2 is supplied to the consumption tank pos.8 of the foaming machine. At the same time, T80 is supplied from operating tank pos.5 by metering pump pos.4 to service tank pos.9. Component A from container pos.8 is drained into mixing cylinder pos. 10, tin octoate is fed there by means of dosing pump pos.7 from service tank pos.6, stirrer is switched on and the first mixing takes place. The T 80 is then quickly drained into the mixer from the container 9 and a second mixing takes place. The bottom of the mixer opens and the reaction mass is poured onto the bottom of the mold. Then the bottom of the mixer is closed and drained from the doser pos.8 of component A, for 2-3 s the stirrer is turned on to flush component A from the cylinder walls. The foaming reaction mass mould is shifted to the local suction zone, and the following mould is placed in its place, the operation is repeated. A cover is suspended on the foaming mass mold to give the finished block a square shape. During the production of PPU EL-50/1, the blocks are filled in the same way as PPU-35, only one is mixed: component A Isolan -EL-50/1 and B Isolan EL-50/1. After filling the last block, the mixer is washed with water supplied from the container pos. 14 mounted on a foaming machine. 1.4.6 Units maturation. After pouring, the block is kept for 3-5 minutes in the mold, the cover is removed and the side walls of the mold are opened. After 10 minutes, the block is taken out of the mould and taken to the maturation room on the trolley. The ripening chamber shall be located in a room fenced off from the foaming area by a fire-retardant partition. The blocks are installed in the chamber on the floor on the lower surface at a distance not closer than 0.3 m from each other. A 1-fold air exchange is created in the ripening chamber. During ripening, the conversion of the starting materials to non-volatile polymer products is completely completed, reactive compounds are bound and the block is cooled. SGP ripening time is not less than 24 hours at temperature of 15-20 ° С. 1.4.7 Cutting of SGP units into sheets, packing. From the ripening chamber, the blocks on the trolley are delivered to a horizontal cutting machine (pos. 13), where the blocks are cut into sheets of a given thickness. After cutting, SGP sheets are disassembled, packed in bales, bound with twine and taken to the storage place.