POLYURETHANE FOAM

[EIRI/EDPR/3762] J.C.: 1852

INTRODUCTION

Polyurethane describes several kinds of products that are characterised by

common chemistry, the reaction of an Iso cyanate with an Alchohol to make a
urathane.

RNCO + ROH......RNHCOOR.

Poly Urathanes contains carbonate groups i.e. NHCOO --- also referred to as
urethane groups in their back bone structure. They are obtained by the reaction
of a di-isocynate with a macroglycol, also called polyol,. or with a
combination of a macro glycol and a short chain glycol extender. In the latter
case, segmented block copolymer are produced. The macroglycols are based on
polyethers, polyesters, or a combination of both. a linear polyurethane polymer
has the structure as.

O O
" "
ROCNHR NHCO

Where as a linear segmented co-polymer obtained from a di-isocynates, a

macroglycol, and ethylene glycol has structure.

O O
| |
R O C N H R ' N H C O C U, C U, O C N H R N H’

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In addition to linear Urethene plastic polyurethanes obtained from difunctional
monomers, branched a cross linked Lthermoset polymers are made with higher
functional monomers linear polymers have good impact strength, good physical
properties and excellent processability, but owing to their thermoplasticity,
thermal stability is limited, thermoset polymers on the other hand, have thermal
stability but lower impact strength. Water blown flexible foams contain urethane,
urea and some biuret group in their new work structure.

Water-blown rigid foams are big considered for pour in place retrofit insulation
applications Urea modified segmented polyurethane elastomers are manufactured
from di-iso cyanates, macroglycols and diamine extenders.

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 CONTENTS

INTRODUCTION
PROPERTIES
THERMOPLASTIC POLYURETHANES.
A TYPICAL MODULUS V/S TEMPERATURE CURVE IS
USES AND APPLICATIONS
B.I.S. SPECIFICATION
RAW MATERIALS FOR POLYURETHANE
ISOCYANATES
POLYOLS
ADDITIVES
MARKET OVERVIEW OF POLYURETHANE FOAM
RENEWABLE POLYOLS FOR THE PRODUCTION OF PUFS
MARKET POSITION OF POLYURETHANE IN INDIA
OUTLOOK FOR POLYURETHANES
METHYLENE DIPHENYL DIISOCYANATE (MDI), TOLUENE DIISOCYANATE (TDI)
FORMULATIONS OF FLEXIBLE POLY URETHANE FOAM
MANUFACTURING PROCESS FOR FLEXIBLE POLY URETHANE FOAM
(SLAB STOCK PROCESS)
ASPECTS OF POLYMERIZATION PROCESS
TABLE - TYPICAL MONOMERS FOR POLYURETHANES
OTHER METHODS OF PREPARATION
SEMI PREPOLYMER METHOD
ONE SHOT PROCESS
ONE SHOT POLY FOAM FORMULATION
FLOW DIAGRAM FOR A FLEXIBLE FOAM MOULDING PLANT
PROCESSING OF POLYURETHANES (CASTING PROCESS)
THE TECHNOLOGY IS OUTLINES AS
PROCESS TECHNOLOGY OF POLYURETHANE
MANUFACTURING PROCESS OF POLYURETHANE
POLYMER REACTIONS
PROCESSING
MANUFACTURING PROCESS OF REBONDED POLYURETHANE FOAM
FORMULATION FOR CHEMICALS USED IN MIXER
PROCESS FLOW DIAGRAM FOR THE MANUFATURE OF REBONDED
POLYURETHANE FOAM
OTHER COMMERCIAL METHODS
PROCESS FOR PREPARING FLEXIBLE POLYURETHANE FOAM
EXAMPLES
EXAMPLE 1

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THE FOLLOWING POLYISOCYANATES WERE USED:
OTHER INGREDIENTS:
THE PHYSICAL PROPERTIES WERE MEASURED BY THE FOLLOWING METHOD
FLEXIBLE CELLULAR POLYURETHANE FOAM COMPOSITIONS HAVING
INCREASED FLAME RETARDANCE
EXAMPLES I-XV
EXAMPLES XVI-XXII
PROCESS FOR PRODUCING ANTIBACTERIAL FLEXIBLE POLYURETHANE FOAM
EXAMPLES 1 AND COMPARATIVE EXAMPLES 1
EXAMPLE 3 AND COMPARATIVE EXAMPLE 2
PREPARATION EXAMPLE OF THE ANTIBACTERIAL AGENT
POLYOL FORMULATION FOR PRODUCING LATEX-LIKE FLEXIBLE
POLYURETHANE FOAM
EXAMPLE
COMBUSTION-MODIFIED FLEXIBLE POLYURETHANE FOAMS
EXAMPLES 1-2
COMPARATIVE EXAMPLES 1-4, EXAMPLES 3-14
RECYCLING OF FLEXIBLE POLYURETHANE FOAM SCRAP
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
EXAMPLE 5
COMPARATIVE EXAMPLE A
EXAMPLE 6
COMPARATIVE EXAMPLE B
EXAMPLE 7
EXAMPLE 8
COMPARATIVE EXAMPLE C
FLAME RETARDANT, CHAR-FORMING, FLEXIBLE POLYURETHANE FOAMS
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
EXAMPLE 5
EXAMPLE 6
EXAMPLE 7
EXAMPLE 8
FLEXIBLE POLYURETHANE FOAM AND PROCESS FOR ITS PRODUCTION
HIGH MOLECULAR WEIGHT POLYOXYALKYLENE POLYOL (A)
POLYOXYALKYLENE POLYOL (P)
ORGANIC POLYISOCYANATE COMPOUND (B)
BLOWING AGENT (C)
CATALYST (D)
OTHERS
AIR FLOWABILITY

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CHARACTERISTICS
MOLDING METHOD
EXAMPLES
EXAMPLES 1 TO 11
INDUSTRIAL APPLICABILITY
PLANT LAYOUT
COMPLETE PLANT SUPPLIERS FOR PU FOAM
FOAM REBONDING MACHINE
CONSULTANCY OF PU FOAM MACHINES
WELCOME TO CONSULTANCY OF PU FOAM & MACHINES
OTHER EQUIPOMENTS
BUCKET ELEVATOR
EFFLUENT TREATMENT PLANT
BOILER
SUPPLIERS OF RAW MATERIALS
POLYOL
SILICON COMPOUNDS
METHYLENE CHLORIDE
STANNOUS OCTATE

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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 COST ESTIMATION

Plant Capacity 5 Ton/Day

Land & Building (3 Acres) Rs. 7.62 Cr
Plant & Machinery Rs. 13.66 Cr
Working Capital for 2 Months Rs. 4.01 Cr
Total Capital Investment Rs. 26.29 Cr
Rate of Return 23%
Break Even Point 55%

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