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Production of rigid foam slabstock from polyurethane or polyisocyanurate at low investment cost

Siegfried Buschkamp

Page 1 of 9 File No.: PU21020-0409 Issue 2004-09-10

Insulation
Technical Information

Production of rigid foam slabstock from polyurethane or polyisocyanurate at low investment cost
Summary
This technical information sheet describes the minimal resources and equipment required to start and run polyurethane rigid foam slabstock production, for example in developing countries.

1. General introduction
This information sheet is intended to show the minimal expenditure on buildings, equipment and personnel required for polyurethane rigid foam slabstock production. Polyurethane also includes polyisocyanurate rigid foam, as this is merely a specific variant. Slabstock manufacture by stirrer mixing offers the following advantages in addition to the low cost of investment: High-viscosity products can be mixed Formulations can easily be varied Pastes and colorants can be added

Contents
Page 1. 2. General introduction Equipment and resources required for operating a slabstock foaming plant Buildings Personnel Slabstock molds Technical equipment and apparatus Containers Accessories Raw materials Procedure Example of slab production Observations on personnel Shed plan Suppliers' addresses 2 3

Working by this method does, however, mean certain disadvantages: Increased costs through greater losses of material (residues of about 2 kg in the mixing vessel) Costs of a polyethylene bag to line the mixing vessel A considerable amount of air is taken in. This is generally beneficial as it leads to a fine cell structure due to nucleation. Increased viscosity of raw materials and/or short cream times can lead to large individual pores (entrapped air) and lower thermal insulation. Products with short reaction times are difficult to process. However, this applies only very rarely as the reaction times can usually be adjusted by varying the catalyst content.

2.1 2.2 2.3 2.4 2.5 2.6 2.7 3. 4. 5. 6. 7.

4 5 7 8 9

Page 2 of 9 File No.: PU21020-0409 Issue 2004-09-10

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2. Equipment and resources required for operating a slabstock foaming plant


2.1. 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.2 2.3 Buildings Space for production, approx. 100 - 200 m Space for storage of raw materials and foam slabstock Space for cutting and packaging equipment Extractor on mixing unit Extractor on cutting machines Extractor on production units, possibly in storage area System for keeping raw materials at temperatures as near as possible to 20 - 22 C Wash basin and eye-rinse water at workplace Personnel (see observations on personnel under Item 5) Slabstock molds (approx. 2 - 3), e.g. 1 x 1 x 0.8 m, costs of wood + 50 manhours + costs for small components

2.6 2.6.1 2.6.2 2.6.3 2.6.4 2.6.5 2.6.6 2.6.7 2.6.8 2.6.9 2.6.10 2.6.11

2.6.12 2.6.13 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5

Accessories Protective goggles Dust filters for sawing Stopwatch Rubber gloves Packaging paper for covering the floor and for making molds for control pours Staplers with staples Scissors/shears Knives Felt pens for writing on the foam Adhesive tape for sticking paper to the floor Work table approx. 1 x 1m, 80 cm high, for putting down the accessories and the measuring beakers for the foam additives (catalysts, etc.) Release agent, wax or grease and sponge Drum-cocks Raw materials Polyol with drum-cock and drum lifting truck Isocyanate with drum-cock and drum lifting truck Blowing agent Catalyst Solvents

Technical apparatus Balance, range up to 200 kg for mixing and production 2.4.2 Balance, range up to 10 kg for addition of small amounts (table balance) 2.4.3 Stirrer 2.4.3.1 Powerful hand drill (sufficient for blocks up 3 to 1/2 m with low-viscosity raw materials) 2.4.3.2 Fixed stirrer (output approx. 2 - 7 kW) 2.4.3.3 Stirrer discs 2.4.4 Drum lifting truck 2.4.5 Band-saw for trimming and cutting 2.4.6 Paper cutting device 2.5 2.5.1 2.5.2 2.5.3 2.5.4 Containers Mixing vessel (size: the vessel should be about half full when it contains the batch) PE round-bottom sacks to fit mixing vessel Plastic container for rinsing liquid Measuring beaker for weighing or measuring out additives If the density of the raw materials is taken into account, balances can often be dispensed with when using measuring beakers Rubbish bags and bins If 2.5.2 is unobtainable, 2.5.1 should be a plastic container with which it is possible to knock out the residues

2.4 2.4.1

2.5.5 2.5.6

Page 3 of 9 File No.: PU21020-0409 Issue 2004-09-10

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3. Procedure
3.1 3.2 Prepare and assemble the mold Apply release wax Place polythene bag into mixing vessel put in polyol put in blowing agent put in catalyst Premix products During the pre-mixing time, fill a separate container with isocyanate and then, with the stirrer running, pour it into the polyol and mix Carefully pour the reaction mixture into the mold Put on lid and secure with wedges Clean stirrer with solvent Remove polythene bag with residue (loss from mixing) 3.3 Mold residence time With densities over 60 kg/m , the slabstock mold should be opened soon after the fiber time, and at the latest before the rise time, so the slab can relax without cracking. Rule of thumb: Slab height in cm = 100 - density 3.4 3.5 Demolding the slab Take the demolded slab (preferably in batches of 4 blocks per hour) to an external store where they should remain for at least 5 days Cutting: About 40 s are needed for one cut through a 1 m long slab. This gives 28 cuts, each of 40 s, when cutting up a 70 cm thick slab into 30 mm sheets = Packaging: By the saw there should be a device in which the sawn sheets can be stacked. This allows simple packaging. 2 minutes
3

3 minutes 2 minutes 1/2 minute 2 - 5 minutes (depending on quantity and viscosity) 1/2 minute 1/2 minute 1 minute

1/2 minute 1/2 minute 1 minute 1/2 minute 1/2 minute 10 - 15 minutes

2 minutes

3.6

18 2/3 minutes

3.7

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4. Example of slab production


The total quantity MA of the batch is obtained from the volume V of the mold to be filled, the desired average density RD, the quantity MV of reaction mix remaining in the mixing vessel and the difference in buoyancy A between the liquid reaction mix and the finished foam (= weight of displaced air, approx. 1.2 kg/m at 20 C) and from the loss MG of blowing agent occurring during mixing and expansion of the reaction mix.

Formulation: 100 parts by weight polyol 20 parts by weight blowing agent 2 parts by weight catalyst 120 parts by weight polyisocyanate 242 parts by weight Total The individual quantities are therefore: Baymer polyol MPolyol = 57.3 x 100 = 23.68 kg 242 = 57.3 x 20 = 34.74 kg 242 = 57.3 x 2 = 0.474 kg 242

M A = V x RD + V x A + M V + MG
Blowing agent MTM The quantities MK of components are calculated as follows:
MK = Total quantity MA of parts by weight per formulation

Catalyst MDesmorapid

Parts by weight of component per formulation Here is an example: Volume of molding V = 2.05 x 1.05 x 0.7 = 1.5 m Desired average density RD = 35 kg/m Buoyancy difference A = 1.2 kg/m Quantity remaining in mixing vessel MV 2.5 kg (determined experimentally) Loss of blowing agent MG = approx. 0.5 kg (determined experimentally) From the foregoing equation, the batch quantity is: MA = 1.5 m 35 kg/m + 1.5 m 1.2 kg/m + 2.5 kg + 0.5 kg = 52.5 kg + 1.8 kg + 2.5 kg + 0.5 kg = 57. 3 kg

Polyisocyanate MDesmodur = 57.3 x 120 = 28.4 kg 242 The mold in which the foam is formed and cures can be a wooden box in the simplest case. To simplify demolding, the internal surfaces should be smooth. Release papers (for example polyethylenecoated kraft paper or soda kraft paper) may be laid or stuck in the mold prior to foaming or release agents (for example release wax) may be used. In the latter case, the mold walls may be lined with sheet metal (for example aluminum sheet) or melamine resin-coated sheets. Release agent suppliers can be found under "Suppliers' addresses". Slabs are produced as follows: The mold is set up, and a release agent is applied to the interior of the walls. The mixing vessel is balanced, and polyol, blowing agents and catalysts are poured in and mixed. The components are introduced in the following order: large quantities before small and low-viscosity products before highviscosity products. Finally, the polyisocyanate component is weighed in or a weighed quantity added. The components must be mixed thoroughly and poured into the mold within the cream time which is sometimes very short (approx. 15 to 40 s).

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Fig. 1: Front elevation of a slabstock mold

Fig. 2: Side elevations and perspective view of a slabstock mold

It is easiest to foam in open molds. The reaction mix is introduced into a mold (which is open at the top) where it expands and forms a foam slabstock. Although the pressure building up on the side walls is relatively low, it must be allowed for when designing the mold on account of the large areas. With polyurethane slabstock, pressures of 0.1 bar have been measured with a density of 35 kg/m and

about 0.15 bar with a density of 60 kg/m. Polyisocyanurate foam develops higher pressures. The build-up of pressure may be counteracted by opening the mold 5 to 15 min after foaming of the block and allowing the foam to expand freely. This is achieved by loosening the wing nuts of the screwed rods. The foam slab which now expands beyond the mold dimensions should be able to

Page 6 of 9 File No.: PU21020-0409 Issue 2004-09-10

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move unimpeded over the edge of the baseplate. If the mold is not opened after these short periods, it is necessary to wait a few hours to prevent the slab from tearing. The slab should be demolded when the pressure on the mold has become sufficiently low, and this moment should be determined experimentally. The freely rising foam forms a domed surface and its cells are oriented predominantly vertically (anisotropically). The dome formation, which may result in a considerable quantity of scrap when cut to size, may be reduced if the foam is allowed to rise with a floating lid. Once the reaction mix has distributed

itself on the bottom of the mold and the foaming process has begun, a lid is placed on top. This lid floats on the surface of the reaction mix and is forced up by the foam. The mold can also have a very simple design here, but should have smooth internal surfaces to prevent the tightly sealing lid from jamming. The rising lid may have to be guided by hand. The lid normally has a weight per unit area 2 of about 40 kg/m . A completely rectangular slab may be obtained if the lid abuts against a stop and compacts the foam slightly.

Fig. 3: Foaming against a floating lid

In some applications, the foam must have only a very slight cell orientation. This can be achieved by introducing the reaction mix into a mold which can be sealed all round and compacts the foam to a greater extent. The pressure applied to the mold is correspondingly higher. This foaming under pressure necessitates long mold residence times as the slabs might otherwise tear. After production, the slabs are left to cool for at least 3 to 5 days - usually in an open store - before sheets or shaped parts are cut from them.

slab. These points, together with the production time per slab and the quantity of raw materials that can be processed per year, are given in the table below. The figures are based on the assumption that one man can handle a batch quantity of 30 kg and two men, one of 80 kg. With larger quantities, a foaming machine is needed. At least two persons are needed to put on the floating lid if no crane is available. When a lid of this kind is used, the amount of cutting waste is reduced by about 5 % to 15 - 20 %. A lid should therefore be applied in each case. A figure of 3 - 5 % has already been included in the table for the amount of residue left in the mixing 3 vessel. An overall density of 35 kg/m was assumed.

5. Observations on personnel
The number of staff needed for the foaming process depends on the number of slabs, the size of the slab and the amount of mix to be processed per

Page 7 of 9 File No.: PU21020-0409 Issue 2004-09-10

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On a large vertical bench band-saw, one man can 3 cut up about 20 m of foam slabstock in 6 h full working time. This represents approx. 150 tonnes per year. Two foaming machine operators produce as much slab material as two men can cut up on two bench band-saws (see table). It is therefore essential to ensure proper investment in the cutting machines, i.e. considerable automation and perhaps mill saws should be provided.

6. Shed plan

Fig. 4: Slab production diagram

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7. Addresses of suppliers in Germany


7.1 Laboratory stirrer: Type LM 34 Pendraulik Maschinen und Apparate GmbH Phillipp-Reis-Str. 36 31832 Springe Tel.: 05041 / 40 61 Fax: 05041 / 50 29 7.5 Drum-cocks Will & Hahnenstein GmbH Fasstechnik, Wrmetechnik Anl. Fax: 0271 / 3 75 91 - 25 Arnsbacher Weg 5 - 9 57072 Siegen Tel.: 0271 / 3 75 91 - 0

7.2 Production stirrer Lehmann Maschinenfabrik GmbH, F. B. Daimlerstr. 12 73431 Aalen Tel.: 07361 / 5 62 - 0 Fax: 07361 / 5 62 - 60 E-Mail: sales@fblehmann.de

7.6 Balances Mettler-Toledo GmbH Ockerweg 3 35396 Gieen Fax: 0641 / 5 29 51 Tel.: 0641 / 5 07 - 0 E-Mail: mettler.toledo@mt.com

7.3 Stirrer discs: e.g. Lenart rapid stirrer Vollrath GmbH & Co., Paul Max-Planck-Str. 13 50354 Hrth Tel.: 02233 / 79 89 - 0 Fax: 02233 / 7 87 49

7.7 Release wax Acmos Chemie GmbH & Co. Industriestr. 37 + 49 28199 Bremen Tel.: 0421 / 51 89 - 0 Fax: 0421 / 51 14 15 IGEFA GmbH Bonnstr. 31 50226 Frechen Tel.: 02234 / 9 57 21 - 0 Fax: 02234 / 5 21 37 Th. Goldschmidt AG Goldschmidtstr. 100 45127 Essen Tel.: 0201 / 1 73 - 01 Fax: 0201 / 1 73 - 18 31

7.4 Round bottom polybags Nittel GmbH & Co. KG (Rau) Kelsterbacher Str. 18 65479 Raunheim Tel.: 06142 / 94 67 - 0 Polymer-Synthese-Werk GmbH Landrat-von-Laer-Str. 12 47495 Rheinberg Tel.: 02844 / 10 - 0

This information and our technical advice whether verbal, in writing or by way of trials are given in good faith but without warranty, and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify the information currently provided - especially that contained in our safety data and technical information sheets - and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery. The methods described in this publication for testing the fire performance of polyurethane and the results quoted do not permit direct conclusions to be drawn regarding every possible fire risk there may be under service conditions. Publisher: Business Development Insulation Bayer MaterialScience AG D-51368 Leverkusen www.bayermaterialscience.com

Page 9 of 9 File No.: PU21020-0409 Issue 2004-09-10

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