Detailed Project Report (DPR) on poly urethane foam

POLYURETHANE FOAM
[code no 3762]


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
     "          "
R O C N H R   N H C O

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’


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.

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%                

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    
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    
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)