Detailed Project Report on polyol used for polyurethanes

POLYOL USED FOR POLYURETHANES

[EIRI/EDPR/1027] J.C. 9668

INTRODUCTION

Polyols are higher molecular weight materials manufactured from an initiator and monomeric building blocks. They are most easily classified as polyether polyols, which are made by the reaction of epoxides (oxiranes) with active hydrogen containing starter compounds, or polyester polyols, which are made by the polycondensation of multifunctional carboxylic acids and hydroxyl compounds. They can be further classified according to their end use as flexible or rigid polyols, depending on the functionality of the initiator and their molecular weight. Taking into account functionality, flexible polyols have molecular weights from 2,000 to 10,000 (OH# from 18 to 56). Rigid polyols have molecular weights from 250 to 700 (OH# from 300 to 700). Polyols with molecular weights from 700 to 2,000 (OH# 60 to 280) are used to add stiffness or flexibility to base systems, as well as increase solubility of low molecular weight glycols in high molecular weight polyols.

Polyether polyols come in a wide variety of grades based on their end use, but are all constructed in a similar manner. Polyols for flexible applications use low functionality initiators such as dipropylene glycol (f=2), glycerine (f=3) or a sorbitol/water solution (f=2.75). Polyols for rigid applications use high functionality initiators such sucrose (f=8), sorbitol (f=6), toluenediamine (f=4), and Mannich bases (f=4). Propylene oxide is then added to the initiators until the desired molecular weight is achieved. Polyols extended with propylene oxide are terminated with secondary hydroxyl groups. In order to change the compatibility, rheological properties, and reactivity of a polyol, ethylene oxide is used as a co-reactant to create random or mixed block heteropolymers. Polyols capped with ethylene oxide contain a high percentage of primary hydroxyl groups, which are more reactive than secondary hydroxyl groups. Because of their high viscosity (470 OH# sucrose polyol, 33 Pa•s at 25 °C), carbohydrate initiated polyols often use glycerine or diethylene glycol as a co-initiate in order to lower the viscosity to ease handling and processing (490 OH# sucrose-glycerine polyol, 5.5 Pa•s at 25°C).

COST ESTIMATION

Plant Capacity            20 MT/Day  

Land & Building (10,000 sq.mt.)    Rs. 5.27 Cr    

Plant & Machinery                    Rs. 2.76 Cr 

Working Capital for 3 Months    Rs. 10.97 Cr 

Total Capital Investment          Rs. 19.19 Cr 

Rate of Return                          82%

Break Even Point                      20%

CONTENTS

INTRODUCTION

HOW ARE POLYOLS MANUFACTURED?

VORANOL

APPLICATION:

MARKET SURVEY

PRODUCTION CAPACITY IN THE WORLD

MANALI PETROCHEM NET ZOOMS; SKIPS DIVIDEND

NEW PZN CATALYST TO IMPROVE PPG PRODUCTIVITY

MANUFACTURERS/SUPPLIERS OF POLYOLS

METHOD FOR PREPARING POLYETHER POLYOLS

METHOD

2- POLYOL POLYETHER PREPARATION PROCESS

METHOD

3- POLYETHER POLYOLS

METHOD 1

METHOD 2

METHOD 3

METHOD 4

4- SUCROSE BASED POLYETHER POLYOLS

METHOD 1

THE PRODUCT HAD THE FOLLOWING PROPERTIES:

EXAMPLE 2

5- PHOSPHOROUS-CONTAINING POLYETHER POLYOLS

MOST PREFERRED RANGES ARE:

METHOD 1

THE POLYMERS PREPARED CORRESPONDED TO THE FORMULA:

EXAMPLE 2

THE POLYMER THUS PREPARED CORRESPONDED TO THE FORMULA: ##STR5##

METHOD 3

METHOD 4

PHOSPHORUS ACID

THE POLYMER THUS PREPARED CORRESPONDED TO THE FORMULA: ##STR6##

METHOD 5

PHENYL PHOSPHONIC ACID

THE POLYMER THUS PREPARED CORRESPONDED TO THE FORMULA:

METHOD 3

METHOD 4

PHOSPHORUS ACID

THE POLYMER THUS PREPARED CORRESPONDED TO THE FORMULA: ##STR6##

METHOD 5

PHENYL PHOSPHONIC ACID

THE POLYMER THUS PREPARED CORRESPONDED TO THE FORMULA:

METHOD 6

TRICHLOROMETHYLPHOSPHONIC ACID

THE POLYMER THUS FORMED CORRESPONDED TO THE FORMULA: ##STR8##

METHOD 7

PHOSPHORUS PENTOXIDE DERIVATIVES

THE POLYMERS THUS FORMED CORRESPONDED TO THE FOLLOWING FORMULAS:

METHOD 8

THE POLYMER THUS FORMED WAS OF THE FORMULA: ##STR10##

METHOD 9

THE POLYMER THUS FORMED WAS OF THE FORMULA:

6- POLYETHER POLYOL COMPOSITION

COMPOSITE METAL CYANIDE COMPLEX CATALYST

COMPOSITE METAL CYANIDE COMPLEX CATALYST

POLYETHER POLYOL

PHOSPHORIC ACID COMPOUND

FURTHER, POLYPHOSPHORIC ACID IS REPRESENTED BY THE FOLLOWING FORMULA (2):

FURTHER, POLYMETAPHOSPHORIC ACID IS REPRESENTED BY THE FORMULA (3):

USES

REFERENCE METHOD 1

REFERENCE METHOD 2

METHOD A1

7- HIGH PURITY POLYETHER POLYOLS

GENERAL PROCEDURE

METHOD 1

METHOD 2

METHOD 3

METHOD 4

METHOD 5

CONTROLS 1-3

CONTROL 4

CONTROL 5

8- PREPARING POLYETHER POLYOLS WITH DMC CATALYSTS

1. STRUCTURE OF STARTER

FIGURE 1

2. IMPURITIES IN THE STARTER AND MOLES PO/MOLES STARTER IN THE INITIATOR FEED (SEE TABLES 2-5)

3. CATALYST LEVEL/CATALYST TYPE

METHOD 1

PRELIMINARY SCREENING EXPERIMENTS

METHOD 2

STERIS EFFECTS OF THE STARTER ON DMC CATALYST INITIATION

METHOD 3

CONVENTIONAL POLYOL INITIATORS

METHOD 4

EFFECT OF PO/STARTER RATIO AND IMPURITIES ON PO INITIATION RATE

METHOD 5

EFFECT OF IMPURITIES ON PO STARTER INITIATION

METHOD 6

DMC CATALYST COMPARISON

METHOD 7

SINGLE REACTOR BATCH PROCESS FOR TMP (SEE TABLE 6)

METHOD 8

SINGLE REACTOR BATCH PROCESS FOR CHDM (SEE TABLE 6)

9- POLYETHER POLYOLS WITH INCREASED FUNCTIONALITY

10- PROCESS FOR THE REMOVAL OF CATALYSTS FOR POLYETHER POLYOLS

METHOD 1

METHOD 2

METHOD 3

METHOD 4

11- PREPARATION OF LOW VISCOSITY POLYETHER POLYOLS

METHODS 1-3

METHODS 4-6

METHODS 7-10

METHODS 11-13

12- PROCESS FOR PREPARING POLYETHER POLYOLS

METHOD 1

(LONG SIDE HEADING)

METHOD 2 (COMPARISON)

METHOD 3 (COMPARISON)

METHOD 4

METHOD 5

13- PROCESS FOR THE PREPARATION OF POLYETHER POLYOLS

METHOD 1

PREPARATION OF UNNEUTRALISED POLYETHER POLYOL

METHOD 2

NEUTRALISATION

METHOD 3

METHOD 4

COMPARATIVE METHODS A AND B

14- PRODUCTION OF POLYETHER POLYOL COMPOSITIONS

METHOD I

METHOD II

METHOD III

METHODS IV--VI

TABLES VII-VIII

METHODS IX-X

METHODS XI-XII

METHODS XIII-XVIII

METHOD XIX

PLANT LAYOUT

SUPPLIERS OF POLYOLS

SUPPLIERS OF PLANT AND MACHINERY

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)