Part of the Complete Polyols Facility, IPP Stock #601057 which includes Propylene Oxide Plant #600894, Polyols Plant #600893 and Polyurethane Plant #601366
The Polyols Plant consists of two separate streams, each capable of producing the full range of polyols. Common raw material storages feed the two streams and each product has its own finished product storage. The capacity of the plant is 20,000 tons per year of polyols (10,000 tons per year per stream). All equipment and installations at the Polyols facility are in functional condition and were subject to regular technical examination. Licenses are transferable. The plant was closed in 2010. All installations are protected.
All of the processing equipment and piping is 304L stainless steel. This is a small, but nicely designed polyol plant with good technology (Chemetics). There are two completely independent lines; each with two reactors and a dehydration vessel followed by filters. Polyol recipes will be available with the plant.
The Polyols Plant consists of two separate streams, each capable of producing the full range of polyols. Common raw material storages feed the two streams and each product has its own finished product storage. The capacity of the plant is 20,000 tons per year of polyols (10,000 tons per year per stream).
Each production stream consists of a reaction section and a work up section. In the reaction section the condesation reaction of glycerolwit propylene oxide and ethylene oxide takes place, catalyzed by potassium hydroxide. In the work up section the catalyst is neutralized with adipic acid and the resulting potassium adipate precipitate is removed by filtration.
Metered quantities of glycerol and 50% KOH are pumped into the initiator solution vessel. The mixture is agitated and the water of reaction is removed by heating under a vacuum. This leaves the basic initiator solution. The mixture is then blown by nitrogen into reactor 1.
Propylene oxide is pumped into the propylene oxide break vessel and a preset quantity of the propylene oxide is fed at a controlled rate into reactor 1. The temperature of the reactor 1 mixture is controlled by pumping the mixture through an external heat exchanger. After the preset quantity of propylene oxide has been fed, the reaction is allowed to come to completion. The polyether is then pumped to reaction 2.
A preset quantity of propylene oxide is metered into reactor 2 at a rate which is controlled by the pressure within the vessel. Upon completion of the reaction, either:
a) the polyether is transferred to the dehydration panb) ethylene oxide from the ethylene oxide break vessel is fed to reactor 2c) propylene oxide and ethylene oxide are fed concurrently into reactor 2. They are fed under flow-ratio-controlled conditions to give the correct ratio of propylene oxide to ethylene oxide in the final product
The temperature of the polyether is automatically controlled by means of an internal cooling coil. When the oxide charge is terminated, the reaction is allowed to come to completion before transferring the polyether to the dehydration pan.
Traces of residual oxide in the polyether batch are removed under a vacuum in the dehydration pan. The polyether is then treated with an aqueous solution of adipic acid, Topanol OC and phenotiazione that is prepared in the slurry vessel. The adipic acid neutralizes the basic catalyst and produces a potassium adipate precipitate. The TopanolOC and the phenithiazine act as polyether antioxidants and as scorch inhibitors during foam manufacture. The polyether batch is then dehydrated by heating and by the application of a vacuum. The polyether batch is now ready for filtration. A precoat (filtercel) slurry is prepared in the precoat vessel. It is applied to the product filter prior to filtration. The polyether/potassium adipate slurry is then pumped from the dehydration pan through the filter. A guard filter or polishing filter prevents the breakthrough of fine material. The filtered polyether then enters the buffer product storage, where it is analyzed for quality before being pumped to either the final product storage or the bulk storage.
The solids retained in the filter occlude polyether which is recovered by the circulation of an aqueous solution of sodium sulphate. The solution is prepared in the sodium sulphate solution vessel. After displacing the residual polyether the mixed liquor is allowed to settle in the separator.
The polyether is returned to the process, via the recovered product storage, at the dehydration pan.
The product filter residues are then flushed to the effluent system by water jets that are fitted internally.
The various polyethers are pumped through product coolers to the final product storage or the bulk storage.
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