我国无氟高压发泡模塑生产设备的研发现状

我国聚氨酯无氟高压发泡模塑生产成套设备摘要：介绍了目前我国采用环戊烷和二氧化碳作发泡剂替代CFC-11的聚氨酯泡沫发泡新工艺路线，以及对应于这两种新工艺路线，武汉轻工业机械厂所开发研制出的两大类成套设备的用途及构成要点。关键词：发泡设备；聚氨酯泡沫塑料；模塑；无氟；预混为了加快履行联合国《关于消耗臭氧层物质的蒙特利尔协定书》的义务，根据我国编制并修订的《中国消耗臭氧层物质逐步淘汰国家方案》的精神，聚氨酯泡沫行业2010年前要实现CFC-11零消费。据此，我们采用对大气臭氧层无任何损害的环戊烷和二氧化碳作为聚氨酯硬泡和软泡的发泡剂，以替代CFC-11，且按新的工艺路线，经消化吸收并改进创新世界上先进的技术，研制了分别使用两种新发泡剂的聚氨酯无氟高压发泡模塑生产成套设备。1聚氨酯无氟(环戊烷)高压发泡模塑生产成套设备环戊烷的物理性质及与CFC-11的比较如表1[1]。表1环戊烷的物理性质及与CFC-11的比较发泡剂分子式相对分子质量密度g/cm3沸点℃气相热导率mW/(m•K)蒸汽压kPa爆炸极限(v/v)%臭氧消耗潜值(ODP值)环戊烷C5H10700.744912.0341.4～8.00CFC-11CCl3F137.41.49248.5－无1.0注：密度为20℃数据，气相热导率为25℃数据，蒸汽压为20℃数据。根据环戊烷的物理性质，使用环戊烷作聚氨酯硬泡发泡剂的优点为：对大气臭氧层无破坏作用，环保性能较好；价廉，资源丰富；室温下为液态；因分子量低，同密度的泡沫所需发泡剂用量比CFC-11小。缺点是：易燃、易爆，设备费用高；气相热导率较CFC-11高，因而泡沫绝热性相对差些。目前国内海尔、科龙、新飞、长岭等厂家已大批使用环戊烷作冰箱、冷柜绝热层硬泡的发泡剂。使用环戊烷作发泡剂的生产工艺路线如下：[2]根据环戊烷特性和工艺路线，我们研制了聚氨酯无氟（环戊烷）高压发泡模塑生产成套设备。在设备研制时特别注重防爆安全措施的研发，确保安全生产。聚氨酯无氟（环戊烷）高压发泡模塑生产成套设备由环戊烷/多元醇预混系统、聚氨酯无氟（环戊烷）高压发泡机和聚氨酯无氟发泡模塑生产线组成。各组成部分的构成描述如下：1.1环戊烷/多元醇预混系统[2]根据环戊烷的特性，新开发的环戊烷/多元醇预混系统的环戊烷贮料罐，须防止外力的撞击，周围应无火花，如果地面条件不能满足安全要求，或外界气温可能低于0℃，则贮料罐宜置于地下。环戊烷/多元醇预混系统见图1。图1环戊烷预混系统工艺流程图环戊烷和多元醇分别采用二套高精度、中低压的计量泵计量，以保证混合配比的精度。采用混合能力高、低热量产生、防静电的静态混合器，对环戊烷与多元醇进行混合，使环戊烷均匀地溶入多元醇，提高泡沫质量。形成的混合料贮存于由氮气保压的多元醇/环戊烷料罐，以供发泡机使用。环戊烷/多元醇预混系统的安全配置为：环戊烷的计量泵防爆；所有可能接触环戊烷及其气体的装置防静电火花；电机、电器元件均选用防爆等级；且相应管道、接头及阀双层密封，管道上配置电控截止阀；装有环戊烷及其混合料的容器均输入氮气保压，料罐搅拌电机与搅拌轴的连接采用磁性连轴节；在环戊烷贮料罐、计量、混合及混合料罐等区域均配置隔板或护罩，并设有检测探头、抽风系统及防爆控制系统。该防爆控制系统的电源与设备电源分开，并分三级进行防爆控制：第一级为正常工作时控制风机低速抽风，换气量约为每小时换气10次；[2]第二级为当检测传感器检测到环戊烷浓度达到爆炸下限的20%时，[2]控制风机高速抽风；第三级为当检测传感器检测到环戊烷浓度达到爆炸下限的40%时，[2]则切断设备电源，关闭环戊烷进料阀，并使风机高速抽风，使环戊烷的释放浓度被控制在安全值以下。1.2聚氨酯无氟(环戊烷)高压发泡机环戊烷/多元醇混合料的料罐由氮气保压，其搅拌轴与搅拌电机的连接采用磁性连轴节，电机为防爆电机，且料罐用隔离罩分隔，并配有检测探头、抽风系统及防爆三级控制系统；混合料计量泵电机为防爆电机，计量泵及电机也用隔离罩分隔，并配有检测探头、抽风系统及防爆三级控制系统；异氰酸酯料罐和计量泵不必防爆；根据环戊烷释放速度和释放量，可选用可充氮气的混合头，使注射前可向模腔充氮，且注射时使混合料与异氰酸酯进行高速碰撞混合。所有接触混合料的装置须防静电火花并接地。聚氨酯无氟（环戊烷）高压发泡机示意图见图2。图2聚氨酯环戊烷高压发泡机简图1.3聚氨酯无氟(环戊烷)发泡模塑生产线该聚氨酯无氟（环戊烷）发泡模塑生产线按形式可分为直线式、水平环行式和垂直环行式。各种形式生产线均根据原料加工工艺情况、运行速度及产量决定生产线工位数。直线式聚氨酯无氟（环戊烷）发泡模塑生产线直线式聚氨酯无氟（环戊烷）发泡模塑生产线示意图见图3。图3直线式聚氨酯环戊烷发泡模塑生产线简图该生产线用于冰箱箱体隔热层的发泡生产。采用固定模架结构，模具与模架设计为一体；混合头和冰箱分别由小车带动，在模架、烘箱和下线升降台之间自动识别运动。生产线全自动完成冰箱体的预热、上模架、浇注、固化及下线等任务。浇注、固化区的安全要求为：模板、模芯由水加热或热风加热；模架上所有可能接触释放出的环戊烷的电机、电器元件均须选用防爆等级或选用增安型加浇注后停电来防爆。停电时间依发泡时环戊烷气体的释放曲线（见图4）可选为1min；机械运动件均须防静电火花，机械构件均接地；将模架区进行隔离，并设置检测探头、抽风系统及防爆三级控制系统。水平环行式聚氨酯无氟（环戊烷）发泡模塑生产线该生产线用于冰箱箱体隔热层的发泡生产。采用模架小车装载模具；链传动使载模小车作水平环状间歇移动；除操作工位（上、下箱体、清理、开、闭、锁模、浇注及抽风）外，其余工位均被罩在半环行固化烘箱内，烘箱采用热风循环加、保温。浇注、固化区的安全要求为：所有电机、电器元件均采用防爆等级；机械运动件均须防静电火花，机械构件均接地；烘箱上热风循环风机及其电机须防爆；根据环戊烷在发泡时的释放曲线（见图4），在浇注工位及浇注后1min内模具运行区间的上、下方区域，设置抽风装置，并在烘箱内及浇注处设置检测探头及防爆三级控制系统。水平环行式聚氨酯无氟(环戊烷)发泡模塑生产线示意图见图5。图4冰箱腔发泡时环戊烷气体释放图图5水平环行式聚氨酯无氟(环戊烷)发泡模塑生产线简图垂直环行式聚氨酯无氟（环戊烷）发泡模塑生产线（见图6）。该生产线用于冰箱箱门隔热层的发泡生产。采用模架小车装载模具；链传动使载模小车作垂直环状间歇移动；除操作工位（上、下箱门、清理、开、闭、锁模、浇注及抽风）外，其余工位均被罩在矩形固化烘箱内，烘箱采用热风循环加、保温；开、合模采用气、液压控制机械手。浇注、固化区的安全要求同上述水平环行式无氟发泡模塑生产线。垂直环行式聚氨酯无氟（环戊烷）发泡模塑生产线示意图见图6。图6垂直环行式聚氨酯无氟发泡模塑生产线简图2聚氨酯无氟(二氧化碳)高压发泡模塑生产成套设备二氧化碳的主要物理性质见表2[1,3]。表2二氧化碳的主要物理性质发泡剂分子式气相热导率(25℃)mW/(m•K)临界温度/℃临界压力/MPaODP值二氧化碳CO216.3317.360温度及压力对二氧化碳密度的影响见图7[3]。1－10℃，2－20℃，3－30℃，4－40℃，5－50℃，6－60℃图7CO2密度随温度压力变化图二氧化碳作发泡剂的优点为：二氧化碳价廉，降低发泡成本；改善混合质量，减少成型重量，改善泡沫特性；二氧化碳不可燃、环保，有丰富的自然资源。该发泡剂在国内正开始使用。使用二氧化碳作发泡剂的加工方法有“批量”和“在线”两种，则工艺路线相应有以下两条[3]。2.1“批量”加工方法的工艺路线“批量”加工方法的工艺路线如下：

“批量”加工方式各批次二氧化碳与多元醇或异氰酸酯的溶解比可不同。2.2“在线”加工方法的工艺路线“在线”加工方法的工艺路线框图如下：“在线”加工方法允许每次浇注时二氧化碳的量可以不同，该方法适于连续生产。由表2及图7可知，液态二氧化碳只存在于31℃以下、压力7.36MPa以上，且温度及压力对二氧化碳的密度影响很大，所以研制的设备充分考虑温度与压力对二氧化碳计量精度的影响。根据以上所述特征，我们研发了聚氨酯无氟（二氧化碳）高压发泡模塑生产成套设备。由于“在线”加工方法适于连续生产，以下主要介绍与“批量”加工方法工艺路线相适应的聚氨酯无氟（二氧化碳）高压发泡模塑生产成套设备。聚氨酯无氟（二氧化碳）高压发泡模塑生产成套设备由二氧化碳预混系统、聚氨酯无氟（二氧化碳）高压发泡机、聚氨酯无氟（二氧化碳）发泡模塑生产线组成。各组成部分的构成如下：（1）二氧化碳预混系统[3]某一组分经高精度、中低压的计量泵计量进入静态混合器，并进入预混料罐循环；同时，气态二氧化碳经恒质量流量的计量单元被注入组分中。由于采用恒质量流量，所以二氧化碳的计量精度高，与温度、压力的变化无关。二氧化碳注入时间取决于预混料罐的容积、二氧化碳与组分的溶解比及二氧化碳的质量流量。静态混合器能使二氧化碳均匀地溶解在组分中，而不是粗略地混合。这不仅节约二氧化碳的耗量，还防止泡沫产生洞穴，改善模塑质量。当二氧化碳按设定比例均匀地溶解于组分原料中后，预混料罐加料阀被控制打开，将混合完毕的二氧化碳/组分的混合料送入无氟（二氧化碳）高压发泡机的料罐。二氧化碳预混系统示意图见图8。

图8二氧化碳预混系统工艺流程图（2）聚氨酯无氟（二氧化碳）高压发泡机构成与有氟高压发泡机相似（略）。（3）聚氨酯无氟（二氧化碳）发泡模塑生产线该聚氨酯无氟（二氧化碳）发泡模塑生产线按形式可分为转台式和水平环行式。转台式聚氨酯无氟（二氧化碳）发泡模塑生产线(见图9)和水平环行式聚氨酯无氟（二氧化碳）发泡模塑生产线（见图10）均根据原料加工工艺情况、运行速度及产量决定生产线工位数。两种形式生产线均可用于聚氨酯高回弹汽车坐垫、靠垫及头枕、摩托车坐垫等的冷熟化发泡生产。转台式需要的动力配置小，节约能源；管道固定安装，不易损坏；运行成本低；适于大批量同品种生产。水平环行式方便换模具，适于小批量多品种生产。图9转台式聚氨酯无氟(二氧化碳)发泡模塑生产线转台、水平环形式发泡生产线均由电机驱动，按工艺需要间歇或连续运转，其上配备水、电、气、液源，安装在转台和输送车上的模架可自动进行气、液自控的开、合、锁模的动作，根据工艺需要配备单、双、多混合头，并配置机械手带动混合头进行自动识别模具的浇注。3结束语以上两大类成套设备均采用计算机技术控制，如：网络技术、逻辑控制技术等。采用人机界面进行数据的输入和监控，并根据用户需要可配制远程监控装置。还应用了最新的变频计量、传动及伺服技术。对温度、压力、气体浓度、速度、位置、工位识别、安全保护等均采用了多种传感技术来检测，使设备的性能和使用效果得到提高，成为具有国际先进水平的机电一体化产品。图10水平环行式聚氨酯无氟(二氧化碳)发泡模塑生产线聚氨酯无氟（环戊烷）高压发泡模塑生产成套设备和聚氨酯无氟（二氧化碳）高压发泡模塑生产成套设备先后有多套或部分在海尔、新飞、科龙和澳柯玛等厂家投入使用，且性能稳定、可靠，得到了用户的好评，其技术水平达到世界先进水平。随着世界科学技术的不断发展，将研制出更新、更好、更安全、更经济且环保的发泡剂及生产工艺，我们也将开发出更完美的生产设备，为人类创造财富、保护生存环境而作出更大的贡献！参考文献1国家环保总局对外经济合作领导小组办公室、联合国工业发展组织、北京华塑贸易公司.聚氨酯硬泡CFC-11替代技术手册.2002年8月.352ElastogranGmbH.ProcessingofCyclo-pentaneintheRefrigeratorIndustry3ElastogranGmbH.CO2-loadingofPUR-systems;ProcessingAlternatives(On-LineandBatch-Process).1997TheCompleteRIMEquipmentsforPUHighPressureCFC-freeFoamingProcessinChinaZengHongQiuHongli(WuhanLightIndustryMachineryWorks,ChinaLightIndustryMachineryCompany,HubeiWuhan430034)Abstract:ThenewtechnicalprocessesofcyclopentaneandcarbondioxideblownpolyurethanefoamsystemforthereplacementofCFC-11blowingagentinChinaareintroduced.WuhanLightIndustryMachineryWorksmakestwoseriescompletesetsofequipmentrelatedtothetwoblowingsystems.Theusageandstructurefeaturesoftheequipmentareintroduced.Keywords:foamingequipment;polyurethanefoam;RIM;CFC-free;premixing作者简介：曾红高级工程师，华南理工大学化工机械系轻工机械专业毕业，现任武汉轻工业机械厂副总工程师兼技术部部长，长期从事聚氨酯发泡成套设备的研发，主持开发的产品曾获国家级新产品和省级科技进步奖。

TheCompleteRIMEquipmentsforPUHighPressureCFC-freeFoamingProcessinChinaZengHong,QiuHongli(WuhanLight-industryMachineManufactoryofChinaLight-industryMachineCorporation,430034)Abstract:ThispaperdescribestwonewprocessroutesinwhichcyclopentaneandcarbondioxideareusedasfoamingagenttoreplaceCFC-11inChinaaswellastheuseandstructuralessentialsoftwotypesofcompleteequipmentsresearchedanddevelopedaccordingtothenewprocessroutes.Keywords:RIM,CFC-free,premixing,polyol,isocynate,staticmixer,batch,onlineInordertoacceleratefulfillmentofobligationsofMontrealMemorandumofAgreementaboutMaterialsConsumingOzonosphere,accordingtoNationalSchemeofgraduallyEliminatingMaterialsConsumingOzonosphereinChina,foamingpolyurethaneindustryshallrealizezeroconsumptionofCFC-11before2010.Accordinglycyclopentaneandcarbondioxidethatdon’tdamageozonosphereatallareusedasthefoamingagentofhardandsoftfoamingpolyurethanetoreplaceCFC-11.Inaddition,accordingtonewoperateprocess,throughdigesting,absorbing,improvingandinnovatingtheadvancedtechnologyintheworld,developtwotypesofcompleteRIMequipmentsforpolyurethanehighpressureCFC-freefoamingprocessthatseparatelyusebothfoamingagents.I.PhysicalpropertyofCFC-free(cyclopentane)usedbycompleteRIMequipmentsforpolyurethanehighpressureCFC-freefoamingprocessandcomparisonofthemandCFC-11areshownasTable1.[1]Table1.PhysicalpropertyofcyclopentaneandcomparisonofthemandCFC-11FoamingagentMolecularformulaRelativemolecularmassDensity(20℃)g/cm3Boilingpoint℃Gasheatconductivity(25℃)mW/(m•K)Steampressure(20℃)kPaExplosivelimitv%(DOPvalueCyclopentaneC5H10700.744912.0341.4-8.00CFC-11CCl3F137.41.49248.5None1.0Accordingtophysicalpropertyofcyclopentane,theadvantagesofusingcyclopentaneasthefoamingagentofhardfoamingpolyurethaneareasfollows:Don’tdamageozonospherewithgoodenvironmentalprotectionperformance,cheapandabundantresource;itisliquidintheroomtemperature;comparedwithCFC-11whosedensityissameasfoamingmaterial,foamingagentusedforcyclopentaneislessbecauseitsmolecularweightislight.Itsshortagesare:Inflammable,easytoblast,equipmentcostishigh;itsgas-phaseheatconductivityishigherthanthatofCFC-11,thustheinsulationperformanceofthefoamsispoorer.Atpresent,manufacturerssuchasHaier,Kelon,XinfeiandChanglingareusingcyclopentaneinthegreatbatchesasthefoamingagentofthehardformingmaterialsintheinsulationlayeroftherefrigeratorsandice-box.Productionprocessrouteusingcyclopentaneasthefoamingagentisasfollows:[2]Accordingtothecharacteristicsofcyclopentaneandtheprocessroute,wedevelopcompleteRIMequipmentsforpolyurethanehighpressureCFC-freefoamingprocess.Indevelopingtheequipment,payspecialattentiontodevelopingthesafetymeasuresofexplosionprotectiontoguaranteethesafeproduction.ThecompleteRIMequipmentsforpolyurethanehighpressureCFC-free(cyclopentane)foamingprocessconsistsofcyclopentane/polyolpremixingsystem,highpressurepolyurethaneCFC-free(cyclopentane)foamingmachineandpolyurethaneCFC-freeRIMfoamingproductionline.Descriptionofthestructuresofallunitsisasfollows:1.Cyclopentane/polyolpremixingsystem(showninFig.1):[2]Accordingtothecharacteristicsofcyclopentane,newlydevelopthecyclopentanestorage-tankofcyclopentane/polyolpremixingsystem,whichshallbeplacedundergroundiftheconditionsofthegroundcan’tmeetthesafetyrequirementortheambienttemperaturemaybebelow0℃,becausethattankmustbepreventedfromimpactingofexternalforcewithoutsparkaroundit.Fig.1ProcessflowdiagramcyclopentanepremixingsystemSafetyconfigurationsofCyclopentane/polyolpremixingsystemare：Cyclopentanemeteringpumpmusthaveflameprooffunction;alldevicesthatmaycontactcyclopentaneoritsgasshallbeabletopreventthestaticsparks;motorsandelectricelementsshallconformtothecorrespondingflameproofcategory;correspondingpipes,adaptorsandvalvesshallbesealedtightlywithbi-layerpacking,pipesshallbeequippedwiththeelectric-operatedcut-offvalves;thecontainersfillingwithcyclopentaneanditsmixturesshallbefilledwithnitrogentomaintainpressure;mixingmotorofthematerialtanksandmixingshaftsareconnectedwithmagneticcouplings;theareasofthecyclopentanetank,metering,mixingandmixturetankareallequippedwithbafflesorprotectioncoversandinstalledthedetectionsensors,exhaustingsystemandflameproofcontrolsystem.Thepoweroftheflameproofcontrolsystemisseparatedfromtheequipmentpowerandtheflameproofcontrolisperformedinthreestages:Thefirststageistocontrolthefansforairdraftingduringthenormaloperation,airexchangingflowrateinwhichis10times/second;[2]thesecondstageistocontrolthefansforairdraftinginhighspeedwhenthedetectionsensorsfindsthatcyclopentaneconcentrationreaches20%ofthebottomlimitofblasting;thethirdstageisto[2]disconnecttheequipmentpower,shutthefeedingvalveandcontrolthefansforairdraftinginhighspeedwhenthedetectionsensorsfindsthatcyclopentaneconcentrationreaches40%ofthebottomlimitofblastingtomakethedischargingcontentofcyclopentanetobecontrolledbelowthesafetyvalue.Thematerialtankofcyclopentane/polyolmixtureisfilledwithnitrogentomaintainpressure;mixingmotorandmixingshaftsofwhichareconnectedwithmagneticcouplings,themotoristheflameproofmotor;thetankiscompartedwiththepartitioncoverswiththedetectionsensors,exhaustingsystemandflameproofthree-stagecontrolsystem;themotormixturemeteringpumpistheflameproofmotor,motorandmeteringpumparecompartedwiththepartitioncoverswiththedetectionsensors,exhaustingsystemandflameproofthree-stagecontrolsystem;isocynatetankanditsmeteringpumpneedn’ttakeflameproofmeasures;accordingtoreleasingspedandquantityofcyclopentane,themixingheadthatcanbeforfillingnitrogenisusedsothatthemoldingchamberisfilledwithnitrogenbeforeinjectingandmixtureandisocynateimpactandmixinhigh-speedduringinjecting.Alldevicescontactingmaturesmustpreventthesparkscausedbystaticelectricityandbegrounded.Fig.2Schematicdiagramofp3.PolyurethaneCFC-freeRIMfoamingproductionlineThisproductionlinecanbedividedintolineartype,horizontalcyclingtypeandverticalcyclingtypeaccordingtoitslayoutforms.Thestationsofeachlinearedecidedaccordingtotheprocessingtechnologyoftherawmaterials,runningspeedandtheoutput.Thisproductionlineissuitableforfoamingandproducingoftheinsulationlayerofthecasingbody,whichadoptsthefixedmouldholderstructure.Themouldandholderaredesignedintoawhole.Themixingheadandtherefrigerator,drivenseparatelywiththetrolley,automaticallyidentifiesandmovesamongtheholder,theovenandtheliftingtableforunloading.Thelineautomaticallyperformsworksuchaspreheatingofcasingbody,loadingitontheholder,pouring,casingandunloading.Safetyrequirementsofpouringoradoptsafety-strengtheningtypeoneswithswitchingoffposerafterpouring.Accordingtocyclopentanegasreleasingcurve(showninFig.4),timeofswitchingoffpowercanlastoneminute.Mechanicalmovementpartsmustpreventthesparksduetostaticelectricityandmechanicalcomponentsareallgrounded.Theholderareaisseparatedandthedetectionsensors,exhaustingsystemandflameproofthree-stagecontrolsystemisinstalled.Fig.4Cyclopentanegasreleasingdiagramwhencasingbodyisfoamedb.Horizontalcycling(showninFig.5)Fig.5SchematicdiagramofThisproductionlineissuitableforfoamingandproducingoftheinsulationlayerofthecasingbodyandtheholderisplacedontheholdertrolley.Mould:Theholdertrolleymovesalongthehorizontalcyclerailunderactionofchaindrivedevice.Besidesoperationstations(loadingandunloadingthecasingbody,clearing,openingmould,shuttingmould,lockingmould,pouringandairdrafting,etc.),otherstationsarearrangedinthesemi-cyclingcuringoven,whichisheatedandmaintainedtemperaturewithcirculatinghotair.SafetyrequirementsofpouringMechanicalmovementpartsmustpreventthesparksduetostaticelectricityandmechanicalcomponentsareallgrounded.Thefansforhotaircirculatingintheovenanditsmotormustbetakentheflameproofmeasures.Accordingtocyclopentanegasreleasingcurve(showninFig.4)duringfoaming,installthedraftfansatthepouringstationaswellasthelowerandupperareasofmouldmovementsectionwithinoneminuteafterpouring,andsetupthedetectionsensorsandflameproofthree-stagecontrolsystem.c.Verticalcycling(showninFig.6)Fig.6SchematicdiagramofThisproductionlineissuitableforfoamingandproducingoftheinsulationlayerofthecasingbodyandtheholderisplacedontheholdertrolley.Besidesoperationstations(loadingandunloadingthecasingbody,clearing,openingmould,shuttingmould,lockingmould,pouringandairdrafting,etc.),otherstationsarearrangedintherectangularcuringoven,whichisheatedandmaintainedtemperaturewithcirculatinghotair.Themouldisopenedandshutwiththepneumatic-hydraulic-operatedrobot.SafetyrequirementsofpouringaresameasthoseofhorizontalcyclingII.CompleteRIMequipmentsforpolyurethanehighpressureCFC-freefoamingprocessMainphysicalpropertiesofcarbondioxideareshownintable2.[3,1]Table2MainphysicalpropertiesofcarbondioxideFoamingagentMolecularformulaGas-phaseheatconductivity(25℃)mW/(m•K)CriticalTemperature℃CriticalpressureMPaODPvalueCarbondioxideCO216.3317.360InfluenceoftemperatureandpressureonthedensityofcarbondioxideisshowninFig.7.[3]Fig.7DiagramofCO2densityvaryingwithtemperatureandpressureTheadvantagesofcarbondioxideasfoamingagent:Carbondioxideischeaptodecreasethefoamingcost;mixingqualityandfoamperformancesareimproved,theweightofthefinishedcasingbodyisincreased;carbondioxideisnonflammablewithaplentyofnaturalsource,whichisofenvironmentalprotection.SuckafoamingagentisstartingtobeusedinChina.Processingmethodsofusingcarbondioxideasfoamingagentinclude“batch”and“online”,processroutesofwhichincludethefollowingtwo:[3](1).Processrouteof“batch”processingmethodFor“batch”processingmode,solvingratioofcarbondioxideandpolyolorisocynatemaybedifferentfordifferentbatches.(2).Processrouteof“online”processingmethod“Online”processingmethodallowsquantityofcarbondioxidemaybedifferentforeachpouring,whichissuitableforcontinuousproduction.ItisknowninTableandFig.7thatliquidcarbondioxideonlyexistsbelowof31℃andabove7.36MPapressure,temperatureandpressurehasthegreatinfluenceonthedensityofcarbondioxide.Thusinfluenceoftemperatureandpressureonmeteringaccuracyisfullyconsideredindevelopedequipment.Accordingtotheabove-mentionedcharacteristics,weresearchanddevelopcompleteRIMequipmentsforpolyurethanehighpressureCFC-free(carbondioxide)foamingprocess.Because“online”processingmethodisadaptableforcontinuousproduction,thefollowingmainlydescribesthecompleteRIMequipmentsforpolyurethanehighpressureCFC-free(carbondioxide)foamingprocessthatissuitablefor“batch”processingmethod.ThecompleteRIMequipmentsforpolyurethanehighpressureCFC-free(carbondioxide)foamingprocessconsistsofcarbondioxidepremixingsystem,polyurethaneCFC-free(carbondioxide)high-pressurefoamingmachineandpolyurethaneCFC-free(carbondioxide)foamingRIMproductionline,eachunitofwhichisstructuredasfollows:(1).Carbondioxidepremixingsystem(showninFig.8)[3]Fig.8ProcessflowdiagramofCO2premixingsystemOnecompositionentersthestaticmixeraftermeteringthroughhigh-accurateandmedium-low-pressuremeteringpumpandgoesintothepremixingbankforcycling.Atthesametime,gascarbondioxideisinjectedintothemeteringunitwithconstant-massflowrate.Becauseofadoptingconstant-massflowrate,meteringaccuracyofcarbondioxideishighandnotimpactedbythechangeoftemperatureandpressure.Itsinjectingtimedependsonvolumeofthepremixingtank,solvingratioofcarbondioxideandcompositionaswellasmassflowrateofcarbondioxide.Staticmixerallowscarbondioxidetoevenlysolveinthecompositioninsteadofmixinginthegross,whichnotonlydecreasesconsumptionofcarbondioxidebutalsopreventsthefoamfromproducingcavitiestoimproveRIMquality.Aftercarbondioxideevenlysolvesintherawmaterialsascompositionsaccordingtothesetproportion,feedingvalveofthepremixingtankiscontrolledtoopenandcarbondioxide/compositionmixturethathasevenlybeenmixedisconveyedintothematerialtankofthepolyurethaneCFC-free(carbondioxide)high-pressurefoamingmachine.(2).PolyurethaneCFC-free(carbondioxide)high-pressurefoamingmachineItsstructureissameasthatofpolyurethaneCFChigh-pressurefoamingmachine(omitting).(3).PolyurethaneCFC-free(carbondioxide)foamingRIMproductionlinepolyurethaneThislinecanbedividedintoswiveltabletypeandhorizontalcyclingtype.Fig.9SchematicdiagramofswiveltablepolyurethaneCFC-free(carbondioxide)foamingRIMproductionlineSwiveltablepolyurethaneCFC-free(carbondioxide)foamingRIMproductionline(showninFig.9)andhorizontalcyclingpolyurethaneCFC-free(carbondioxide)foamingRIMproductionline(shownFig.10)aredecidedtheirstationnumberaccordingtotheconditionsofprocessingtechnology,runningspeedandtheoutput.Bothlinesaresuitableforproducingthecold-curingfoamingmaterialssuchashigh-reboundingpolyurethaneseatcushion,leaningcushionandheadrestoftheautomobileaswellasseatcushionofthemotorcycle.ForswiveltablepolyurethaneCFC-free(carbondioxide)foamingRIMproductionline,neededpowerconfigurationissmalltosaveenergyresource;itspipesaremountedinthefixedmodetobedifficulttobedamaged;operationcostislowtobesuitableforproductionofthesameproductsinthegritbatches.Horizontalcyclingoneisconvenientforchangemouldssothatitissuitableforproductionofmulti-varietyproductsinthesmallbatches.Bothproductionlinesaredrivenwiththemotorsthatintermittentlyorcontinuouslyoperateaccordingtotheneedoftheprocess,onwhichwater-supply,power-supply,gas-supplyandliquid-supplyareequipped.Themouldholderserectedontheswiveltableandconveyingtrolleycanautomaticallyperformthepneumatic-hydraulic-operatedactionofopening,shuttingandlockingmoulds.Accordingtotheneedoftheprocess,single,doubleormultiplemixingheadisequippedandtheequippedrobotwiththefunctionofautomaticidentifyingmoulddrivesthemixingheadtoperformpouring.Fig.10SchematicdiagramofhorizontalcyclingpolyurethaneCFC-free(carbondioxide)foamingRIMproductionlineBoththeabove-mentionedcompleteequipmentsarecontrolledwiththecomputertechnologiessuchasnetworktechnologyandlogiccontroltechnology.Dataiscontrolledandmonitoredwithman-machineinterfaceandtheremotemonitoringdevicecanbeequippedaccordingtotheuser’sneed.Inaddition,thenewestVFmetering,driveandservotechnologyarealsoused;theparameterssuchastemperature,pressure,gasconcentration,speed,position,positionidentifyingandsafeguardingaredetectedbymeansofmulti-kindsensingtechnologytoimprovetheperformanceandtheuseoftheequipmentsothattheybecomethemechatronicmachinesthatreachtheinternationaladvancedlevel.SeveralpackagesofcompleteRIMequipmentsforpolyurethanehighpressureCFC-free(cyclopentane)foamingprocessandcompleteRIMequipmentsforpolyurethanehighpressureCFC-free(carbondioxide)foamingprocessaresuccessivelyputintooperationinthecompaniessuchasHaier,Xinfei,KelonandAucma.Theyarepraisedbytheusersbecauseoftheirstableandreliableperformanceandtheirtechnologyreachestheadvancedlevelintheworld.Withthecontinuousdevelopmentofscienceandtechnologyintheworld,newer,better,saferandmoreeconomicalfoamingagentsandtheirproductiontechnologywithfunctionofenvironmentalprotectionwillbedeveloped.Wewillalsodevelopthemoreperfectproductionequipmenttomakethegreatercontributionforcreatingthehuman’swealthandprotectinglivingenvironment.Reference1.PolyurethaneHard-foamCFC-11AlternativeTechnologyManualcompiledbyOfficeofForeignEconomicCooperationLeadershipGroupunderStateEnvironmentalProtectionAdministration,UnitedNationsIndustrialDevelopmentOrganization,BeijingSino-plasticTradecompany,August2002,352.ElastogranGmbH.ProcessingofCyclo-pentaneintheRefrigeratorIndustry3.ElastogranGmbH.CO2-loadingofPUR-systems;ProcessingAlternatives(On-Line-andBatch-Process),August1997

附录资料：不需要的可以自行删除Xxxxx煤矿Xxxx使用气割安全技术措施一、施工概述根据工作安排，于2010年4月3日对xxxx维修，施工过程中需用气割作业。为确保施工安全，特制定本专项安全技术措施。二、作业环境及施工时间1、作业地点位于我矿副井处，全负压通风，符合煤矿安全规程气割作业环境的要求。2、施工时间：xxxxxxxx。三、施工组织施工人员3人，其中现场负责人：xxx现场监护工：xxx气割操作工：xxx火种携带工：xxx洒水灭火工：xxx四、施工前准备（一）地面施工准备1、检查气瓶。必须认真检查，检查氧气瓶、乙炔瓶阀门关闭严密无泄漏，氧气、乙炔足量，压力负荷达到要求，并认真清点好领取数量。2、检查气割器具。必须对气管、减压阀、气压表、回火防止器、割炬等认真检查，确保气割器具完好，气管及连接部位不漏气。3、气割器具装车。将氧气、乙炔及气割器具装入矿车，作好入井准备。氧气瓶、乙炔瓶不能装在同一矿车内，且不得与其它可燃材料、大型金属物件以及大块矸石等混装；气管及其它器具不得装车运输，必须专人携带以防挤坏。4、入井要求。地面准备工作负责人持审批完成的气割措施，在井口向把钩人员登记氧气、乙炔数量及施工地点后，方能将气瓶和施工材料装入矿车推到井口位置，准备下井。5、地面准备工作由xxxx完成，由地面负责人具体负责检查确认。（二）井下运输1、气瓶二次检查。将氧气瓶、乙炔瓶下放到八号行人斜巷，派专人再次检查氧气瓶、乙炔瓶的装车情况，并对运输过程监管。2、运输路线：地面→主井→xxx→xxx。3、气瓶运输。氧气瓶、乙炔瓶的井下运输由xxx负责，按照井口登记的施工地点，将氧气瓶、乙炔瓶运送到指定地点；xxx派专人在指定地点现场交接，并作好交接记录。4、气瓶卸车。气瓶要小心从矿车中取出，接气瓶人员拿稳之后，取气瓶人员才能松手，气瓶要轻抬轻放。5、井下运输监管工作由xxx负责。器具交接、检查由xxx现场负责人具体负责。（三）施工人员入井前准备1、施工人员要求。经过培训考试合格并持证上岗，配齐防护用品。2、火源携带。火源为打火机一只，由火种携带工负责携带，火源入井时，要携带审批好的专项气割措施，并在井口进行火源登记。3、施工现场施工人员必须携带便携式甲烷检测仪。4、施工人员入井前准备检查工作由井口检身工负责。（四）井下施工准备1、清理施工现场。将工作地点及附近前后两端各10米2、放置气瓶。气瓶距工作地点间距必须在10米以上，且两种气瓶间距不小于10米；气瓶必须垂直站立放置在3、备好水源及消防器材。工作地点应配备不少于0.2m3的消防沙和合格的4kg干粉灭火器2台，工作人员必须了解灭火器使用方法；施工地点配有清水管路，4、井下施工准备工作由杨付强负责检查落实；安检员负责施工安全设施检查。（五）气割作业前准备1、人员到位。现场负责人检查气割操作工、现场监护工、火种携带工、洒水灭火工、瓦斯检查工、安检员到位情况。2、设定安全监护。指定专人负责整个施工现场安全监护。3、气割前器具检查。由气割操作工再次对气瓶、减压阀、气压表、气管、割炬等器具进行详细的安全检查，确认完好后，将各部件对接。4、现场洒水。由专职洒水工向施工点洒水，确保施工点10m范围内润湿。5、检查瓦斯。瓦斯检查工对气割工作地点及附近20m范围风流中的瓦斯浓度和通风状况进行检查，瓦斯浓度不得超过0.5%，只有在检查证明作业地点及附近20m范围内巷道顶部无瓦斯积存时，方能进行气割作业。6、在施工点上风侧3m范围内，距顶板500mm处悬