Detailed Project Report (DPR) on polyol used for polyurethane

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 an 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).^[15] 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). Graft polyols (also called filled polyols or polymer polyols) contain finely dispersed styrene-acrylonitrile, acrylonitrile, or polyurea (PHD) polymer solids chemically grafted to a high molecular weight polyether backbone. They are used to increase the load-bearing properties of low-density high-resiliency (HR) foam, as well as add toughness to microcellular foams and cast elastomers. PHD polyols are also used to modify the combustion properties of HR flexible foam. Solids content ranges from 14% to 50%, with 22% and 43% being typical. Initiators such as ethylenediamine and triethanolamine are used to make low molecular weight rigid foam polyols that have built-in catalytic activity due to the presence of nitrogen atoms in the backbone. They are used to increase system reactivity and physical property build, and to reduce the friability of rigid foam molded parts. A special class of polyether polyols, poly(tetramethylene ether) glycols are made by polymerizing tetrahydrofuran. They are used in high performance coating and elastomer applications. Polyester polyols fall into two distinct categories according to composition and application. Conventional polyester polyols are based on virgin raw materials and are manufactured by the direct polyesterification of high-purity diacids and glycols, such as adipic acid and 1,4-butanediol. They are distinguished by the choice of monomers, molecular weight, and degree of branching. While costly and difficult to handle because of their high viscosity, they offer physical properties not obtainable with polyether polyols, including superior solvent, abrasion, and cut resistance. Other polyester polyols are based on reclaimed raw materials. They are manufactured by transesterification (glycolysis) of recycled poly(ethyleneterephthalate) (PET) or dimethylterephthalate (DMT) distillation bottoms with glycols such as diethylene glycol. These low molecular weight, aromatic polyester polyols are used in the manufacture of rigid foam, and bring low cost and excellent flammability characteristics to polyisocyanurate (PIR) boardstock and polyurethane spray foam insulation. Many polyols are polydispersive materials, being blends of two or more polyols each of specific molecular weights, to give intermediate molecular weight materials. It is not unusual to find blends of polyether and polyester polyols, to give specific compromises in properties.

POLYOL USED FOR POLYURETHANES (EIRI-1027)

Cost Estimation

Plant Capacity                                          20 Tons/Day
Land & Building (Area 10000 Sq.Mt.)  Rs. 5.27 Cr.
Plant & Machinery                                    Rs. 2.76 Cr.        
W.C. for 3 Months                                    Rs. 10.98 Cr.          
Total Capital Investment                        Rs. 19.19 Cr.             
Rate of Return                                         82%  
Break Even Point                                    20%


•    EIRI can modify the Capacity of the Project and Total Capital Investment as per your requirement.
•    Note: The project investment cost and capacity are subject to change without any notice. Future projects may have different values of project cost and capacity.
 

MARKET SURVEY CUM DETAILED TECHNO
ECONOMIC FEASIBILITY REPORT covers
 

• Introduction
• Uses and Applications
• Properties
• Market Survey with future aspects
• Present Manufacturers
• Detailed Process of Manufacture
• Formulations
• B.I.S. Specifications
• Process Flow Sheet Diagram, Plant Layout
• Method
• Reference Method  1
• Reference Method  2
• Method  A1
• 1. Structure of Starter
• Figures
• 2. Impurities in the Starter and Moles PO/Moles Starter in the Initiator Feed
• Tables
• 3. Catalyst Level/Catalyst Type
• Method  1
• Preliminary Screening Experiments
• Method 2   
• Steric 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
• Preparation of Unneutralised Polyether Polyol
• Neutralisation
• COMPARATIVE METHODS A AND B
• Polyols Suppliers
• Contact Details
• Cost Economics with Profitability Analysis
• Capacity
• Land & Building Requirements with Rates
• List & Details of Plant and Machinery with their Costs
• Raw Materials Details/List and Costs
• Power & Water Requirements
• Labour/Staff Requirements
• Utilities and Overheads
• Total Capital Investment
• Turnover
• Cost of Production
• Break Even Point
• Profitability
• Land Man Ratio
• Suppliers of Plant & Machineries and Raw Materials
• Cash Flow Statement
• Repayment Schedule
• Interest Chart
• Depreciation Chart
• Projected Balance Sheet for 5 Years etc

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