我國無氟高壓發(fā)泡模塑生產(chǎn)設(shè)備的研發(fā)現(xiàn)狀

我國聚氨酯無氟高壓發(fā)泡模塑生產(chǎn)成套設(shè)備摘要：介紹了目前我國采用環(huán)戊烷和二氧化碳作發(fā)泡劑替代CFC-11的聚氨酯泡沫發(fā)泡新工藝路線，以及對(duì)應(yīng)于這兩種新工藝路線，武漢輕工業(yè)機(jī)械廠所開發(fā)研制出的兩大類成套設(shè)備的用途及構(gòu)成要點(diǎn)。關(guān)鍵詞：發(fā)泡設(shè)備；聚氨酯泡沫塑料；模塑；無氟；預(yù)混為了加快履行聯(lián)合國《關(guān)于消耗臭氧層物質(zhì)的蒙特利爾協(xié)定書》的義務(wù)，根據(jù)我國編制并修訂的《中國消耗臭氧層物質(zhì)逐步淘汰國家方案》的精神，聚氨酯泡沫行業(yè)2010年前要實(shí)現(xiàn)CFC-11零消費(fèi)。據(jù)此，我們采用對(duì)大氣臭氧層無任何損害的環(huán)戊烷和二氧化碳作為聚氨酯硬泡和軟泡的發(fā)泡劑，以替代CFC-11，且按新的工藝路線，經(jīng)消化吸收并改進(jìn)創(chuàng)新世界上先進(jìn)的技術(shù)，研制了分別使用兩種新發(fā)泡劑的聚氨酯無氟高壓發(fā)泡模塑生產(chǎn)成套設(shè)備。1聚氨酯無氟(環(huán)戊烷)高壓發(fā)泡模塑生產(chǎn)成套設(shè)備環(huán)戊烷的物理性質(zhì)及與CFC-11的比較如表1[1]。表1環(huán)戊烷的物理性質(zhì)及與CFC-11的比較發(fā)泡劑分子式相對(duì)分子質(zhì)量密度g/cm3沸點(diǎn)℃氣相熱導(dǎo)率mW/(m?K)蒸汽壓kPa爆炸極限(v/v)%臭氧消耗潛值(ODP值)環(huán)戊烷C5H10700.744912.0341.4～8.00CFC-11CCl3F137.41.49248.5－無1.0注：密度為20℃數(shù)據(jù)，氣相熱導(dǎo)率為25℃數(shù)據(jù)，蒸汽壓為20℃數(shù)據(jù)。根據(jù)環(huán)戊烷的物理性質(zhì)，使用環(huán)戊烷作聚氨酯硬泡發(fā)泡劑的優(yōu)點(diǎn)為：對(duì)大氣臭氧層無破壞作用，環(huán)保性能較好；價(jià)廉，資源豐富；室溫下為液態(tài)；因分子量低，同密度的泡沫所需發(fā)泡劑用量比CFC-11小。缺點(diǎn)是：易燃、易爆，設(shè)備費(fèi)用高；氣相熱導(dǎo)率較CFC-11高，因而泡沫絕熱性相對(duì)差些。目前國內(nèi)海爾、科龍、新飛、長嶺等廠家已大批使用環(huán)戊烷作冰箱、冷柜絕熱層硬泡的發(fā)泡劑。使用環(huán)戊烷作發(fā)泡劑的生產(chǎn)工藝路線如下：[2]根據(jù)環(huán)戊烷特性和工藝路線，我們研制了聚氨酯無氟（環(huán)戊烷）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備。在設(shè)備研制時(shí)特別注重防爆安全措施的研發(fā)，確保安全生產(chǎn)。聚氨酯無氟（環(huán)戊烷）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備由環(huán)戊烷/多元醇預(yù)混系統(tǒng)、聚氨酯無氟（環(huán)戊烷）高壓發(fā)泡機(jī)和聚氨酯無氟發(fā)泡模塑生產(chǎn)線組成。各組成部分的構(gòu)成描述如下：1.1環(huán)戊烷/多元醇預(yù)混系統(tǒng)[2]根據(jù)環(huán)戊烷的特性，新開發(fā)的環(huán)戊烷/多元醇預(yù)混系統(tǒng)的環(huán)戊烷貯料罐，須防止外力的撞擊，周圍應(yīng)無火花，如果地面條件不能滿足安全要求，或外界氣溫可能低于0℃，則貯料罐宜置于地下。環(huán)戊烷/多元醇預(yù)混系統(tǒng)見圖1。圖1環(huán)戊烷預(yù)混系統(tǒng)工藝流程圖環(huán)戊烷和多元醇分別采用二套高精度、中低壓的計(jì)量泵計(jì)量，以保證混合配比的精度。采用混合能力高、低熱量產(chǎn)生、防靜電的靜態(tài)混合器，對(duì)環(huán)戊烷與多元醇進(jìn)行混合，使環(huán)戊烷均勻地溶入多元醇，提高泡沫質(zhì)量。形成的混合料貯存于由氮?dú)獗旱亩嘣?環(huán)戊烷料罐，以供發(fā)泡機(jī)使用。環(huán)戊烷/多元醇預(yù)混系統(tǒng)的安全配置為：環(huán)戊烷的計(jì)量泵防爆；所有可能接觸環(huán)戊烷及其氣體的裝置防靜電火花；電機(jī)、電器元件均選用防爆等級(jí)；且相應(yīng)管道、接頭及閥雙層密封，管道上配置電控截止閥；裝有環(huán)戊烷及其混合料的容器均輸入氮?dú)獗海瞎迶嚢桦姍C(jī)與攪拌軸的連接采用磁性連軸節(jié)；在環(huán)戊烷貯料罐、計(jì)量、混合及混合料罐等區(qū)域均配置隔板或護(hù)罩，并設(shè)有檢測探頭、抽風(fēng)系統(tǒng)及防爆控制系統(tǒng)。該防爆控制系統(tǒng)的電源與設(shè)備電源分開，并分三級(jí)進(jìn)行防爆控制：第一級(jí)為正常工作時(shí)控制風(fēng)機(jī)低速抽風(fēng)，換氣量約為每小時(shí)換氣10次；[2]第二級(jí)為當(dāng)檢測傳感器檢測到環(huán)戊烷濃度達(dá)到爆炸下限的20%時(shí)，[2]控制風(fēng)機(jī)高速抽風(fēng)；第三級(jí)為當(dāng)檢測傳感器檢測到環(huán)戊烷濃度達(dá)到爆炸下限的40%時(shí)，[2]則切斷設(shè)備電源，關(guān)閉環(huán)戊烷進(jìn)料閥，并使風(fēng)機(jī)高速抽風(fēng)，使環(huán)戊烷的釋放濃度被控制在安全值以下。1.2聚氨酯無氟(環(huán)戊烷)高壓發(fā)泡機(jī)環(huán)戊烷/多元醇混合料的料罐由氮?dú)獗海鋽嚢栎S與攪拌電機(jī)的連接采用磁性連軸節(jié)，電機(jī)為防爆電機(jī)，且料罐用隔離罩分隔，并配有檢測探頭、抽風(fēng)系統(tǒng)及防爆三級(jí)控制系統(tǒng)；混合料計(jì)量泵電機(jī)為防爆電機(jī)，計(jì)量泵及電機(jī)也用隔離罩分隔，并配有檢測探頭、抽風(fēng)系統(tǒng)及防爆三級(jí)控制系統(tǒng)；異氰酸酯料罐和計(jì)量泵不必防爆；根據(jù)環(huán)戊烷釋放速度和釋放量，可選用可充氮?dú)獾幕旌项^，使注射前可向模腔充氮，且注射時(shí)使混合料與異氰酸酯進(jìn)行高速碰撞混合。所有接觸混合料的裝置須防靜電火花并接地。聚氨酯無氟（環(huán)戊烷）高壓發(fā)泡機(jī)示意圖見圖2。圖2聚氨酯環(huán)戊烷高壓發(fā)泡機(jī)簡圖1.3聚氨酯無氟(環(huán)戊烷)發(fā)泡模塑生產(chǎn)線該聚氨酯無氟（環(huán)戊烷）發(fā)泡模塑生產(chǎn)線按形式可分為直線式、水平環(huán)行式和垂直環(huán)行式。各種形式生產(chǎn)線均根據(jù)原料加工工藝情況、運(yùn)行速度及產(chǎn)量決定生產(chǎn)線工位數(shù)。直線式聚氨酯無氟（環(huán)戊烷）發(fā)泡模塑生產(chǎn)線直線式聚氨酯無氟（環(huán)戊烷）發(fā)泡模塑生產(chǎn)線示意圖見圖3。圖3直線式聚氨酯環(huán)戊烷發(fā)泡模塑生產(chǎn)線簡圖該生產(chǎn)線用于冰箱箱體隔熱層的發(fā)泡生產(chǎn)。采用固定模架結(jié)構(gòu)，模具與模架設(shè)計(jì)為一體；混合頭和冰箱分別由小車帶動(dòng)，在模架、烘箱和下線升降臺(tái)之間自動(dòng)識(shí)別運(yùn)動(dòng)。生產(chǎn)線全自動(dòng)完成冰箱體的預(yù)熱、上模架、澆注、固化及下線等任務(wù)。澆注、固化區(qū)的安全要求為：模板、模芯由水加熱或熱風(fēng)加熱；模架上所有可能接觸釋放出的環(huán)戊烷的電機(jī)、電器元件均須選用防爆等級(jí)或選用增安型加澆注后停電來防爆。停電時(shí)間依發(fā)泡時(shí)環(huán)戊烷氣體的釋放曲線（見圖4）可選為1min；機(jī)械運(yùn)動(dòng)件均須防靜電火花，機(jī)械構(gòu)件均接地；將模架區(qū)進(jìn)行隔離，并設(shè)置檢測探頭、抽風(fēng)系統(tǒng)及防爆三級(jí)控制系統(tǒng)。水平環(huán)行式聚氨酯無氟（環(huán)戊烷）發(fā)泡模塑生產(chǎn)線該生產(chǎn)線用于冰箱箱體隔熱層的發(fā)泡生產(chǎn)。采用模架小車裝載模具；鏈傳動(dòng)使載模小車作水平環(huán)狀間歇移動(dòng)；除操作工位（上、下箱體、清理、開、閉、鎖模、澆注及抽風(fēng)）外，其余工位均被罩在半環(huán)行固化烘箱內(nèi)，烘箱采用熱風(fēng)循環(huán)加、保溫。澆注、固化區(qū)的安全要求為：所有電機(jī)、電器元件均采用防爆等級(jí)；機(jī)械運(yùn)動(dòng)件均須防靜電火花，機(jī)械構(gòu)件均接地；烘箱上熱風(fēng)循環(huán)風(fēng)機(jī)及其電機(jī)須防爆；根據(jù)環(huán)戊烷在發(fā)泡時(shí)的釋放曲線（見圖4），在澆注工位及澆注后1min內(nèi)模具運(yùn)行區(qū)間的上、下方區(qū)域，設(shè)置抽風(fēng)裝置，并在烘箱內(nèi)及澆注處設(shè)置檢測探頭及防爆三級(jí)控制系統(tǒng)。水平環(huán)行式聚氨酯無氟(環(huán)戊烷)發(fā)泡模塑生產(chǎn)線示意圖見圖5。圖4冰箱腔發(fā)泡時(shí)環(huán)戊烷氣體釋放圖圖5水平環(huán)行式聚氨酯無氟(環(huán)戊烷)發(fā)泡模塑生產(chǎn)線簡圖垂直環(huán)行式聚氨酯無氟（環(huán)戊烷）發(fā)泡模塑生產(chǎn)線（見圖6）。該生產(chǎn)線用于冰箱箱門隔熱層的發(fā)泡生產(chǎn)。采用模架小車裝載模具；鏈傳動(dòng)使載模小車作垂直環(huán)狀間歇移動(dòng)；除操作工位（上、下箱門、清理、開、閉、鎖模、澆注及抽風(fēng)）外，其余工位均被罩在矩形固化烘箱內(nèi)，烘箱采用熱風(fēng)循環(huán)加、保溫；開、合模采用氣、液壓控制機(jī)械手。澆注、固化區(qū)的安全要求同上述水平環(huán)行式無氟發(fā)泡模塑生產(chǎn)線。垂直環(huán)行式聚氨酯無氟（環(huán)戊烷）發(fā)泡模塑生產(chǎn)線示意圖見圖6。圖6垂直環(huán)行式聚氨酯無氟發(fā)泡模塑生產(chǎn)線簡圖2聚氨酯無氟(二氧化碳)高壓發(fā)泡模塑生產(chǎn)成套設(shè)備二氧化碳的主要物理性質(zhì)見表2[1,3]。表2二氧化碳的主要物理性質(zhì)發(fā)泡劑分子式氣相熱導(dǎo)率(25℃)mW/(m?K)臨界溫度/℃臨界壓力/MPaODP值二氧化碳CO216.3317.360溫度及壓力對(duì)二氧化碳密度的影響見圖7[3]。1－10℃，2－20℃，3－30℃，4－40℃，5－50℃，6－60℃圖7CO2密度隨溫度壓力變化圖二氧化碳作發(fā)泡劑的優(yōu)點(diǎn)為：二氧化碳價(jià)廉，降低發(fā)泡成本；改善混合質(zhì)量，減少成型重量，改善泡沫特性；二氧化碳不可燃、環(huán)保，有豐富的自然資源。該發(fā)泡劑在國內(nèi)正開始使用。使用二氧化碳作發(fā)泡劑的加工方法有“批量”和“在線”兩種，則工藝路線相應(yīng)有以下兩條[3]。2.1“批量”加工方法的工藝路線“批量”加工方法的工藝路線如下：

“批量”加工方式各批次二氧化碳與多元醇或異氰酸酯的溶解比可不同。2.2“在線”加工方法的工藝路線“在線”加工方法的工藝路線框圖如下：“在線”加工方法允許每次澆注時(shí)二氧化碳的量可以不同，該方法適于連續(xù)生產(chǎn)。由表2及圖7可知，液態(tài)二氧化碳只存在于31℃以下、壓力7.36MPa以上，且溫度及壓力對(duì)二氧化碳的密度影響很大，所以研制的設(shè)備充分考慮溫度與壓力對(duì)二氧化碳計(jì)量精度的影響。根據(jù)以上所述特征，我們研發(fā)了聚氨酯無氟（二氧化碳）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備。由于“在線”加工方法適于連續(xù)生產(chǎn)，以下主要介紹與“批量”加工方法工藝路線相適應(yīng)的聚氨酯無氟（二氧化碳）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備。聚氨酯無氟（二氧化碳）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備由二氧化碳預(yù)混系統(tǒng)、聚氨酯無氟（二氧化碳）高壓發(fā)泡機(jī)、聚氨酯無氟（二氧化碳）發(fā)泡模塑生產(chǎn)線組成。各組成部分的構(gòu)成如下：（1）二氧化碳預(yù)混系統(tǒng)[3]某一組分經(jīng)高精度、中低壓的計(jì)量泵計(jì)量進(jìn)入靜態(tài)混合器，并進(jìn)入預(yù)混料罐循環(huán)；同時(shí)，氣態(tài)二氧化碳經(jīng)恒質(zhì)量流量的計(jì)量單元被注入組分中。由于采用恒質(zhì)量流量，所以二氧化碳的計(jì)量精度高，與溫度、壓力的變化無關(guān)。二氧化碳注入時(shí)間取決于預(yù)混料罐的容積、二氧化碳與組分的溶解比及二氧化碳的質(zhì)量流量。靜態(tài)混合器能使二氧化碳均勻地溶解在組分中，而不是粗略地混合。這不僅節(jié)約二氧化碳的耗量，還防止泡沫產(chǎn)生洞穴，改善模塑質(zhì)量。當(dāng)二氧化碳按設(shè)定比例均勻地溶解于組分原料中后，預(yù)混料罐加料閥被控制打開，將混合完畢的二氧化碳/組分的混合料送入無氟（二氧化碳）高壓發(fā)泡機(jī)的料罐。二氧化碳預(yù)混系統(tǒng)示意圖見圖8。

圖8二氧化碳預(yù)混系統(tǒng)工藝流程圖（2）聚氨酯無氟（二氧化碳）高壓發(fā)泡機(jī)構(gòu)成與有氟高壓發(fā)泡機(jī)相似（略）。（3）聚氨酯無氟（二氧化碳）發(fā)泡模塑生產(chǎn)線該聚氨酯無氟（二氧化碳）發(fā)泡模塑生產(chǎn)線按形式可分為轉(zhuǎn)臺(tái)式和水平環(huán)行式。轉(zhuǎn)臺(tái)式聚氨酯無氟（二氧化碳）發(fā)泡模塑生產(chǎn)線(見圖9)和水平環(huán)行式聚氨酯無氟（二氧化碳）發(fā)泡模塑生產(chǎn)線（見圖10）均根據(jù)原料加工工藝情況、運(yùn)行速度及產(chǎn)量決定生產(chǎn)線工位數(shù)。兩種形式生產(chǎn)線均可用于聚氨酯高回彈汽車坐墊、靠墊及頭枕、摩托車坐墊等的冷熟化發(fā)泡生產(chǎn)。轉(zhuǎn)臺(tái)式需要的動(dòng)力配置小，節(jié)約能源；管道固定安裝，不易損壞；運(yùn)行成本低；適于大批量同品種生產(chǎn)。水平環(huán)行式方便換模具，適于小批量多品種生產(chǎn)。圖9轉(zhuǎn)臺(tái)式聚氨酯無氟(二氧化碳)發(fā)泡模塑生產(chǎn)線轉(zhuǎn)臺(tái)、水平環(huán)形式發(fā)泡生產(chǎn)線均由電機(jī)驅(qū)動(dòng)，按工藝需要間歇或連續(xù)運(yùn)轉(zhuǎn)，其上配備水、電、氣、液源，安裝在轉(zhuǎn)臺(tái)和輸送車上的模架可自動(dòng)進(jìn)行氣、液自控的開、合、鎖模的動(dòng)作，根據(jù)工藝需要配備單、雙、多混合頭，并配置機(jī)械手帶動(dòng)混合頭進(jìn)行自動(dòng)識(shí)別模具的澆注。3結(jié)束語以上兩大類成套設(shè)備均采用計(jì)算機(jī)技術(shù)控制，如：網(wǎng)絡(luò)技術(shù)、邏輯控制技術(shù)等。采用人機(jī)界面進(jìn)行數(shù)據(jù)的輸入和監(jiān)控，并根據(jù)用戶需要可配制遠(yuǎn)程監(jiān)控裝置。還應(yīng)用了最新的變頻計(jì)量、傳動(dòng)及伺服技術(shù)。對(duì)溫度、壓力、氣體濃度、速度、位置、工位識(shí)別、安全保護(hù)等均采用了多種傳感技術(shù)來檢測，使設(shè)備的性能和使用效果得到提高，成為具有國際先進(jìn)水平的機(jī)電一體化產(chǎn)品。圖10水平環(huán)行式聚氨酯無氟(二氧化碳)發(fā)泡模塑生產(chǎn)線聚氨酯無氟（環(huán)戊烷）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備和聚氨酯無氟（二氧化碳）高壓發(fā)泡模塑生產(chǎn)成套設(shè)備先后有多套或部分在海爾、新飛、科龍和澳柯瑪?shù)葟S家投入使用，且性能穩(wěn)定、可靠，得到了用戶的好評(píng)，其技術(shù)水平達(dá)到世界先進(jìn)水平。隨著世界科學(xué)技術(shù)的不斷發(fā)展，將研制出更新、更好、更安全、更經(jīng)濟(jì)且環(huán)保的發(fā)泡劑及生產(chǎn)工藝，我們也將開發(fā)出更完美的生產(chǎn)設(shè)備，為人類創(chuàng)造財(cái)富、保護(hù)生存環(huán)境而作出更大的貢獻(xiàn)！參考文獻(xiàn)1國家環(huán)?？偩謱?duì)外經(jīng)濟(jì)合作領(lǐng)導(dǎo)小組辦公室、聯(lián)合國工業(yè)發(fā)展組織、北京華塑貿(mào)易公司.聚氨酯硬泡CFC-11替代技術(shù)手冊(cè).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作者簡介：曾紅高級(jí)工程師，華南理工大學(xué)化工機(jī)械系輕工機(jī)械專業(yè)畢業(yè)，現(xiàn)任武漢輕工業(yè)機(jī)械廠副總工程師兼技術(shù)部部長，長期從事聚氨酯發(fā)泡成套設(shè)備的研發(fā)，主持開發(fā)的產(chǎn)品曾獲國家級(jí)新產(chǎn)品和省級(jí)科技進(jìn)步獎(jiǎng)。

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

附錄資料：不需要的可以自行刪除Xxxxx煤礦Xxxx使用氣割安全技術(shù)措施一、施工概述根據(jù)工作安排，于2010年4月3日對(duì)xxxx維修，施工過程中需用氣割作業(yè)。為確保施工安全，特制定本專項(xiàng)安全技術(shù)措施。二、作業(yè)環(huán)境及施工時(shí)間1、作業(yè)地點(diǎn)位于我礦副井處，全負(fù)壓通風(fēng)，符合煤礦安全規(guī)程氣割作業(yè)環(huán)境的要求。2、施工時(shí)間：xxxxxxxx。三、施工組織施工人員3人，其中現(xiàn)場負(fù)責(zé)人：xxx現(xiàn)場監(jiān)護(hù)工：xxx氣割操作工：xxx火種攜帶工：xxx灑水滅火工：xxx四、施工前準(zhǔn)備（一）地面施工準(zhǔn)備1、檢查氣瓶。必須認(rèn)真檢查，檢查氧氣瓶、乙炔瓶閥門關(guān)閉嚴(yán)密無泄漏，氧氣、乙炔足量，壓力負(fù)荷達(dá)到要求，并認(rèn)真清點(diǎn)好領(lǐng)取數(shù)量。2、檢查氣割器具。必須對(duì)氣管、減壓閥、氣壓表、回火防止器、割炬等認(rèn)真檢查，確保氣割器具完好，氣管及連接部位不漏氣。3、氣割器具裝車。將氧氣、乙炔及氣割器具裝入礦車，作好入井準(zhǔn)備。氧氣瓶、乙炔瓶不能裝在同一礦車內(nèi)，且不得與其它可燃材料、大型金屬物件以及大塊矸石等混裝；氣管及其它器具不得裝車運(yùn)輸，必須專人攜帶以防擠壞。4、入井要求。地面準(zhǔn)備工作負(fù)責(zé)人持審批完成的氣割措施，在井口向把鉤人員登記氧氣、乙炔數(shù)量及施工地點(diǎn)后，方能將氣瓶和施工材料裝入礦車推到井口位置，準(zhǔn)備下井。5、地面準(zhǔn)備工作由xxxx完成，由地面負(fù)責(zé)人具體負(fù)責(zé)檢查確認(rèn)。（二）井下運(yùn)輸1、氣瓶二次檢查。將氧氣瓶、乙炔瓶下放到八號(hào)行人斜巷，派專人再次檢查氧氣瓶、乙炔瓶的裝車情況，并對(duì)運(yùn)輸過程監(jiān)管。2、運(yùn)輸路線：地面→主井→xxx→xxx。3、氣瓶運(yùn)輸。氧氣瓶、乙炔瓶的井下運(yùn)輸由xxx負(fù)責(zé)，按照井口登記的施工地點(diǎn)，將氧氣瓶、乙炔瓶運(yùn)送到指定地點(diǎn)；xxx派專人在指定地點(diǎn)現(xiàn)場交接，并作好交接記錄。4、氣瓶卸車。氣瓶要小心從礦車中取出，接氣瓶人員拿穩(wěn)之后，取氣瓶人員才能松手，氣瓶要輕抬輕放。5、井下運(yùn)輸監(jiān)管工作由xxx負(fù)責(zé)。器具交接、檢查由xxx現(xiàn)場負(fù)責(zé)人具體負(fù)責(zé)。（三）施工人員入井前準(zhǔn)備1、施工人員要求。經(jīng)過培訓(xùn)考試合格并持證上崗，配齊防護(hù)用品。2、火源攜帶。火源為打火機(jī)一只，由火種攜帶工負(fù)責(zé)攜帶，火源入井時(shí)，要攜帶審批好的專項(xiàng)氣割措施，并在井口進(jìn)行火源登記。3、施工現(xiàn)場施工人員必須攜帶便攜式甲烷檢測儀。4、施工人員入井前準(zhǔn)備檢查工作由井口檢身工負(fù)責(zé)。（四）井下施工準(zhǔn)備1、清理施工現(xiàn)場。將工作地點(diǎn)及附近前后兩端各10米2、放置氣瓶。氣瓶距工作地點(diǎn)間距必須在10米以上，且兩種氣瓶間距不小于10米；氣瓶必須垂直站立放置在3、備好水源及消防器材。工作地點(diǎn)應(yīng)配備不少于0.2m3的消防沙和合格的4kg干粉滅火器2臺(tái)，工作人員必須了解滅火器使用方法；施工地點(diǎn)配有清水管路，4、井下施工準(zhǔn)備工作由楊付強(qiáng)負(fù)責(zé)檢查落實(shí)；安檢員負(fù)責(zé)施工安全設(shè)施檢查。（五）氣割作業(yè)前準(zhǔn)備1、人員到位?，F(xiàn)場負(fù)責(zé)人檢查氣割操作工、現(xiàn)場監(jiān)護(hù)工、火種攜帶工、灑水滅火工、瓦斯檢查工、安檢員到位情況。2、設(shè)定安全監(jiān)護(hù)。指定專人負(fù)責(zé)整個(gè)施工現(xiàn)場安全監(jiān)護(hù)。3、氣割前器具檢查。由氣割操作工再次對(duì)氣瓶、減壓閥、氣壓表、氣管、割炬等器具進(jìn)行詳細(xì)的安全檢查，確認(rèn)完好后，將各部件對(duì)接。4、現(xiàn)場灑水。由專職灑水工向施工點(diǎn)灑水，確保施工點(diǎn)10m范圍內(nèi)潤濕。5、檢查瓦斯。瓦斯檢查工對(duì)氣割工作地點(diǎn)及附近20m范圍風(fēng)流中的瓦斯?jié)舛群屯L(fēng)狀況進(jìn)行檢查，瓦斯?jié)舛炔坏贸^0.5%，只有在檢查證明作業(yè)地點(diǎn)及附近20m范圍內(nèi)巷道頂部無瓦斯積存時(shí)，方能進(jìn)行氣割作業(yè)。6、在施工點(diǎn)上風(fēng)側(cè)3m范圍內(nèi)，距頂板500mm處懸