Project Abstract

The production of high quality foam was carried. The actualization of the production of polyurethane (fibre) foam was made possible by using the components / chemical raw materials such as polyol (polyurethes resin). TDI (toluene di-Iso-cyanate, methylane chloride (MC)-(CH2CL). Silicon oil, stannous octoate, calcum carbonate and water.

As a result of chemistry of polyurethane foams, properties of foams and fibre materials (physical, chemical, thermal and mechanical properties) gotten from the literature, review including the functions and reactions of the components proper formulation was made and conversions / translation to actual weights also done which lead to the production of the desired product. The experiment was done at ambient temperature of 320c following the normal procedures.

The foam produced is of very high density, good quality, durable and profitable. The densities of the various samples are 35kg/m3 and 40kg/m3.

As a result of poor storage conditions of the chemicals mentioned above here in the pilot plant, the stipulated and specified environmental conditions, there is a slight deviation of the foam from the international standard specification of 155. The foam produced are measured to standard and can be used for applied to any field of engineering and technology. They can be used for any purpose and is expected to last longer depending on the handling.

Project Overview

Chapter One

1.0             Introduction

1.1       Problem statement

1.2             Aims and objectives of the project

Chapter two

2.0             Literature Review

2.1       Origin of foam

2.2             Structure of polyurethane

2.3             Properties of polyurethane foam

2.4             Classification of polyurethane

2.5             Flexible foam

2.6             Rigid foam

2.7             Basic chemistry of foam production

2.8             Polyurethane chemicals and functions

2.8.1       Man chemicals

2.8.2       Blowing agents

2.8.3       Catalyst

2.9             Foam stabilizers

2.10         Making / Agitation

2.11         Characteristic features of methyl come chloride

2.12         Some possible faults, causes and their remedies.

2.13         Characteristics of fibre foams

2.14         Physical properties of foam polyurethane

2.15         Thermal properties of polyurethane foams

2.16         Foam fibres applications

2.17         Factors that causes defect during process

Chapter three

3.0             Foam formulation

3.1       The roles of chemicals in foaming reactors

3.2             Determination of Chemical consumption rates

3.2.1       Water

3.2.2       Tohiene DI – Isocyate

3.2.3       Blowing Agents

3.2.4       Schlone

3.2.5       Amine

3.2.6       Stannous actuate

3.2.7       Colorant

3.3             Summary of the formulation

Chapter four

4.0             Production procedure / Analyses

4.1       Essential Raw Materials Used

4.2             Procedures / methods

4.3             Experimental Results / Analysis

4.4             General Thermal properties

4.5             Chemical properties

4.6             Optical properties

4.7             Electrical properties

4.8             Permanence and service properties

4.9             Characteristic Test

4.10         Sampling and conditioning

4.11         Storage and Handling of urethane raw materials

Chapter five

5.0             Discussion

Chapter six

6.0             Conclusion

6.1       Recommendation

6.2             Cost Analysis

6.3             References