Static Mixers and Mixer Heat Exchangers for PU Foam Processes
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1 Static Mixers and Mixer Heat Exchangers for PU Foam Processes A report presented by Fluitec mixing + reaction solutions AG, Alain Georg, Dipl. Ing. HTL, Research and Development CH-8413 Neftenbach
2 Overview of Topics Topic State of the Art Fluitec Polyol Mixer Functionality Mixer Heat Exchanger Functionality A New Approach New PU Concept New Mixer Heat Exchanger 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 2
3 Topic Foaming agent Formulation Temperature control Systems engineering Dosing technique Mixing technique 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 3
4 Topic Foaming agent Formulation Temperature control Systems engineering Dosing technique Mixing technique 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 4
5 State of the Art Typical applications since 1992 Catalyst blowing agent Pentane / R1416 / R134a... Polyol Activator Flame proofing agent High pressure pump CSE-XR Mixer- Heat Exchanger Polyol mixer High pressure pump Isocyanate CSE-XR Mixer- Heat Exchanger Mixing head 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 5
6 State of the Art Fluitec CSE-XR Mixer Heat Exchanger 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 6
7 State of the Art Fluitec CSE-XR Mixer Heat Exchanger Product out L1 = Product in DN2 DN1 H DN DN1 Water out Water in Patented System X DN2 L = Fluitec CSE-XR Mixer Heat Exchanger type A2-LQ PN Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 7
8 State of the Art Fluitec CSE-XR Mixer Heat Exchanger P I P P P PO P O P I I P P I S O P P I I P I S 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 8
9 State of the Art Heating and cooling systems 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 9
10 State of the Art Fluitec polyol mixer 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 10
11 State of the Art Fluitec polyol mixer for mixing air into polyol 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 11
12 State of the Art High pressure air injection Unit for testing available 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 12
13 State of the Art Loop Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 13
14 State of the Art Loop Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 14
15 Fluitec Polyol Mixer Functionality Characteristics of static mixing No moving parts Mixing effect only by pumping energy Exclusively radial mixing effect CSE-X polyol mixer A B Objective: - increases the potential of diffusive mixing - with pulsation free dosing of additives Mixture 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 15
16 Fluitec Polyol Mixer Functionality Soluble mixing application 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 16
17 Mixer Heat Exchanger Functionality 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 17
18 Mixer Heat Exchanger Functionality 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 18
19 A New Approach Solubility in a PU foam with partial pressure Ps Vapor pressure ps (bar) Temperature ( C) 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 19
20 A New Approach 6.0 Solubility of n-pentane approx. 5.5% by weight for aromatic Solubility in a PU foam with partial pressure Ps ester polyol under pressure. (Source: Evonik) Solubility in a polyurethane foam system (%) Vapor Pressure ps (bar) Temperature ( C) 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 20
21 A New Approach With most PU applications we have: A miscibility gap (normally more than 8% pentane) -> Ensures a 2-phase flow -> Means segregation effects if the dispersion is not stable (droplet size d t > 10 µm) outgassing during the cooling process -> solubility change due to cooling 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 21
22 A New Approach The following conditions are therefore of major importance: The pentane must be dispersed as a stable emulsion. During the cooling process, the mixture should be constantly mixed or dispersed. The pipe system after mixing must not have any dead zones. 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 22
23 New PU Concept Continuous sandwich panel lines High pressure pump (closed system) NEW CSE-XR heat exchanger Polyol Activator Catalyst Flame resistant NEW CSE-XR heat exchanger Mixing head Low pressure pump (closed system) Blowing agent n-pentane iso-pentane... Isocyanate High pressure pump (closed system) NEW CSE-XR heat exchanger Continuous production of metal composite elements 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 23
24 New PU Concept Loop Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 24
25 New PU Concept No soluble mixing application 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 25
26 New PU Concept Critical Capillary Number Ca 1.0E+03! simple shear flow (a = 0, Grace, 1982)! planar elongational flow (a = 1, Grace, 1982)! Critical capillary number Ca krit (-)! 1.0E+02! 1.0E+01! 1.0E+00! 1.0E-01! planar elongational flow (a=1, Bentley und Leal, 1986)! measuring points CSE-X mikromakro Technologie! 1.0E-02! 1.0E-07! 1.0E-06! 1.0E-05! 1.0E-04! 1.0E-03! 1.0E-02! 1.0E-01! 1.0E+00! 1.0E+01! 1.0E+02! Viscosity ratio λ 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 26
27 New PU Concept Critical Capillary Number Ca 1.0E+03! simple shear flow (a = 0, Grace, 1982)! planar elongational flow (a = 1, Grace, 1982)! Critical capillary number Ca krit (-)! 1.0E+02! 1.0E+01! 1.0E+00! 1.0E-01! planar elongational flow (a=1, Bentley und Leal, 1986)! measuring points CSE-X mikromakro Technologie! 1.0E-02! 1.0E-07! 1.0E-06! 1.0E-05! 1.0E-04! 1.0E-03! 1.0E-02! 1.0E-01! 1.0E+00! 1.0E+01! 1.0E+02! Viscosity ratio λ 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 27
28 New PU Concept µ 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 29
29 New Mixer Heat Exchanger Product out L1 = Product in DN2 DN1 H DN DN1 Water out Water in Patented System X DN2 L = Fluitec CSE-XR Mixer Heat Exchanger type A2-LQ PN Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 30
30 New Mixer Heat Exchanger 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 31
31 New Mixer Heat Exchanger Fluitec CSE-XR Mixer Heat Exchanger with no dead zones, less volume and higher mixing performance 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 32
32 Evaluation Advantages Additives savings No emulsifier needed No dead zones Stable emulsion Less soil disturbance Less waste Low cost dosing units Less wear of pump technology Pulsations are compensated Disadvantages Closed high pressure pumps are needed Air must be injected at high-pressure if bigger droplets are needed 28 Oktober 2015 Fluitec AG, CH 8413 Neftenbach Seite 33
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