(完整word版)年产1000吨聚氨酯改性环氧树脂车间工艺设计

论文设计了一种用聚氨酯增韧环氧树脂的生产工艺，对生产方法、生产工艺、设备装置、物料衡算和热量衡算都进行了详细设计说明，这对于环氧树脂的增韧工业生产起到指导作用。环氧树脂应用广泛，利用聚氨酯增韧改性环氧树脂的研究在国际上已经有实验室研究，设计合理的生产工艺加快推进其工业生产，很有意义。论文设计有条理，论述全

面细致，书写良好。

设计总说明

环氧树脂是一种重要的热固性树脂品种。它具有优良的物理机械性能、电绝缘性能、耐化学腐蚀性能、耐热及粘接性能， 然而环氧树脂在韧性等方面还存在不足，因此需要改性来增强其韧性。本设计中，用聚氨酯来改性环氧树脂来增强韧性，因为聚氨酯具有柔性的大分子链，高弹性及很好的耐振耐磨性能，用来增韧环氧树脂可获得性能优异环氧树脂基体，而环氧树脂增韧最常用的方法是利用弹性体改性，因此本设计选用了聚氨酯作为环氧树脂的增韧剂，同时聚氨酯的引入也使体系的强度有了很大的提高。

根据设计任务书，本设计进行了年产1000吨聚氨酯改性环氧树脂车间工艺设计。通过查阅大量的文献资料和认知实习，对聚氨酯改性环氧树脂的生产工艺、生产设备等进行了科学论证和设计。

针对聚氨酯改性环氧树脂后产品在技术上的严格要求，本设计选择了相应的配方和生产工艺条件。

根据有关实验得到结果，改变环氧树脂与聚氨酯两组分的质量比，改性环氧树脂的硬度、拉伸性能、冲击性能、断裂伸长率、维卡软化点和Tg都发生了变化。随着聚氨酯加入量的增加，拉伸强度逐渐增大，但聚氨酯加入量大于20％后，拉伸强度急剧下降，表明80/20时性能最佳，因此本设计中，环氧树脂与聚氨酯预聚体的质量配比取80/20。因此，本设计中聚氨酯预聚体与环氧树脂的质量比为1:4。聚氨酯预聚体的合成方法有一步法、预聚体法（二步法）、半预聚体法，一般现在的企业中以一步法，二步法为主。本设计中选用一步法合成聚氨酯预聚体，一步法是把聚醚二元醇和TDI(甲苯二异氰酸酯)在有机锡催化剂作用下进行合成；聚氨酯与环氧树脂的复合有反应型和非反应型，本设计中选用反应型的方法，通过反应型的方法会增加体系黏度，用稀释的方法降低黏度，这样保证了产品的黏度。

本设计中，确定的产品生产的工艺流程，依次为脱水、聚氨酯预聚体的合成 、聚氨酯预聚体与EP复合、稀释及脱泡。在脱水过程中，温度需要加热到120℃，时间在1小时左右，真空压力为0.1MPa，脱水后的水分含量在0.07%左右；在聚醚二元醇与TDI的合成中，温度需要加热到80℃，并在2个小时内保持反应温度；在聚氨酯预聚体与环氧树脂的复合过程中，温度控制在80℃，时间控制在1小时；在稀释过程中，温度控制在60℃，时间控制在半小时；在脱泡过程中，温度加热到140℃，时间在10至40分钟，

真空压力减至-0.098MPa。

本设计中对聚氨酯预聚体的反应釜进行了釜体，釜盖，搅拌装置，传动装置的设计。由于工艺操作中脱水聚醚的量占7.8%，因此本设计着重进行了搅拌轴的型式、长度的设计，并计算了所需搅拌轴的功率，从而计算出电动机的功率；计算出搅拌轴与反应釜釜底的距离为0.035m；使用了减压缓冲釜，目的是起到缓冲、减压、稳压的作用。本设计中，在聚醚二元醇脱水的过程中使用了真空装置和脱水装置，可以保证脱水后水的百分含量在0.5％以下；在过滤的过程中，使用了袋式过滤器，目的是过滤掉杂质。

结合实际选择的生产工艺方案，还进行了有关物料和热量平衡的计算。本设计任务聚氨酯改性环氧树脂的年生产总量为1000吨。根据计算，可连续班次生产，每日两班，因此计划每班的产量为2173.91kg，整个生产过程是在同一台反应釜中进行的。

根据年产1000吨聚氨酯改性环氧树脂车间工艺设计进行了车间布置设计。本设计中，车间厂房采用长方形双层厂房。厂房的尺寸（长×宽×高）为35m×17m×16m。长方形厂房便于工厂总图布置，便于车间内设备布置，节约占地面积，可供采光通风的墙体多，便于安排交通和出入口。

本设计也充分考虑了人员安全和环境保护方面的问题。在生产过程中，要求生产人员严格遵守操作规程，做好毒性防护措施，并经常参加相关培训，了解相关信息。

根据设计任务书所下达的任务，顺利完成对聚氨酯改性环氧树脂车间工艺的设计。在整个设计过程中，对聚氨酯预聚体生产以及其与环氧树脂复合的流程有一个全面的认识，并根据所学的专业知识，结合自己在认知实习中的经验，灵活应用，为今后从事相关的生产管理工作打下了一定的基础。

由于聚氨酯改性环氧树脂车间工艺设计的知识面很广，而我的知识和经验有限，设计错误和不妥之处，恳请批阅老师批评指正。

Illustration

Epoxy is a very important varieties of thermosetting resins. It has excellent mechanical properties, electrical insulation properties, corrosion-resistant chemical, and heat-resistant adhesive properties. However, epoxy resin still exist deficiency in toughness, so it needs to be modified to enhance its toughness. In this design, epoxy resin is modified by polyurethane to enhance the toughness, because polyurethane has a flexible macromolecular chains, high flexibility and good resistance of abrasion vibration. Being modified epoxy can obtain high performance epoxy resin matrix, and the most commonly used method of toughening epoxy resin is to use elasticity to modify. Therefore, the design uses polyurethane as the toughening of epoxy resin, in the mean time, the introduction of polyurethane also makes the strength of the system greatly improved.

According to the task, an annual output of 1000 tons of the polyurethane-modified epoxy resin workshop is designed in this task. Through access to a large number of literature and cognitive training, the production technology of polyurethane-modified epoxy resin and production equipment are scientific proofed and designed.

For the technical requirements of the production of polyurethane-modified epoxy resin, the design in accordance with the polyurethane-modified epoxy resin enterprise quality standards, the corresponding formulation and production process are selected.

According to the results of experiments, with the changes in mass ratio of two components, epoxy resin and polyurethane, hardness, tensile properties, impact properties, elongation at break, vicat softening point and glass transition temperature of polyurethane-modified epoxy resin have changed. With increase of the addition of polyurethane, the tensile strength increases, but after the additon of polyurethane is greater than 20%, tensile strength decreased sharply, which shows that the best performance is 80/20. Therefore, in this design, the mass ratio of epoxy resin and polyurethane prepolymer selects 80/20. The mass ratio of polyurethane and epoxy resin prepolymer is 1:4. The method of synthesis of polyurethane prepolymer:, the prepolymer method (two-step), semi-prepolymer method, the general now in an enterprise to one-step, two-step oriented. The selection of the

design synthesis is one-step, one step is that polyether binary alcohol and TDI (toluene diisocyanate) make synthesis in organic tin catalyst. The compositon of polyurethane and epoxy resin are reactive and non-reactive, The selection of the design is reactive approach. By reactive approach it can increase the viscosity, and it can reduced viscosity with dilution methods, thus ensuring the viscosity of the product.

In this design, the production process to determine the product is dehydration, the synthesis of polyurethane prepolymer, the composition of polyurethane prepolymers and EP, dilution and deaeration. In the dehydration process, the temperature needs to be heated to 120 ℃;the time is at 1 hour;the vacuum pressure is 0.1MPa; and the water content after dehydration is about 0.07%; in the synthesis of polyether diols and TDI, the temperature needs to be heated to 80 ℃, and it has been maintained the reaction temperature for two hours; in the composion process of polyurethane prepolymer and epoxy resin, the temperature is controlled at 80 ℃, and the time is controlled in 1 hour; in the dilution process, the temperature needs to be at 60 ℃, and time is controlled in half an hour; in the deaeration process, the temperature needs to be heated to 140 ℃, the time is at 10 to 40 minutes, and the vacuum pressure is reduced to -0.098MPa.

In the design, the kettle body, covered kettle, stirring device, transmission device of the polyurethane prepolymer reactor was designed. As amount of dehydration polyether account for 7.8% in process operations, the design has been focused on the type shaft, the length of the design and calculation of the required shaft power, so that motor power can be calculated; it is calculated that the distance from the mixing shaft to the end of reactor vessel is 0.035m;In the process of polyether glycol dehydration, vacuum devices and dehydration unit are used, which can guarantee that the removal percentage of water content is below 0.5%, in the process of filtration, a bag filter is selected, which filters out impurities.

Combining the producing craft and the products, the balance of materials and energy have been calculated. Originally, the annual output of the polyurethane-modified epoxy resin year designing is 1000 tons. According to calculations, there are two classes in the daily in the frequency of continuous production, so each class of the production plan for 2173.91 kg.The entire production process is advanced in the same reactor .

According to an annual output of 1000 tons of the polyurethane-modified epoxy resin workshop, a workshop is designed. The workshop adopts rectangular and double layer. The size of workshop is 35m×17m×16m. During the design of workshop, the rectangular workshop is advantaged to design the whole workshop, and advantage to arrange equipments and save areas, and advantaged to adopt the light and ventilate well, and also advantage to

arrange transport ,export and import.

This design also gives full consideration to the safety and environmental protection issues. In the production process, request that the personnel obey strictly the regulation to operate, and usually attend the related training to know about the relevant information.

According to the task issued by the design, the polyurethane-modified epoxy resin workshop design is successful accomplish. Throughout the design process, I have a comprehensive understanding of production processes of polyurethane prepolymer and processes of composition of polyurethane prepolymer and epoxy resin. And according to the basis of expertise, combining my knowledge of the internship experience and flexible application, there is a certain foundation for me to engage in work related to production management for the future.

As polyurethane-modified epoxy resin workshop design of knowledge is broad, and my knowledge and experience are limited, cordially requesting teachers make a comment to the mistakes and the inadequacies of the design.