Seminar HCFC ALTERNATIVES FOR THE FOAM SECTOR TECHNOLOGIES AND EQUIPMENT SOLUTIONS July 2014 Chapecó (SC) Brazil

Transcription

1 Seminar HCFC ALTERNATIVES FOR THE FOAM SECTOR TECHNOLOGIES AND EQUIPMENT SOLUTIONS July 2014 Chapecó (SC) Brazil

2 ABOUT EKOSYSTEM Located in Italy, Ekosystem has been producing Polyurethane machinery and equipment for more than 10 years. 90% of our machines are sold abroad: this is an important percentage for a little company but this amazing result is the fruit of our ability, our flexibility and our international presence (possible also thanks to our Representatives and Agents). Flexibility is our strength: being a little company allows us to be as close as possible to our customers: our little dimensions allow us to maintain great flow of information inside and outside the company allowing our customers to get information and news in a really short time, no matter where they are located.

3 EKOSYSTEM MACHINES Ekosystem produce low and high pressure foaming machines that are able to improve the productivity paying attention to expenses reduction. Each model is tailored to meet any costumer s need. Our machines can produce different kind of foam: Low density rigid polyurethane: used for panels in the building sector or insulation in the refrigerator field; High density rigid polyurethane: used for decorations and imitation wood in the furniture industry; Structural foams for technical particulars, for example in the health field and in the refrigerator one; Flexible and viscous-elastic foams for the production of stuffing, armchairs, couches, etc.; Integral foams (imitation leather) used in the automotive sector for the production of steering wheels, knobs, etc and in the furniture sector for armrest and seats (and in the motorbike sector as well); Elastomers used in different fields where high elasticity and mechanical strength are considered essential such as in the footwear and gasket production.

4 EKOSYSTEM AND ENVIRONMENT The Kyoto Protocol is an international treaty that sets binding obligations on industrialized countries to reduce emissions of greenhouse gases. Preventing dangerous human interference with the climate system is the ultimate aim of the UNFCCC, so how can we prevent? BY USING ALTERNATIVE BLOWING AGENTS such as Pentane, Methylformate, Methylal, HFC and water based solutions.

5 EKOSYSTEM AND PENTANE Pentane: classified as an alternative blowing agent by Montreal and Kyoto Protocol and it is used as a blowing agent during the manufacture of Polyurethane foams. Thanks to Pentane rigid and integral foam can be manufactured without an impact on the environment. In fact, since it does not contain chlorine (unlike CFCs and HCFC), Pentane does not harm to the ozone layer and can replace more harmful chemicals and greenhouse gases. The primary route of Pentane release is to the air due to its volatility. It rapidly degrades in the atmosphere and it is unlikely to contribute to ozone depletion. Even if it does not cause adverse health or environmental effects at levels typically found in workplace and environment, Pentane is considered potentially explosive and flammable and for this reason safety measures must be adopted. It must be processed with safety measures and Atex certified products.

6 WHEN KNOWLEDGE AND EXPERIENCE MEET Ekosystem has developed several projecs fot the use of Pentane. The delevelopment consists in looking after each phase, from the draft of the project to its production and start-up. WHAT ARE THE SECURITY MEASURES UNDERTAKEN? THE ANSWER IS IN THE PROJECT ITSELF.

7 PENTANE PLANT PENTANE PLANT FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE: IT CONSISTS OF 2 HIGH PRESSURE FOAMING MACHINES AND A BAMIX. BAMIX MIXES POLYOL AND PENTANE AND SUPPLIES THE BLEND TO THE MACHINES TANKS. THE PENTANE-POLYOL SIDE IS CONTAINED IN A CABIN IN ACCORDANCE WITH NORMATIVES

8 PREMIX UNIT: BAMIX SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE - SAUDI ARABIA, TRANSFER PUMP TRANSFERING THE BLEND FROM THE STORAGE TANK TO THE MACHINES TANKS 300 LT STORAGE TANK CONTAINING THE BLEND THAT IS TRANSFERRED TO THE TANK BY PUMPS ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

9 PREMIX UNIT: BAMIX SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE. SAUDI ARABIA, POLYOL PUMP WITH MAGNETIC COUPLING PRESSURE SWITCH TO CHECK PRESSURE AND ANOMALIES SELF CLEANING FILTER FLOW METER IN ORDER TO KNOW THE CORRECT FLOW OF THE POLYOL TO BE MIXED ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

10 PREMIX UNIT: BAMIX SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE. SAUDI ARABIA, STATIC MIXER FOR POLYOL AND PENTANE BLEND

11 PREMIX UNIT: BAMIX SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE - SAUDI ARABIA, MASS FLOW METER: HIGH ACCURACY TO MEASURE FLOW, DENSITY AND TEMPERATURE OF THE BLOWING AGENT FIRE-PROOF VALVE CONNECTED TO DETECTORS STOPS MIXING IN CASE OF ANOMALY GAS DETECTOR ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

12 Premix unit: BAMIX SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE - SAUDI ARABIA, SYSTEM THAT DETECTS LEAKAGES IN THE PUMP AND CONTROLS OIL LEVEL ATEX PRESSURE SWITCH WITH MIN AND MAX PRESSURE CONTACTS AND ANALOGICAL OUTPUT TO DISPLAY PRESSURES ON CONTROL PANEL EXCHANGER FOR PENTANE COOLING DOSING PUMP THAT TRANSFERS PENTANE TO THE MIXER WHERE IT MIXES WITH POLYOL ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

13 VENTILATION SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE - SAUDI ARABIA, ASPIRATOR WITH SPARK- PROOF FAN WHEEL AND ATEX MOTOR AIR GAUGE TO CONTROL THE AIR FLOW INSIDE THE VENTILATION DUCT IN CASE OF PENTANE LEAKAGES, THE SECOND FAN STARTS SUCTIONING THE GAS DEPOSITING ON THE BOTTOM OF THE VASSEL. THEN, THE GAS IS DISCHARGED OUTSIDE.

14 SAFETY MEASURES for BAMIX TO SUM UP: GAS DETECTORS AND LEAKAGES LIQUID SENSOR MANAGED BY A PLC IN ORDER TO PROTECT THE PLANT IN CASE OF ANOMALY; PUMP WITH ATEX MOTOR; METAL PARTS MUST BE GROUNDED; GAS SUCTION; ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA.

15 polyol side of the machine SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE - SAUDI ARABIA, DOUBLE VENTILATION GAS DETECTOR LIQUID SENSOR FOR PENTANE DETECTION ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

16 polyol side of the machine SUPPLY OF TWO HIGH PRESSURE FOAMING MACHINES AND A BAMIX FOR THE PRODUCTION OF PANELS IN DISCOUNTINUOUS MODE. SAUDI ARABIA, CAPACITANCE LEVEL PROBE STIRRER WITH DOUBLE SEAL ON SHAFT AND ATEX MOTOR LIMIT SWITCH IN ATEX BOX MANOMETER TO DISPLAY PRESSURE INSIDE THE TANK ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA SUPERMAX LEVEL: IN CASE OF PROBLEMS WITH CAPACITANCE LEVEL, IT STOPS LOADING BEFORE IT REACHES A DANGEROUS LEVEL

17 FOAMING MACHINE: SAFETY MEASURES ON POLYOL SIDE TO SUM UP: PUMP WITH ATEX MOTOR; EXPLOSION-PROOF GAS DETECTORS; EXPLOSION-PROOF LIQUID SENSOR; DOUBLE VENTILATION; METAL PARTS MUST BE GROUNDED; ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA.

18 ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA HIGH PRESSURE DOSING UNIT FOR CONTINUOUS PANEL PRODUCTION: UNIDO PROJECT MP/TUR/10/003 PURCHASE OF EQUIPMENT AND TECHNICAL SERVICES REQUIRED FO THE CONVERSION OF RIGID POLYURETHANE FOAM BLOWING FROM CFC-141B TO N-PENTANE AT MEKPAN METAL PANEL, KONYA, TURKEY MASS FLOW METER PANEL FOR PENTANE SAFETY MEASURES. CARDS CONNECTED WITH GAS DETECTORS GIVE ACCURATE INFORMATION ABOUT THE PERCENTAGE OF GAS IN THE AIR. CARDS WITH 3 ALARM LEVELS LIQUID SENSOR, GAS DETECORS AND INFRARED SENSOR

19 HIGH PRESSURE DOSING UNIT FOR CONTINUOUS PANEL PRODUCTION: UNIDO PROJECT MP/TUR/10/003 PURCHASE OF EQUIPMENT AND TECHNICAL SERVICES REQUIRED FO THE CONVERSION OF RIGID POLYURETHANE FOAM BLOWING FROM CFC-141B TO N-PENTANE AT MEKPAN METAL PANEL, KONYA, TURKEY CAPACITANCE LEVEL PROBE LOADING VALVE C/W LIMIT SWITCH MANOMETER TO DISPLAY PRESSURE INSIDE THE TANK ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA SUPERMAX LEVEL: IN CASE OF PROBLEMS WITH CAPACITANCE LEVEL, IT STOPS LOADING BEFORE IT REACHES A DANGEROUS LEVEL

20 HIGH PRESSURE DOSINH UNIT POR CONTINUOUS PANEL PRODUCTION: UNIDO PROJECT MP/TUR/10/003 PURCHASE OF EQUIPMENT AND TECHNICAL SERVICES REQUIRED FO THE CONVERSION OF RIGID POLYURETHANE FOAM BLOWING FROM CFC-141B TO N-PENTANE AT MEKPAN METAL PANEL, KONYA, TURKEY DIAPHRAGM PUMPS HIGH ACCURACY PENTANE DOSING ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

21 HIGH PRESSURE DOSING UNIT TO SUM UP: GAS DETECTORS, LIQUID SENSOR AND INFRARED SENSOR; CONTROL PANEL FOR PENTANE; DOUBLE VENTILATION; METAL PARTS MUST BE GROUNDED; ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA.

22 *PRESSURE GAUGES HAVE 2 CONTACTS, MIN AND MAX PRESSURES THAT CAN SHUT DOWN THE PLANT. ALL THE PRESSURE GAUGES HAVE BARRIERED CONTACTS. SAFETY MEASURES: STORAGE UNIDO PROJECT MP/TUR/10/003 PURCHASE OF EQUIPMENT AND TECHNICAL SERVICES REQUIRED FO THE CONVERSION OF RIGID POLYURETHANE FOAM BLOWING FROM CFC-141B TO N-PENTANE AT MEKPAN METAL PANEL, KONYA, TURKEY SUBMERSIBLE PUMPS, TAKING PENTANE DIRECTLY FROM THE INSIDE OF THE TANK. ASSEMBLED ON THE FLANGE, THEY DELIVER PENTANE DIRECTLY IN THE DOSING ZONE PRESSURE GAUGE FOR TANK PRESSURE BARRIERED SENSOR ON/OFF VALVE: IT BLOCKS PENTANE FLOW IN CASE OF ANOMALY BARRIERED SENSOR PRESSURE GAUGE FOR TANK JACKET PRESSURE BARRIERED SENSOR PRESSURE GAUGE FOR PENTANE PIPING PRESSURE* BARRIERED SENSOR PRESSURE GAUGE FOR JACKET PRESSURE* BARRIERED SENSOR INFRARED SENSOR FOR GAS LEAKAGES SAFETY VALVE TO DISCHARGE JACKET NITROGEN PRESSURE IN CASE OF EXCESSIVE INCREASE

23 SAFETY MEASURES: STORAGE PENTANE LOADING PIPE NITROGEN UNLOADING PIPE SAFETY VALVES FOR PRESSURE DISCHARGE IN CASE OF OVER PRESSURE

24 SAFETY MEASURES: STORAGE SUPERMAX LEVEL ADDITIONA L SAFETY MEASURE. ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

25 SAFETY MEASURES: STORAGE GROUNDING SYSTEM AUTOMATIC VALVES BLOCKING LOADING OPERATIONS IN CASE OF ANOMALY PIPE FOR PENTANE LOADING OPERATIONS PIPE FOR NITROGEN UNLOADING FROM TANK TO TANK TRUCK

26 SAFETY MEASURES: STORAGE PLIERS FOR TANK TRUCK IN ORDER TO GROUND IT FOR A SAFE UNLOADING. EMERGENCY BUTTON IN CASE THE OPERATOR NOTICES ANY ANOMALY NOTE: LOADING OPERATIONS CANNOT BE CARRIED OUT WITHOUT THE OK GIVEN BY THE GROUNING SYSTEM.

27 SAFETY MEASURES: STORAGE MANOMETERS BOX TO REGULATE AND CONTROL THE PRESSURE OF THE TANK, OF ITS JACKET AND OF THE PENTANE PIPE JACKET. ALL OF THEM ARE FED BY NITROGEN REGULATORS ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN

28 SAFETY MEASURES: STORAGE MANOMETER FOR INLET PRESSURE USED TO CHECK THE QUANTITY OF NITROGEN IN THE CYLINDER. MANOMETER FOR OUTLET PRESSURE REGULATOR/REDUCER TO REDUCE THE TANK PRESSURE IN ORDER TO DISTRIBUTE NITROGEN WITHOUT ANY PROBLEM. ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

29 SAFETY MEASURES: STORAGE ACCESSORIES FOR PENTANE TANK SUPPLY OF ACCESSORIES FOR LITRES CAPACITY TANK HORIZONTAL UNDERGOUND POSITIONING, ROMANIA 2014 MATIC VALVE TO REGULATE THE PRESSURE OF PENTANE RECYCLE REGULATOR AND MANOMETER FOR PENTANE PIPE JACKET SENSORS FOR LEAKAGES INSIDE THE PUMPS REGULATOR AND MANOMETER FOR MATIC VALVE DIAPHRAGM PUMPS. PUMPS FED BY THE TANK DIRECTLY. THANKS TO PRESSURE APPLIED TO THE TANK, THEY CAN DELIVER PENTANE FROM STORAGE TO THE DOSING UNIT. PRESSURE GAUGE PUMP WITH CONTACTS FOR MAX AND MIX PRESSURE IN ORDER TO INFORM ABOUT ANOMALIES ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

30 SAFETY MEASURES: STORAGE ACCESSORIES FOR PENTANE TANK SUPPLY OF ACCESSORIES FOR LITRES CAPACITY TANK HORIZONTAL UNDERGOUND POSITIONING, ROMANIA 2014 HOW TO GRANT SAFETY INSIDE THE PRODUCTION AREA: THE STAINLESS STEEL PENTANE PIPING IS COVERED WITH ANOTHER STEEL JACKET TO CHECK PENTANE LEACKAGES THROUGH THE NITROGEN PRESSURE CONTROLLED BY PRESSURE GAUGES IN THE JACKET. THE SAME OCCURS IN THE TANK JACKET. ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA

31 SAFETY MEASURES: STORAGE ACCESSORIES FOR PENTANE TANK SUPPLY OF ACCESSORIES FOR LITRES CAPACITY TANK HORIZONTAL UNDERGOUND POSITIONING - ROMANIA 2014

32 SAFETY MEASURES: STORAGE TO SUM UP: EX PROOF SUBMERSIBLE OR DIAPHRAGM PUMPS CONNECTED TO EX. PROOF MOTORS; PRESSURE GAUGES TO KEEP PENTANE PRESSURE UNDER CONTROL; SAFE VALVES TO DETECT PENTANE IN CASE OF LEAKAGE; DUEL PIPELINE; GAS DETECTORS; MECHANICAL PARTS MUST BE GROUNDED; ALL THE ELECTRICAL DEVICES ARE IN COMPLIANCE WITH ATEX DIRECTIVES IN ACCORDANCE WITH THE SAFETY REGULATIONS OF THE HAZARDOUS AREA.

33 EKOSYSTEM AND METHYLAL: Methylal is flammable and in Europe it belongs to the middle class of flammability. Pure Methylal is treated with the same safety measures used for Pentane. In 2014 Ekosystem has provided an high pressure foaming machine able to work with polyols that have incorporated Methylal as blowing agent. These polyol/ Methylal blends may eventually be flammable.

34 THANK YOU! FOR FURTHER INFORMATION: Visit our web site: you will find any further information you may need. Join our network on LinkedIn Do not hesitate to contact us for any need via phone no or via