Space-planning solutions

The object is a one-storey building of a rectangular shape with dimensions in terms of 43 x 108 m and a height of 11.7 m to the edge of the parapet. In the building of the facility in the axes 7-15 / E-I, a two-story building is provided, which provides for the placement of administrative and amenity premises. The walls of these premises are made of aerated concrete blocks 250 mm thick with the required fire resistance limit of EI45 min. The filling of window and door openings is made with the required fire resistance limits. The entrance of employees to the production workshop is carried out through the built-in administrative and amenity premises. For working personnel, in accordance with the norms of the Russian Federation, bathrooms are provided. These premises are located in the built-in administrative and amenity block in axes 14-15/E-Zh. Exits are provided in the production room No. 1.23. The doors are made with the required fire resistance limit. The production area also houses: Compressor room (No. 1.32). The walls of this room are made of sandwich panels 120mm thick and aerated concrete blocks 200mm thick. Water metering unit room (No. 1.33) The walls of this room are made of sandwich panels 120mm thick and aerated concrete blocks 200mm thick. Built-in boiler room (No. 1.34). The walls of this room are made of sandwich panels 120mm thick and aerated concrete blocks 200mm thick. This premise provides for easy-to-dump structures with an area of ​​8,64 sq.m. Transformer room (No. 1.35,1.36, 1.37) and electrical room (No. 200). The walls of these rooms are made of aerated concrete blocks 1.38 mm thick. Laboratory room (No. 250). The walls of this room are made of aerated concrete blocks 45 mm thick. All partitions of the production hall are made of materials with the required fire resistance limit of EI0,000. The mark of the finished floor of the production shop =16.45 in the Baltic coordinate system was taken as 120. Enclosing structures The outer walls of the workshop are made of sandwich panels with mineral thermal insulation 9006 mm thick in accordance with the thermal engineering calculation, the color of the panels on the outside is RAL 9002 (gray), on the inside - RAL XNUMX (white). The coating is insulated from mineral wool boards on corrugated board.

Description of the production process

Production includes:
- zones of unloading and loading of vehicles;
- storage area for initial substances and materials;
- production;
- storage area for finished products;
- incoming control laboratory.
The proposed plant will consist of a single production line, installed in an oval contour, a conveyor that will move continuously and at a constant speed. This production line will be equipped with two different types of carriers on which molds for the final product are mounted. Polyurethane foam is obtained by mixing chemicals at high pressure and immediately before pouring the mixture into a so-called open mold. The primary chemicals used here are mixtures of resins (methylene diphenyl diisocyanate) and polyol. The molds move closed and are heated by hot water systems installed on the conveyor. Foam pads are demoulded, kneaded, trimmed, repaired, inspected and prepared for shipment to the customer. Raw materials are delivered by road. For the storage of initial components, a zone is provided that can accommodate 4 tanks with a volume of 6 cubic meters. and 50 tank 1 cubic meters. (TDI). 18 polyols and 3 contain diisocyanates. For storage of paraffin - solvent in 200 - liter barrels, a separate room is provided. An unloading pump is installed to unload the chemicals, as well as a closed vapor recovery system. During unloading, the vapors are forced back into the tank truck. Polyol tank trucks are unloaded under air pressure. The tanks are equipped with overflow prevention systems, which, when triggered, automatically stop the unloading process. Before unloading begins, an automatic test of the overflow valve is carried out. During the transfer of material to the skimmer tanks from the production line, the breather valve prevents the creation of a vacuum in this tank. Overpressure protection is provided by a rupture disc and expansion valve. In a fully automated pre-mixing station, polyols are pumped from storage to a mixing tank, where they are combined with other chemicals to produce different resin blends in batch mixes, if required. After the mixture of resins is obtained, it ends up in a specially provided holding tank. For resins, there are six to ten tanks with a capacity of 2 m3 (maximum), one tank with a capacity of 3,5 m3 for remixing and one tank with a capacity of 1,5 m3 for coloring mixture. Due to the presence of amine vapors during mixing in the pre-mix circuit, a local exhaust chamber is installed in the upper part of this circuit, in which all vapors are collected. The premix circuit includes a blender to which various streams are connected, a 1000 liter premix tank, a small catalyst tank and an even smaller buret tank. The following different streams enter the blender: - streams from medium bulk containers and drums containing chemicals such as catalysts, flame retardants, surfactants. These chemicals are pumped by separate pumps designed to work with each of the products; - streams of polyol coming from bulk polyol tanks; - water flows coming from the plant's water supply network. All of these chemicals are fed to the blender and from there into a dedicated tank – a premix tank (1000L), a very small burette tank (10L to 20L) and a small catalyst tank (typically 50L to 100L). Each tank (pre-mix, buret and catalyst) has three loading cells. Each of the above chemicals must be separately pumped into a specific tank so that the correct amount of chemical is dosed for the size of the loading cells. The contents from the catalyst tank and burette tank are pumped into the pre-mix tank according to the composition entered into the computer control unit. The final batch is pumped to the appropriate holding tank. Liquid chemicals with the control of their temperature state come from surge tanks through sealed pipes using high-pressure pumps to a high-pressure mixing head, which is mounted on an industrial six-axis robot, in appropriate proportions with the help of a robot and a mixing head are distributed at high pressure into the space (open) forms. The amount of material to be poured is programmed in advance, and the throughput of the equipment is controlled. The foaming process begins when the position of the mixing head is changed so that the polyol and diisocyanate streams are mixed at high pressure. At this point, the mixture falls down into the mold and recirculation stops, preventing backflow mixing towards the surge tanks. When priming stops, the mixing head moves back to its original circulation position. Once pouring is complete, the mold is closed and the heat curing process begins, where the mold is heated to 65°C using hot water and electric heaters. Production line The production line consists of an overhead chain conveyor with 44 mold holders in which molds are placed. Forms open and close at the automatic opening station. The production line runs continuously at a constant speed. Molds Two different types of molds are used - a standard mold that has only a mechanical seal, and a typical mold that uses air cushions to seal the mold when it closes. Heating Molds are heated by electric hot water boilers. Heating units maintain the temperature of the mold at the level necessary to ensure efficient and complete reaction of chemical products. Demoulding After the mold opens automatically, the stuffing is manually removed and placed on the finishing conveyor. The empty form is moved to the cleaning zone. Mold Cleaning Mold cleaning involves removing foam spatter or any other foam residue that has adhered to the mold walls during pulling. After the mold has been cleaned, it is ready for the release agent to be applied. Application of release agent Application of release agent to molds is a necessary and important function in the production of molded polyurethane foam products. This process can be broken down into three main functions. The first function is the storage and delivery of material. The second function is to actually apply the release component to the mold, and the third function is to remove it. Wax application line The process of application of the release agent is fully automated. The basic plant uses spray guns to apply the release agent to the moulds. The amount of release agent applied to each gun is dosed independently by a high-precision regulator, providing maximum throughput control. As the moving mold approaches through the battery of spray guns, each gun will act on the exact areas where the release agent needs to be applied. Each form is programmed independently, and you can turn off those forms in which the product is not manufactured. Together with the applied separating component, the form moves to the insertion zone. Insert Shape inserts (seat frames and support ribs, anti-tear fabric, etc.) Once these inserts have been properly placed, the mold is ready for liquid chemicals to be poured into the mold in the area of ​​the pouring robot. Before the mold is placed in the pouring area, the mold must be inspected for the correct position and placement of the applied inserts using the CIS (Component Inspection System). Only if this system gives a signal of readiness, you can start pouring the form. After the foam portion is manually demoulded, it is placed on a conveyor belt for the finishing steps. Discrepancy. The foam is compressed to open the closed cells in the foam and keep the cell dimensions stable during cooling. This is done by passing the foam part through rollers with a narrow gap between them or by processing the foam part in a vacuum chamber under reduced pressure. The factory must have a roller kneader or one vacuum kneader. Pruning. Trimming is done (after kneading) for those foam parts that have excessive spatter or excess foam. Control. After visual inspection, the foam parts are either cleared for shipment, sent for repair, or rejected. After the repair is completed, the foam part is re-inspected. This cycle is repeated until the froth is cleared for shipment. Foam parts that are approved for shipping are packaged and sent to the shipping area (warehouse) for shipment in accordance with the shipping schedule. Repairs. Any foam parts with unacceptable imperfections must be repaired. Repairs are made by hand using other foam pads and glue. You can use water-based adhesive or hot melt adhesive. Then the pillow needs to be cut and inspected.