Chapter 3 Material Balance

MATERIAL BALANCE

3.1: PLANT CAPACITY

2.95*107Kg/year (3424.68 Kg/hr) of PU Flexible foam (ref 1)

3.2: ASSUMPTIONS

1: Polycondensation mechanism (ref: 2)

2: we restrict ourselves to major groups are taken into account because in
polycondensation mechanism all the chains combine with each other at all times
during reaction hence giving a large no of products.

3.3: REACTIONS

Major reaction is
200 TDI + 100 PPG (PU) 100
Other reactions are
2 TDI + 1 PPG (PU) 1
(PU)1 (PU)5
(PU)5 (PU)10
(PU)10 (PU)100
3.4: CALCULATIONS

TDI needed = 507.58 Kg/hr

PPG needed = 2917.10 Kg/hr

21
Chapter 3 Material Balance

Using Law of conservation of mass;

(A * X) /(n * ML) = (B – U)/(n * ME) = S / M1
Where;
A = Amount of limiting reactant
X = Conversion
N = No. of moles of limiting reactant
B = Amount of excess reactant
U = Unreacted excess reactant
N = No. of moles of excess reactant
S = amount of (PU)1
M1 = Mol. wt of (PU)1
ML = Mol. wt of Limiting reactant
ME = Mol. wt of Limiting reactant
Using above formula we can tabulate the results as shown below

To Final
From TDI From PPG To R-202
Component In R-200 To R-201 To M-300
Storage Storage (2nd TDI)
(1st TDI) product

TDI (Kg/hr) 507.58 192.88 38.57 318.55 3.185

PPG (Kg/hr) 2917.10 2917.1 2030.3045 1830.77 18.30

PU1 (kg/hr) 208.22 44.25 21.36

PU5 (kg/hr) 832.88218 83.29 0.83

PU10 (kg/hr) 1147.81 11.4781

PU100 (kg/hr) 3369.15

R-II (kg/hr) 13.70

SILICON (kg/hr) 34.268

3424.6
Total (kg/hr) 3109.98 3109.98 3424.68 3424.68
8

22
Chapter 3 Material Balance

3.5: VISCOMETERS

A viscometer (also called viscosimeter) is an instrument used to measure the

viscosity and flow parameters of a fluid.

The classical method of measuring due to Stokes, consisted of measuring the

time for a fluid to flow through a capillary tube. Refined by Cannon, Ubbelohde
and others, the glass tube viscometer is still the master method for the standard
determination of the viscosity of water.

Rotational viscometers use the idea that the force required to turn an object in a
fluid, can indicate the viscosity of that fluid.

The common Brookfield-type viscometer determines the required force for

rotating a disk or bob in a fluid at known speed.
'Cup and bob' viscometers work by defining the exact volume of sample which is
to be sheared within a test cell, the torque required to achieve a certain rotational
speed is measured and plotted. There are two classical geometries in "cup and
bob" viscometers, known as either the "Couette" or "Searle" systems -
distinguished by whether the cup or bob rotates. The rotating cup is preferred in
some cases, because it reduces the onset of Taylor vortices.
'Cone and Plate' viscometers use a cone of very shallow angle in bare contact
with a flat plate. With this system the shear rate beneath the plate is constant to a
modest degree of precision and deconvolution of a flow curve; a graph of shear
stress (torque) against shear rate (angular velocity) is very straightforward to
yield viscosity.

3.6: REFERRENCES
1: Statistic data from PCSIR
2: “Polymer science by Gowariker”
“Textbook of polymer science by: Billmeyer” ,

23
Chapter 3 Material Balance

“Polymer science & technology by: Fried”

“Principles of polymerization by: Odian

24