by now we have it all - eoc group pu...polyurethane presentation peter spanhove date......
TRANSCRIPT
NOW WE
HAVE IT ALLHOW SO?
by EOC
WE EXPAND
A FULL RANGE OF
POLYURETHANE
SYSTEMS
EOC
• Mastered the art of making the perfect compound
• Excels at producing high performance latex
• Pioneered with superior hot melt coating
but we want to do even better, reach further and offer more
OUR ANSWER? A NEW BRAND!
POLYURETHANE SYSTEMS
Is the EOC brand name for all systems based on polyurethane
For use in artifical turf we have developed
• for artificial turf pre-coat
ATP
• for artificial turf foam-coat
ATF
WHY SHOULD I
EVEN CONSIDER POLYURETHANE
GRASS BACKING?
by EOC
GRASS BACKING
POLYURETHANE SYSTEMS
Why use a polyurethane grass backing?
• to excellerate production processing with a factor 2 up to 3
• to lower energy consumption with a factor up to 10
• to improve economical production performance and yarn
consumption
• to profit from high flexibility of product properties
• to improve production sustainability
• to produce high performance artificial turf at substantial
lower weight
SOUNDS GOOD!
BUT WHAT ABOUT MY EXISTING EQUIPMENT?
by EOC
EQUIPMENT
POLYURETHANE SYSTEMS
Yes, there is an investment involved but:
• the existing coating line and oven can be used
• you will get high end support from EOC
• and the same equipment can be used for pre-coat,
foam-coat and shockpad.
Count on an investment in
• a seperate PU dosing system
• a filler blending system
SO,
TELL ME MORE ABOUT THE PRE-COAT!
ATP
EXOPUR ATP
POLYURETHANE SYSTEMS
3 COMPONENT SYSTEM
• EXOPUROL ATP 1000 SERIES
polyol blend system (filled or unfilled)
• EXOPURANE ATP 2000 SERIES
isocyanate blend system
• EXOPURACT ATP 3000 SERIES
activator blend system and color
A reactive system that cures and prepolymerises as
soon as the components are mixed together and
heated.
EXOPUR ATP
POLYURETHANE SYSTEMS
POLYOLBLEND
IN IBC OR
STORAGE TANK
CaCO3
IN BIG
BAG OR SILO
ZEOLITE IN BIG
BAG OR PASTE
FILLER
BLENDING
SYSTEM
FILLED
POLYOLBLEND
IN IBC, STORAGE
OR DAYTANK
• Mix liquid polyolblend with solid
powder
• Discontinuous in blend tanks
• Continuous during production
Filler Blending System
EXOPUR ATP
POLYURETHANE SYSTEMS
POLYOLBLEND
IN IBC, STORAGE
OR DAY TANK
PU + AIR DOSING
SYSTEM
• Mix 3 components in the right ratio
• Controlled dosing, mixing, temperature
• Dosing linked to machine speed
• Coating thickness by roll or knife setting
• Short oven/cure at 100°C in 2 – 3 minutes
PU Dosing System
ISOCYANATE
BLEND IN IBC,
STORAGE OR DAY TANK
CATALYST -BLEND
IN IBC OR DAY TANK
COOLED STATIC
MIXER
PU-MIX
EXOPUR ATP
POLYURETHANE SYSTEMS
Advantages of PU pre-coat in production
• Higher production speed (x2, x3) for equal oven length
• PU cures faster than drying a water based system
• PU cures at lower temperatures than temperature
required for drying a water based system
• Evaporating water demands 6 times more energy
• PU-reaction is exothermic and creates heat
• No water vapour to ventilate, no hot air replacement
Savings on yarn consumption of 5% up to 10%
ATP - Pre-coat
• Less coating weight required (500 – 600 g/m²)
• Laydown weight = actual coating weight or dry weight
• High production flexibility
• Adjustable speed by adjustable oven temperature
(80 – 120°C)
• Adjustable speed by adjustable catalyst level
• Adjustable coating stiffness or improved coating
flexibility (by formulation adjustment)
Presentation Peter Spanhove date... meeting
Advantages of PU pre-coat in production
POLYURETHANE SYSTEMS
ATP - Pre-coat
Quality of PU pre-coat finished backing
• More consistent yarn length by moderated temperature
• Lower weight of grass rolls (depends on coating weight)
• Higher flexibility
• High tuft lock with minimum coating weight
• Very good water resistance
• Maintains good strength while wet
• Improved chemical resistance
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
ATP - Pre-coat
Energy required as compared to a water based system
• Energy required to evaporate water = +/- 1100kJ/900g/m² dry latex
• Energy required to heat up PU = +/- 110kJ/600g/m² PU
• Continuous exhaust of water vapour required in case of a water based system
• Exhausted humid air must be replaced by dry hot air (lot of energy loss)
• Very limited exhaust required with PU-system, only maintaining of oven heat is required. Mainly internal oven ventilation required.
• Oven temp latex 130°C – 160°C >< oven temp PU 100°C - 110°C
• Exothermic PU reaction releases heat!
• Exhaust system can be strongly reduced (adapt oven)
• Energy reduction can be reduced by factor 10!
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
ATP - Pre-coat
Substantial increase in yarn yield (temperature)
• Assume low heating at yarn side (< 60°C)
• Assume heating at backing side at different temperatures
– Yarn shrinkage at 140°C = +/- 15%
– Yarn shrinkage at 130°C = +/- 8%
– Yarn shrinkage at 120°C = +/- 5%
– Yarn shrinkage at 110°C = +/- 1%
Dropping oven temp. from 140°C 110°C resultsin an increased yarn yield up to 15%!!!
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
ATP - Pre-coat
Shrink effect of complete yarn at increasing temperature
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
ATP - Pre-coat
Shrink effect of yarn at increasing temperature: only at BACKING side
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
ATP - Pre-coat
POLYURETHANE CHEMISTRY
• Polymerisation starts immediately after mixing REACTIVE system
• Boosted by raw material temperature and oven temperature
• Boosted by catalyst level
• Correct dosing is important ratio between components must be right
• Important to cool raw materials! Increase pot life!
• Properties can be modified by formulation
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
Presentation Peter Spanhove date... meetingPOLYURETHANE SYSTEMS
Are you feeling the Chemistry?
You want to know more?
Contact us at [email protected]