03 Machinery and equipment for the plastics and rubber industries
03.02 Machinery and plant for processing
03.02.005 Machinery for foam and reactive resins
03.02.005.03 Machinery for processing/post processing of foam and parts
Machinery for processing/post processing of foam and parts
Product category: Recycling plants for PUR waste
Recycling reactors for PU residues
H&S Anlagentechnik has developed an innovative technology and reactor installations for the chemical conversion of flexible and rigid polyurethane foam residues into polyol. The technologies enable to produce high-quality recovered polyols on a suitable production scale.
In comparison to previous recycling methods, polyols generated by H&S technology have good reactivity and do not contain primary aromatic amines (methylene and toluene diamine), which are hazardous and not acceptable especially in bedding and upholstery foams.
Polyurethane foam manufacturers of both rigid or flexible types are showing a lot of interest in recycling technology. For flexible foam, this is because the methods previously used, such as rebound foam for carpet underlay and sports mats, are no longer economically attractive. Prices for flexible foam scrap has being decreased permanently.
Chemical recycling is a more efficient way to convert residues. Another factor is that polyol prices are rising permanently. Moreover, the ‘green’ aspect of recycling is increasingly important, as everyone is pushed to decrease CO2 emissions. Recycling is also one of the ways to cut greenhouse gas emissions and a closed production loop is also a highly sustainable route.
For rigid foam scrap, prices for disposal are rising tremendously. In Europe, such scrap can no longer be disposed of in landfill so it must be incinerated, and that is quite expensive.
Applications for mechanically recycled rigid foam, as powder, are limited. Also, since an enormous volume of rigid scrap is generated by processors such as big insulating panels manufacturers, recycling small amounts ground up as a powder filler cannot use it all. Of course the growing price of polyols also plays a role here.
H&S technology of rigid PU foam recycling is based on the glycolysis method where PU residues are being dissolved in a mixture of glycol and catalysts. The highlight of H&S method is that in comparison to previously known glycolysis technologies recovered polyols do not contain hazardous primary aromatic amines which is being achieved through a deamination phase.
Product category: Mixers, continuous type, for liquids
Blending stations for polyol and additives
Polyol formulating is a sensitive process which requires approved input materials, high-qualified personnel and reliable blending equipment. The quality of the PU systems is very important either for system houses or for end users which are consuming ready system polyols for internal application.
H&S blending stations designed for batch method are mostly used for formulating the components for all kinds of PU applications where it is necessary to mix polyol with liquid additives (catalysts, stabilizers etc.). H&S blending installations enable high dosing accuracy of the components due to optimal design of the units consisting out of pre-blender for the small amount of additives and main blender for the basic polyols. The precise weight control is being executed due to load cells installed for both of the blending tanks.
H&S blending stations are easy to operate due to high level of automation of all relevant processes like filling of the raw materials into blending tanks, metering, agitating, protection against overfilling, temperature controlling, discharge etc. Ready polyol blend can be transferred either to the intermediate storage tank, tank truck or into drums and containers by means of specially designed H&S filling station.
Due to operator-friendly visualization running the H&S blending stations is extremely easy. Recipe management “H&S Batch Control” is flexible and allows to save big number of recipes, record the results, control each equipment part, switch between manual and automatic mode in case if some modifications are required. Each step of the process can be programmed and modified according to the recipe features. Due to innovative inventory control it is possible to record and view the consumption of all raw materials for the defined period of time and prepare exact purchasing plan for the raw materials stock.
The control system includes traceability function for all batches what makes the production control more observable. All functions of “H&S Batch Control” system are targeted to achieving of the highest level of reproducibility and improving of quality management. Besides mentioned advantages in-house blending is also one of the instruments to minimize the manufacturing costs. Purchasing of the basic polyols and additives is cheaper than ready formulated polyols and provided up to 15% savings.
Many of H&S customers worldwide are successfully using the blending units for different applications. The majority of the blending stations were supplied for such applications as flexible and rigid foam products, aerosols, CASE etc. Basic and optional equipment for H&S blending stations includes: blender and pre-blender vessel in stainless steel safety trough for protection in case of leakage platform for pre-blender agitator for optimal homogenizing the material pumps for basic polyol and additives temperature control unit (if required) safety valves for protection the reactor vessel against overpressure or negative pressure automatic valves shut-off valves ultrasonic level control system weighing cells overfilling protection device temperature sensor pressure sensors pipeline system wiring of the complete module control cabinet with modern and high-performance Siemens SPS and PC, with operator friendly controlling functions and recipe management
H&S has developed a technology for post-consumer mattresses recycling.
H&S has developed a technology for post-consumer mattresses recycling.
Sulingen, 29 July 2016 — H&S Anlagentechnik has developed an innovative technology and reactor installation for the chemical conversion of PU foam out of post-consumer mattresses into high quality polyols for application in rigid PU foams.
Mattresses are not bio-degradable which makes it very difficult to recycle them in a conventional way. With up to 30 million mattresses annually are reaching their end-of-life in EU, it is estimated that 60% go to landfill under the common designation “Bulky Waste" and 40% are incinerated which is quite an expensive procedure.
The technology is based on an optimised acidolysis method and enables the generation of high-grade recovered polyols which can substitute up to 50% of the original polyol without compromising the physical and mechanical properties of the final product. This was already tested on a continuous lamination line of one of the European producers of insulation panels.
In contrast to previously known methods, polyols generated with the H&S technology have good reactivity and do not contain any hazardous primary aromatic amines. The manufacturing costs of the recovered polyol are approx. 35% lower than the market price of the original polyols.
Industrial installation is emphasizing the reactor, storage and conveying facilities for the solid and liquid input materials as well as recovered polyol and is designed to generate approx. 2,500 t of polyol per year.
H&S Anlagentechnik develops equipment and processing technologies for the efficient, flexible, reliable and environmentally friendly storage, metering, mixing and formulation of polyurethanes as well as equipment for the chemical recycling of polyurethane and PET waste. One of our main advantages is the combination of chemical and technical production expertise. We have enjoyed a reputation as a high-performing and reliable partner for the polyurethane manufacturing industry for in excess of 20 years.
We have specialised in the development of individual solutions to reflect the fact that our customers manufacture a variety of products incorporating a wide range of demands. Each project is planned and implemented in line with specific customer requirements.
It goes without saying that our equipment complies with the relevant statutory provision at all times.
Our engineers are trained to the highest level and bring a wealth of technical know-how and many years of international experience to the table. Modern production facilities at our Sulingen location and a worldwide network of distribution partners guarantee the high quality of our products and ensure that our customers receive attentive on-site service. We have successfully completed over 250 projects thus far. Our export quota of 70% also makes us a leading market supplier internationally.