carbon monoxide and hydrocarbons in the exhaust g a s / ' Dr. Herman F. Feldmann, BattelleColumbus Laboratories, reviewed coal gasification reactions and processes, emphasizing the role of chemical reaction engineering. One major problem area, he says, is that of reactivity studies. In both gasification and hydrogasification, the history of the char affects its subsequent reactivity; thus, experiments have to be conducted to characterize the particular char of interest. And because of the complexity of the system, efforts to develop universally applicable kinetic models for design may be fruitless. "The emphasis in this work should be on increasing the understanding of what goes on rather than on the generation of mathematical rate models," Dr. Feldmann says.
For example, why is production of methane, the desired end product for synthetic natural gas, not favored at optimal gasification conditions? Also needed, the Battelle scientist adds, is development of a better data and technology base for understanding solids-gas flow circuits in complex reactor systems, as well as gas-solids mixing between reactor zones. "Better understanding of these areas will help not only in the design and control of reactor systems now under development but allow new reactor concepts to be developed," Dr. Feldmann says. About 240 scientists from 13 countries attended ISCRE '.). The complete proceedings of the meeting will be published as part of the American Chemical Society's Advances in Chemistry series.
Urethane foam process gives better product The Foamax process is beginning an invasion of the U.S. flexible urethane foam industry. With the first U.S. installation having started up in January and two more nearing readiness, Rubicon Chemicals, Inc., now is moving to expand licensing of the European process in the U.S. Outside the U.S., 15 plants are using the process and 16 more will be in operation before the end of the year. Rubicon marketing director Donald A. Irwin, Sr., noting that high shipping costs are accelerating a trend in the foam industry toward small satellite plants, says Rubicon estimates that 30 to 50 new plants using the Foamax process will be built in the U.S. in the next five years. Rubicon—owned on a 50-50 basis by the chemical division of Uniroyal and by the U.K.'s Imperial Chemical Industries—is the licensor of the process in the U.S. and Canada for the Swiss firm Unifoam, A.G., of Glarus. The Naugatuck, Conn., company is a producer of toluene diisocyanate, one of the chemicals used to make urethane foam. The Foamax process doesn't change
the chemistry involved in making urethane foam. Rather the changes are in the way the material is foamed and handled. In conventional processing, the feed chemicals—commonly toluene diisocyanate, a high-molecular-weight polyol, and catalyst—go to a mixing head, which traverses a paper-lined conveyor. The mixture reacts to form the foam as the conveyor moves the slab forward. In the Foamax process, the mixing head and piping are fixed. The feed chemicals are deposited in a trough, where the mixture begins to react to form the foam. The foam expands and flows over the trough onto a downward-sloping weir to a horizontal paper-lined conveyor. This seemingly simple modification leads to numerous benefits, according to Rubicon. One of these is that expansion of the foam is downward rather than upward, as in the conventional process. As a result, the top of the slab remains flat instead of forming the usual dome. This shape, Rubicon says, gives the producer about 5% more first-quality foam than does the crowned slab.
Foam expands upward in conventional process Traversing mix head
Since expansion starts in the trough, there is a minimum amount of absorption of chemicals by the paper lining and less cell collapse. Thus, Rubicon says, there is very little skin on the bottom of the foam, compared to the dense, thick skin of conventional foams. Again, there is less waste material. A more uniform density gradient is a further advantage. A typical operation is producing foam with a variation of at most 2 pounds in indent load deflection (ILD), a measure of hardness, compared to a possible 8- to 10-pound variation in conventional foam. Rubicon also notes that less labor is involved. Only two or three operators, are required, it says, rather than six or seven. And, the company says, capital investment is lower, since the manufacturing equipment is about three fourths the length and half the height of ordinary equipment, therefore requiring less floor space and height. Among other advantages noted by Rubicon is a reduction in loss of carbon dioxide and 'or fluorohydrocarbon (foam-forming gases). Thus, foam density can be maintained with either less TDI or less fluorohydrocarbon. A further savings, according to Rubicon, may come from a less expensive formulation in which amine catalyst and silicone surfactant are reduced. On the debit side, with the current system it's not possible to change width during operation. The machine must be stopped before width is changed. Companies already using the Foamax process abroad are spread around much of the world—in Britain, the Netherlands, Denmark, Finland, Germany, Indonesia, Iran, Lebanon, Norway, Spain, and Italy. The first U.S. firm to operate the process is Crain Industries, Inc., Ft. Smith, Ark. Originally a distributor-fabricator of urethane foam for furniture, upholstery, and motor home markets, Crain Industries began making its own foam in January because of increasing shipping costs. Since then, according to Homer Crain, Crain Industries presi-
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C&EN Sept. 9, 1974
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dent, the company's volume has increased 250%, with half its business now in foam production. The company is now producing foam at a rate of about 10 million pounds per year. It turns out a "bun" per minute—3V2 feet high, 7 feet wide, and cut off at an 18foot length. Equipment for the Foamax process is made by Viking Engineering, Stockport, England, and Laader Berg, Ltd., Aalsund, Norway. Viking's U.S. representative is McNeil Femco division of McNeil Corp., Cuyahoga Falls, Ohio; Laader Berg's is Alleluia Cushion Co., Fort Worth, Tex. Alleluia is another of the U.S. operators, currently building a Foamax plant at City of Commerce, Calif., where it will have a 500 pound-perminute production line for carpet underlay. The third U.S. foam manufacturer to use the Foamax process is Hickory Springs Mfg. Co., Hickory, N.C., which expects to start up its operation this summer.
NOW, BECKMANS BI& IN SYNTHETIC PEPTIDES. GET A LOT-FOR A LITTLE1.
PPG to market solar energy ceSBs PPG Industries is now producing solar energy collector cells commercially. The company introduced the cells— designed for hot water and heating systems of multistory buildings and homes—late last month at the annual meeting of the U.S. section of the International Solar Energy Society, held at Colorado State University, Fort Collins. Solar energy systems incorporating the new flat plate collector cells can be installed in existing as well as new structures to supplement conventional hot water units, heating systems, or both, according to John P. Bologna, director of new products development of PPG's glass division. A complete system would also include piping and pumps to circulate the heat exchange fluid, a thermal storage unit, and a heat exchanger. Each cell is more than 6 feet long and nearly 3 feet wide. It consists of two tempered glass panels plus an insulated black aluminum absorber plate enclosed in a stainless steel frame. Sealed dry air spaces within the unit, which is l5/i6 inches thick, separate the two glass panels from each other and the absorber plate. An additional 2l/2 inches of glass fiber insulation blankets the back of the absorber plate. Special liquid circulates through tubing built into the plate. In some sunny climates, Mr. Bologna says, the hot water needs for a family of four or five could be met by a system using four of the cells. For the same size family and climate, living in a typical home with 2000 sq. ft. of floor space, about 80% of heating as well as all hot water needs could be met, he says, by a system having 20 cells.
You probably know that Beckman sells high quality synthetic peptides to researchers. But did you know that Beckman's facilities are designed specifically to make gram/kilogram amounts, and that Beckman has expertise in both solid-phase and classical methods? Could be that we can make your peptide more economically than you can yourself! Let us bid on it. Contact John N. Deutschlander, Byproducts Department, Spinco Division, Beckman Instruments, Inc., 1117A California Ave., Palo Alto, CA 94304. Our experience includes Luteinizing Hormone Releasing Hormone (LRH), Parathyroid Hormone (PTH), Melanocyte-Stimuiating Hormone-Release Inhibiting Factor (MIF), Thyrotropin Releasing Hormone (TRH)f Experimental Allergic Encephalitogenic Peptide (EAE), Angiotensins I and II, Substance P, and others. YOU CAN STILL GET
A LITTLER TOO.'
Beckman Sept. 9, 1974 C&EN
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