Thank to the long experience in the Design and manufacturing Plants in the organic chemistry field, MFC Progetti can provide complete Plants also for the Resin Production Unit, based on our own proper know-how or tailored on Client know-how, based on the best available technology in the Mixing Equipment, Reactor manufacturing, Control System, Engineering Design.
The unit is designed to be used for every production recipe among the typical ones for the production of urea resins in water means. A fundamental characteristic of this unit is the specific high productivity, which is obtained thanks to quick dosing of the reagents by continuous electronic weighting of the reactor with pre-determination and efficient agitation study to achieve the maximum heat exchange as well as reaction speed.
The reactor is complete with half-pipe for heating and cooling service, it coils the lower dished bottom and part of the cylindrical shell of the reactor, it is divided into two different parts for eventual partial utilization. The reactor is also equipped with a special agitation device, suitable for polymerization as well as heat transfert film coefficients optimization because of the negligible temperature gradients inside the reactor.
Manhole, sight glass with explosion proof illumination lamp, special coupling for razing ball bottom valve, support saddles and various nozzles and instrumentation couplings are also provided.
The condenser is sloped horizontal to improve the drain of the product, it is complete with expansion device and calculated diaphragms to increase the cooling efficiency.
All the parts in contact with the process fluid are stainless steel AISI304 made, other parts in carbon steel.
The unit is suitable for polyurethanic elastomer resin production, starting from polyadipate, MDI and solvent Dimethylformamide (DMF) or Dimethylacetamide (DMAC).
The unit is composed by one reactor equipped with a heating circuit by hot water and a cooling circuit by cooling water.
The charge of the liquid products is carried out by vacuum from drums under weight control or directly by dosing tank or by volumetric counters.
The polymerization reactor is vertical, cylindrical with elliptical head. The upper head is provided with a flanged connection for agitator assembly. The lower head and the cylindrical part of the vessel are provided with a half coil with several inlets for heating and cooling.
The reactor is equipped with a double turbine high shearing mixer top entry, a special anchor agitator of double polarity complete with an explosion proof electrical motor.
The agitators are designed for a density up to 1.200 kg/m³ and for a viscosity up to 50.000 cp maximum.
Manhole, sight glass, internal lighting and various nozzles and instrument connections are provided.
The pad nozzle for the bottom ball valve is especially designed to avoid dead zones.

The unit is designed for production of the plasticizers used to manufacture plastic materials by phtalic anhydride’s esterification with 2-ethylhexil alcohol. It is possible to produce a wide range of plasticizers starting from similar raw materials Plasticizers production is obtained by a two steps reaction between one mole of anhydride or acid and two moles of a monofunctional alcohol
The first step is the addition of one mole of alcohol to the anhydride giving a monoester: this reaction is exothermic and very quick. The second step is the reaction of the second mole of alcohol with the monoester, giving the final product with formation of water. This second step can be nearly carried out to 100% conversion only if:
• all the water produced is removed by distillation;
• an excess of alcohol is present;
• a catalyst is present;
• the temperature is high enough.
When the reaction is practically completed, the catalyst is removed and the excess of alcohol is recovered from the crude plasticizer by distillation. The plasticizer is than separated from organic and inorganic impurities by washing with water. The purified plasticizer is than dried (by heating under vacuum) and filtered.
Before to effect the loading of the raw material, whether liquid or solid, the reactor R-01 is maintained in nitrogen atmosphere. The raw material have to be loaded in a pre-established molecular ratio, usually with an excess of alcohol respect to the acid or the anhydride. The starting temperature of the reaction is usually about 20-30°C under the alcohol boiling point (ex. 160°C in the case of 2-ethylhexil alcohol esterification). From the phase separator the alcohol return into the reactor and the heavy phase goes to the proper tank. When the reaction is completed, it is necessary to send the product into the blender R-02, where product neutralization and washing is carried out. Afterwards, the product is heated about 150°C under vacuum, and residual alcohol traces are stripped with living vapour followed by final dehydration under vacuum. It is also possible to add decolorant earth and active carbon in order to increase the final purity: solid additives are eliminated with the catalyst through a Filter.
The unit is suitable to manufacture polyester resin with an excess of glycol, recovery of the same using a Column with reflux of rich glycol phase into the reactor, final stripping of waste water and light compounds is carried out at atmospheric pressure and under vacuum.
The plant is also suitable to manufacture practically any kind of medium or high temperature resins, allowing a wide range of possible operations. It is equipped with high efficiency and double circulation diathermic fluid heating and cooling system to avoid scale on the heat exchanger. The charge of liquid products into the reactor is provided by the use of volumetric meters with pneumatic on-off valves to start/stop the reagent flow. The charge of solid reagents is effected by a special appendix on the reactor,