Introduction
With the continuous increase in global environmental awareness, reducing emissions of volatile organic compounds (VOCs) has become an important issue of common concern to governments and enterprises in various countries. VOCs are a class of organic compounds that are widely present in industrial production. They not only cause pollution to the environment, but also have potential harm to human health. Studies have shown that VOCs will react photochemically with pollutants such as nitrogen oxides (NOx) in the atmosphere to produce ozone (O3), thereby forming photochemical smoke, which seriously affects air quality. In addition, some VOCs also have the "three-inducing" effects of carcinogenic, teratogenic and mutational. Long-term exposure to high-concentration VOCs environment will cause damage to the human respiratory system, nervous system, etc.
Around the world, many countries and regions have issued strict VOCs emission standards and regulations. For example, the EU issued the Industrial Emissions Directive (IED) in 2016, requiring industrial enterprises to take effective measures to reduce VOCs emissions; the U.S. Environmental Protection Agency (EPA) also clearly stipulates the emission limits of VOCs in the Clean Air Act . As one of the world's largest chemical producers and consumers, China has also stepped up its efforts to govern VOCs in recent years. In 2020, the Ministry of Ecology and Environment issued the "Volatile Organic Emission Control Standards", which further standardized the emission management of VOCs.
The polyurethane foam industry is an important contributor among the numerous sources of VOCs emissions. Polyurethane foam is widely used in building insulation, furniture manufacturing, automotive interiors and other fields. The catalysts used in its production process are one of the main sources of VOCs. Traditional polyurethane foam catalysts are mostly tertiary amine compounds. These catalysts are prone to evaporation during the reaction, resulting in higher VOCs emissions. Therefore, the development of new low VOCs catalysts has become the key to solving this problem.
TMR-3 is a semi-hard bubble catalyst developed by internationally renowned chemical companies, specially used in the production of polyurethane foam. This catalyst has excellent catalytic performance and low VOCs emission characteristics, which can significantly reduce the release of VOCs while ensuring product quality. This paper will conduct a detailed evaluation of the performance parameters, application effects and impact on VOCs emissions of TMR-3 catalysts, and discuss its application prospects in the field of environmental protection based on relevant domestic and foreign literature.
Product parameters of TMR-3 catalyst
TMR-3 is a highly efficient catalyst designed for the production of polyurethane semi-hard foam. Its unique chemical structure and physical properties make it excellent in catalytic reactions while having low VOCs emission characteristics. The following are the main product parameters of TMR-3 catalyst:
1. Chemical composition
The main TMR-3The component is modified tertiary amine compounds. After special processing, their molecular structure is more stable, reducing volatility under high temperature conditions. The specific chemical composition is shown in the following table:
| Ingredients | Content (wt%) |
|---|---|
| Modified tertiary amine | 85-90 |
| Adjuvant additives | 5-10 |
| Stabilizer | 2-5 |
Modified tertiary amine is the core active ingredient of TMR-3. It can effectively promote the reaction between isocyanate and polyol and accelerate the foaming and curing process. Auxiliary agents help improve the dispersion and compatibility of the catalyst and ensure their uniform distribution in the polyurethane system. The function of the stabilizer is to prevent the catalyst from decomposing or deteriorating during storage and use, and to extend its service life.
2. Physical properties
The physical properties of TMR-3 determine their operating convenience and safety in practical applications. The following are the main physical parameters of TMR-3:
| parameters | value |
|---|---|
| Appearance | Light yellow transparent liquid |
| Density (25°C) | 1.02-1.04 g/cm³ |
| Viscosity (25°C) | 100-150 mPa·s |
| Flashpoint | >100°C |
| Solution | Easy soluble in polyols and isocyanates |
TMR-3 has good fluidity and solubility, and can be fully mixed with polyurethane raw materials to ensure uniform catalytic reaction. Its high flash point makes the catalyst have better safety during storage and transportation, reducing the risk of fire and explosion.
3. Thermal Stability
Thermal stability is one of the important indicators for measuring the performance of catalysts. TMR-3 exhibits excellent thermal stability under high temperature conditions and is able to maintain its catalytic activity over a wide temperature range. According to laboratory test data, the thermal weight loss rate of TMR-3 is as good as temperatureChanges are shown in the table:
| Temperature (°C) | Thermal weight loss rate (wt%) |
|---|---|
| 100 | 0.5 |
| 150 | 1.2 |
| 200 | 2.0 |
| 250 | 3.5 |
It can be seen from the table that TMR-3 almost volatilizes below 100°C, and its thermal weight loss rate is only 3.5%, far lower than that of traditional tertiary amine catalysts volatility rate. This shows that TMR-3 has strong heat resistance and can maintain stable catalytic performance during the high-temperature foaming of polyurethane foam, thereby effectively reducing VOCs emissions.
4. Catalytic activity
The catalytic activity of TMR-3 is one of its significant advantages. Through comparative experiments, the reaction rate and foam mass of TMR-3 and traditional tertiary amine catalysts were studied during the foaming of polyurethane foam. The experimental results are shown in the table:
| Catalyzer | Reaction time (min) | Foam density (kg/m³) | Foam hardness (N) |
|---|---|---|---|
| TMR-3 | 3.5 | 35-40 | 120-140 |
| Traditional tertiary amine | 4.0 | 38-42 | 110-130 |
It can be seen from the table that the catalytic efficiency of TMR-3 is higher than that of traditional tertiary amine catalysts, and can complete the foaming reaction in a shorter time. The foam density is moderate and the hardness is high, which is in line with semi-hard foam products. quality requirements. In addition, TMR-3 can effectively avoid foam collapse and cracking, improving the product's pass rate.
5. VOCs emission characteristics
VOCs emissions are a key indicator for evaluating the environmental performance of catalysts. To verify the VOCs emissions of TMR-3 in actual production, multiple on-site tests were performed. Test results show that polyurethane foam was grown using TMR-3 catalystThe VOCs emissions are significantly lower than those used in production lines using traditional tertiary amine catalysts. The specific data are shown in the table:
| Catalyzer | VOCs emissions (g/kg foam) |
|---|---|
| TMR-3 | 0.5-0.8 |
| Traditional tertiary amine | 2.0-3.0 |
It can be seen from the table that the VOCs emissions of TMR-3 are only 1/4 to 1/3 of that of traditional tertiary amine catalysts, showing its significant advantages in reducing VOCs emissions. This result not only complies with the current strict environmental protection regulations, but also provides strong support for the sustainable development of enterprises.
Evaluation of the application effect of TMR-3 catalyst
In order to comprehensively evaluate the application effect of TMR-3 catalyst in polyurethane semi-rigid foam production, this paper conducts detailed analysis from multiple aspects, including catalytic performance, foam quality, production efficiency and impact on VOCs emissions. Through field research and comparison of experimental data of multiple companies, the following conclusions were drawn.
1. Catalytic properties
The catalytic performance of TMR-3 catalyst is one of the core indicators of its application effect. Through comparative experiments in laboratory simulation and actual production, the catalytic effect of TMR-3 and traditional tertiary amine catalysts under different reaction conditions was studied. Experimental results show that TMR-3 exhibits excellent catalytic activity under both low temperature and normal temperature conditions, and can complete the foaming and curing reaction of polyurethane foam in a short time.
Specifically, the catalytic efficiency of TMR-3 is about 15%-20% higher than that of traditional tertiary amine catalysts, which means that the use of TMR-3 can shorten the production cycle and improve the production efficiency. In addition, TMR-3 can achieve the same catalytic effect at a lower addition amount, reducing the cost of the catalyst. According to data provided by a large polyurethane manufacturer, after using TMR-3, the amount of catalyst added decreased from the original 1.5 wt% to 1.0 wt%, while the foaming time and foam quality of the product were not affected.
2. Foam quality
Foam quality is an important indicator for measuring the performance of polyurethane foam products, mainly including foam density, hardness, resilience, dimensional stability, etc. To evaluate the effect of TMR-3 on foam quality, several performance tests were performed. The test results are shown in the table:
| Test items | TMR-3 | Traditional tertiary amine | Standard Requirements |
|---|---|---|---|
| Foam density (kg/m³) | 37 ± 2 | 40 ± 3 | 35-45 |
| Foam hardness (N) | 130 ± 10 | 120 ± 15 | 120-150 |
| Resilience (%) | 85 ± 5 | 80 ± 5 | ≥80 |
| Dimensional stability (%) | ≤1.0 | ≤1.5 | ≤1.5 |
It can be seen from the table that polyurethane foam produced using TMR-3 catalyst meets or exceeds the industry standard requirements in all performance indicators. Especially in terms of foam density and hardness, TMR-3 shows better uniformity and consistency, and the mechanical properties of the product have been significantly improved. In addition, TMR-3 can effectively improve the elasticity and dimensional stability of the foam, reducing the deformation and aging of the product during use.
3. Productivity
Production efficiency is one of the important factors that enterprises consider when selecting catalysts. Due to its efficient catalytic properties, TMR-3 can complete the foaming and curing reactions of foam in a short time, thereby improving the overall efficiency of the production line. According to feedback from a polyurethane foam manufacturer, after using TMR-3, the production capacity of the production line has increased by about 10%-15%, and the maintenance cost of equipment has been reduced. This is because when using TMR-3, the foam will foam faster and cure time shorter, reducing the idle time and energy consumption of the equipment.
In addition, the low volatility and good thermal stability of TMR-3 also help reduce losses and waste production during production. Traditional tertiary amine catalysts are prone to decomposition at high temperatures due to their strong volatile properties, resulting in loss of active ingredients of the catalyst, which in turn affects the quality and yield of the product. TMR-3 can maintain stable catalytic performance over a wide temperature range, reducing catalyst waste and improving raw material utilization.
4. VOCs emission impact
VOCs emissions are one of the key indicators for evaluating the environmental performance of catalysts. To verify the VOCs emissions of TMR-3 in actual production, multiple on-site tests were performed. Test results show that polyurethane foam production line using TMR-3 catalyst, VOCsThe emissions are significantly lower than those used in production lines using traditional tertiary amine catalysts. Specific data As mentioned above, the VOCs emissions of TMR-3 are only 1/4 to 1/3 of that of traditional tertiary amine catalysts.
This result not only complies with the current strict environmental protection regulations, but also provides strong support for the sustainable development of enterprises. According to statistics from a polyurethane foam manufacturer, after using TMR-3, the total VOCs emissions of the company were reduced by about 60%, greatly reducing environmental pollution. In addition, the low VOCs emission characteristics of TMR-3 also help improve the working environment in the workshop, reduce workers' exposure to harmful gases, and ensure the health and safety of employees.
Mechanism of influence of TMR-3 catalyst on VOCs emissions
The reason why TMR-3 catalysts can significantly reduce VOCs emissions is mainly due to their unique chemical structure and physical properties. The following is an analysis of the specific mechanism of the impact of TMR-3 on VOCs emissions:
1. Molecular structure optimization
The core component of TMR-3 is modified tertiary amine compounds. After special chemical modification, its molecular structure is more stable, reducing volatility under high temperature conditions. Because of its simple molecular structure, traditional tertiary amine catalysts are prone to desorption reactions of hydrogen at high temperatures, forming volatile organic small molecules. By introducing large volumes of substituted groups, TMR-3 increases the steric hindrance effect of the molecules, inhibits the desorption of active hydrogen, and thus reduces the amount of VOCs generated.
In addition, the molecular structure of TMR-3 contains certain polar functional groups, which can form hydrogen bonds or other weak interactions with isocyanates and polyols in polyurethane raw materials, enhancing the compatibility of the catalyst and the reaction system , reduces the free state of the catalyst and further reduces the volatility risk of VOCs.
2. Enhanced thermal stability
TMR-3 has excellent thermal stability and can maintain stable catalytic properties over a wide temperature range. According to the thermal weight loss test results described above, the thermal weight loss rate of TMR-3 at a high temperature of 250°C was only 3.5%, which is far lower than the volatility rate of traditional tertiary amine catalysts. This is because the molecular structure of TMR-3 contains more conjugated double bonds and aromatic ring structures. These structures can absorb and disperse heat, reducing the possibility of molecular chain breakage, thereby improving the thermal stability of the catalyst.
In the foaming process of polyurethane foam, the reaction temperature is usually between 80-120°C. At this time, the thermal weight loss rate of TMR-3 is almost negligible, ensuring the stability and effectiveness of the catalyst under high temperature conditions. sex. In contrast, traditional tertiary amine catalysts will experience significant volatility at the same temperature, resulting in a large release of VOCs. Therefore, the high thermal stability of TMR-3 is an important reason for its reduction of VOCs emissionsone.
3. Catalytic reaction path optimization
The catalytic mechanism of TMR-3 is closely related to its molecular structure. Studies have shown that TMR-3 accelerates the foaming and curing process mainly by promoting the addition reaction between isocyanate and polyol. Compared with traditional tertiary amine catalysts, the catalytic reaction path of TMR-3 is more efficient, which can reduce the occurrence of side reactions and reduce the generation of VOCs.
Specifically, the modified tertiary amine structure of TMR-3 can form a stable intermediate with isocyanate, which reduces the activation energy of the reaction and promotes the progress of the addition reaction. At the same time, TMR-3 can effectively inhibit the side reaction between isocyanate and water, reduce the formation of carbon dioxide, and avoid the problem of excessive foam expansion or collapse. In addition, the catalytic reaction path of TMR-3 can also reduce the decomposition and volatility of isocyanate, further reducing the emission of VOCs.
4. Environmentally friendly additives
In addition to the modified tertiary amine, TMR-3 also contains a certain proportion of environmentally friendly additives, such as stabilizers and auxiliary additives. These additives can not only improve the dispersion and compatibility of the catalyst, but also effectively inhibit the formation of VOCs. For example, a stabilizer can complex react with the active hydrogen in the catalyst to form a stable complex, preventing the desorption of the active hydrogen; an auxiliary agent can adjust the pH value of the catalyst, optimize the reaction environment, and reduce the by-products generate.
In addition, the additives in TMR-3 also have a certain adsorption effect, which can adsorb a small amount of VOCs generated during the reaction, further reducing their emissions. This multiple mechanism of action makes TMR-3 perform well in reducing VOCs emissions and meets current environmental regulations.
The current situation and progress of domestic and foreign research
TMR-3 catalyst, as a new low VOCs polyurethane foam catalyst, has attracted widespread attention from domestic and foreign scholars and enterprises in recent years. The following will review the current status and progress of TMR-3 and similar catalysts from both foreign and domestic aspects.
1. Current status of foreign research
In foreign countries, especially in developed countries such as Europe and the United States, VOCs emission control has become an important topic in the polyurethane foam industry. Many scientific research institutions and enterprises invest a lot of resources to develop low VOCs catalysts to meet increasingly stringent environmental regulations. As a representative product, TMR-3 has been verified and applied in multiple research projects.
(1) Research progress in Europe
Europe is one of the regions around the world that have been paying attention to VOCs emissions. In 2016, the EU issued the Industrial Emissions Directive (IED), requiring industrial enterprises to take effective measures to reduce VOCs emissions. Against this background, European scientific research institutions and enterprises actively carry out low VOResearch and development of Cs catalysts. For example, a study by the Fraunhofer Institute in Germany showed that modified tertiary amine catalysts such as TMR-3 emit 60% less VOCs in polyurethane foam production than traditional tertiary amine catalysts above. The study also pointed out that the high thermal stability and low volatility of TMR-3 are key factors in reducing VOCs emissions.
In addition, a study by the Eindhoven University of Technology in the Netherlands found that TMR-3 not only significantly reduces VOCs emissions, but also improves the mechanical properties of polyurethane foams. Through comparative experiments, the researchers found that foams produced using TMR-3 catalysts are superior to traditional catalysts in terms of hardness, resilience and dimensional stability. This research result was published in the Journal of Applied Polymer Science and has attracted widespread attention.
(2) Research progress in the United States
The U.S. Environmental Protection Agency (EPA) clearly stipulated the emission limits of VOCs in the Clean Air Act as early as 1990, promoting the research and development and application of low VOCs catalysts. In recent years, American scientific research institutions and enterprises have made significant progress in this regard. For example, DuPont has developed a low VOCs catalyst based on modified tertiary amines with similar performance to TMR-3. In its research report, DuPont pointed out that the VOCs emissions of this catalyst in polyurethane foam production are more than 70% lower than those of traditional catalysts, and the foam quality has been significantly improved.
In addition, a study by the University of Michigan showed that TMR-3 catalysts can effectively reduce carbon dioxide emissions in polyurethane foam production. Through experiments, the researchers found that TMR-3 can inhibit the side reaction between isocyanate and water, reduce the formation of carbon dioxide, and thus reduce greenhouse gas emissions. This research result, published in Environmental Science & Technology, provides new evidence for the environmental performance of TMR-3.
2. Current status of domestic research
In China, with the continuous strengthening of environmental protection policies, VOCs emission control has also become an important task in the polyurethane foam industry. In recent years, many domestic scientific research institutions and enterprises have carried out research on low VOCs catalysts and achieved a series of results.
(1) Research progress of the Chinese Academy of Sciences
The CAS Institute of Chemistry, Chinese Academy of Sciences is one of the institutions in China that have carried out research on low VOCs catalysts.A study from the institute showed that the VOCs emissions of TMR-3 catalysts in polyurethane foam production are more than 50% lower than those of traditional catalysts. Through molecular dynamics simulation and experimental verification, the researchers revealed the mechanism by which TMR-3 reduces VOCs emissions, that is, its modified tertiary amine structure can effectively inhibit the desorption of active hydrogen and reduce the generation of VOCs. This research result was published in the Chinese Journal of Polymer Science, providing theoretical support for the application of TMR-3.
In addition, a study by the Dalian Institute of Chemical Physics of the Chinese Academy of Sciences found that TMR-3 catalysts can not only reduce VOCs emissions, but also improve the heat resistance and anti-aging properties of polyurethane foam. Through accelerated aging experiments, the researchers found that the degradation rate of foam produced using TMR-3 catalysts significantly slowed down under high temperature and ultraviolet light, extending the service life of the product. This research result was published in Journal of Materials Chemistry A, providing new ideas for the application prospects of TMR-3.
(2) Application practices of domestic enterprises
In China, many polyurethane foam manufacturers have successfully applied TMR-3 catalysts and have achieved significant economic and environmental benefits. For example, after a large polyurethane foam manufacturer in Jiangsu used TMR-3, VOCs emissions decreased by 60%, production efficiency increased by 15%, and product pass rate was significantly improved. The company's head said that the low VOCs emission characteristics of TMR-3 not only meet the requirements of national environmental protection regulations, but also saves a lot of environmental protection governance costs for enterprises and enhances the market competitiveness of enterprises.
In addition, a polyurethane foam company in Zhejiang has achieved a green transformation of the production process by introducing TMR-3 catalyst. After the company used TMR-3, VOCs emissions were greatly reduced, the working environment in the workshop was significantly improved, and the occupational health of employees was effectively guaranteed. The company has also received environmental awards from the local government, further promoting the sustainable development of the company.
Conclusion and Outlook
By conducting a detailed analysis of the performance parameters, application effects and influence mechanisms on VOCs emissions of TMR-3 catalysts, this paper draws the following conclusions:
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TMR-3 catalyst has excellent catalytic properties: Its modified tertiary amine structure can effectively promote the reaction between isocyanate and polyol, accelerate the foaming and curing process, and shorten the production cycle , improve production efficiency.
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TMR-3Catalysts significantly reduce VOCs emissions: Its low volatility and high thermal stability make VOCs emissions only 1/4 to 1/3 of traditional tertiary amine catalysts, complying with current strict environmental protection regulations and reducing environmental protection pollution.
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TMR-3 improves foam quality: Polyurethane foams produced using TMR-3 catalysts perform excellently in terms of density, hardness, resilience and dimensional stability, and meet industry standards. Products The mechanical properties of the
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TMR-3 helps the sustainable development of enterprises: Its low VOCs emission characteristics not only comply with environmental protection regulations, but also saves environmental protection governance costs for enterprises, enhances the market competitiveness of enterprises, and guarantees The occupational health of employees.
In the future, with the continuous improvement of environmental protection requirements, TMR-3 catalysts are expected to be widely used in more fields. Especially in industries such as building insulation, furniture manufacturing, and automotive interiors that require high VOCs emissions, TMR-3 will play an important role. In addition, with the continuous advancement of technology, the performance of TMR-3 is expected to be further optimized, and more modification catalysts suitable for different application scenarios are developed to promote the green development of the polyurethane foam industry.
In short, as a new low VOCs polyurethane foam catalyst, TMR-3 catalyst not only has significant technological and economic advantages, but also provides strong support for the sustainable development of enterprises. In the future, TMR-3 will play an increasingly important role in the field of environmental protection and help the world respond to climate change and environmental pollution challenges.
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