Mc lc

Trang
M u...........................................................................................................................3

Chng 1. Tng quan v nha phenolic.

..................................................................4
1.Lch s pht trin.................................4
2.Nguyn liu.....................................6
2.1.Phenol.................................6
2.2.Andehyt...................................................9
3. Phn ng tng hp...................................................................................................11
3.1. Phn ng to nha rerolic.....................................................................................11
3.2.Phn ng to nha novolac...................................................................................12
1.3.3. iu kin ngng t nha...................................................................................13
4.ng dng..................................................................................................................17
5.Sn xut nha novolac..............................................................................................19
Chng 2. Tnh ton k thut.......................................................................................23
2.1.Tnh phi liu v cn bng vt cht.......................................................................23
2.2.Tnh ton thit b...................................................................................................25
2.2.1.Tnh ton thit b chnh......................................................................................26
2.2.2.Tnh cnh khuy.................................................................................................30
2.2.3.Tnh bo n thit b phn ng.............................................................................33
2.2.4. Tnh thit b ..................................................................................................36
2.3.Tnh thit b ph....................................................................................................38
2.3.1.Tnh thit b ngng t.........................................................................................38
2.3.2.Thng cha v thng lng................................................................................41
2.3.3.Tnh bm cht lng............................................................................................45
2.3.4.Tnh cn bng nhit lng..................................................................................48
Chng 3 Xy dng...................................................................................................56

3.1.Yu cu v la chn a im xy dng...............................................................57

3.2.Thit k tng mt bng..........................................................................................58
3.3.Gii php cu to nh............................................................................................63
3.4.Gii php thng gi...............................................................................................63
Chng 4 Tnh ton in nc...................................................................................65
4.1.in dng trong sn xut.......................................................................................65
4.2. Nc dng trong sn xut....................................................................................66
Chng 5 Tnh ton kinh t........................................................................................68
5.1.Tm tt d n.........................................................................................................68
5.2.Th trng v k hoch sn xut...........................................................................68
5.3.Tnh ton kinh t....................................................................................................69
Chng 6 An ton lao ng.......................................................................................76
6.1.An ton lao ng trong nh my...........................................................................76
6.2.Nguyn nhn gy mt an ton lao ng................................................................77
6.3.Cc bin php m bo an ton lao ng..............................................................77

M U

Cng ngh vt liu ngy cng ng vai

tr quan trng trong khoa hc v trong
i sng x hi. Cng vi s pht trin
ca cc ngnh khoa hc v k thut,
ngnh cng ngh vt liu ni chung v
cng ngh vt liu polyme ni ring ngy
cng c nhiu tin b vt bc, to ra
nhiu loi vt liu c tnh cht u vit
c ng dng rng ri trong khoa hc
v trong i sng.
Vt liu polyme c s dng rt rng ri, cc sn phm t polyme gn lin vi i
sng con ngi, chng em li nhiu tnh cht tt v hiu qu kinh t cao. Nha
phenolic hay phenolfomandehit ni ring l loi nha tng hp u tin c ng dng
trong thng mi. Mc d c tng hp mun hn nhiu loi nha khc v ch a
vo sn xut cng nghip nhng nm u ca th k 20 nhng cho n nay nha
phenolic khng ngng pht trin c v s lng v cht lng. Sn lng tiu th nha
phenolic hng nm tng ln ng k. Trn c s vic: Thit k dy chuyn sn
xut nha phenolfomandehit dng novolac theo phng php gin on vi nng
sut 300 tn/nm mang tnh thc t v cn thit.

Chng 1 tng quan v nha phenolic

1. Lch s pht trin.
Phenol l nha tng hp, sn phm ca qu trnh trng ngng gia phenol v
fomandehit. Nha phenolic l loi nha tng hp u tin c sn xut thng mi.
Nm 1872 Bayer l ngi u tin pht hin phn ng gia phenol v aldehit. Sau
vo cui th k 19 c cc nh khoa hc Klecbegr, Tollens, Abel nghin cu, tuy
nhin sn phm ca h ch l nha khng nng chy, khng ho tan t thu ht c s
quan tm. Cng thi gian hai nh ho hc Leaderer v Manasse ch ra rng O-, Phydro benzyl alcol (phenol alcol) c th nhn c t phenol v fomadehit trong mi
trng kim.Qu trnh tng hp nha phenolic tip tc c nhiu nh ho hc nghin
cu trong nhng nm cui ca th k 19 v Thus, Claus, Trainer tng hp c nha
phenolict phenol v axetandehit trong mi trng axit (HCl)
Vo nhng nm u ca th k 20 rt nhiu nh ho hc nghin cu v qu trnh
to nha phenolic bng vic s dng cc loi xc tc khc nhau. Blumer ngng t
phenol v fomandehit khi c mt hn hp cc axt, thu c nha ho tan trong ru v
chng c s dng lm nguyn liu sn xut vecni.
Smith tng hp phenolic t phenol v axetandehit vi s c mt ca axt HCl. Sn
phm thu c c tnh cch in tt.[1]
Story li cho phenol phn ng vi aldehit trong thi gian di m khng s dng
xc tc, nha thu c c c im l ng rn chm, thch ng vi cc sn phm
khun c.
Nm 1907 1909 Leo Backeland cng b nhng nghin cu ca mnh v loi
nha phenolfomandehit vi xc tc kim c tn thng mi l Bakelite v trong mi
trng axit to nha nhit do Novolac vi t l cu t phenol/fomandehit >1.Tuy
nhin nha to thnh cha c s dng trc tip nh nhiu loi nha khc. Backerland
nghin cu cu trc nha v a ra gii php khc phc kh khn trong qu trnh gia
cng sn phm. Ngay sau hng Bakelite ln u tin a vo sn xut nha phenolic
nh du bc pht trin ca nha phenolic.
Cc nm sau nha phenolic khng ngng c pht trin c v s lng v
cht lng:[11]
Nm 1935 nha phenolic c sn xut nhiu nht so vi cc loi nha khc.

Nm 1954 nha phenolic c sn xut 20.000 tn.

Nm 1965 nha phenolic c sn xut 65.000 tn.
Nm 1987 nha phenolic ln ti 2,3 triu tn
Nm 1993 l 2,8 triu tn.
Nm 1998 lng nha phenolic c sn xut l 3,4 triu tn.
Vit Nam nha phenolic c s dng mun hn ch yu dng bn thnh
phm v nguyn liu cho mt s loi vt liu nh : bt p, vn p, si p, keo dn,
sn t nha phenolic bin tnh,
Nm 1958 1960 Trung tm nghin cu vt liu polyme trng i hc Bch
Khoa H Ni ( ngy l b mn cao phn t ) gip xy dng phn xng sn
xut keo dn ti nh my g Cu ung.
Nm 1975 Nam T gip xy dng nh my vn dm khu cng nghip Vit tr.
Sau min Nam xy dng cc nh my vn dm, g p ng Nai,Si Gn.
Tnh hnh pht trin nha phenolic Vit Nam 2000 2003:[
Giai oan 1: Xy dng v lp t 6 nh my vn p nng cng sut ln22.000 tn.
Giai on 2: Xy dng v u t chiu su cho 108 nh my ch bin lm nghip.
Giai on 3: Xy dng v hon thin xong 108 nh my nng cng sut ln
85.000 tn p ng mt phn nhu cu trong nc.

2. Nguyn liu.
Nguyn liu chnh sn xut nha phenolic l phenol v aldehit.
2.1.Phenol.
Cng thc cu to ca phenol:

Cng thc ho hc ca phenol C6H5OH, do cu to ho hc ca phenol ti cc v

tr ortho v para nguyn t hydro rt linh ng nn nha t phenol c kh nng chuyn
sang trng thi khng gian ba chiu.
2.1.1.Tnh cht l hc ca phenol.[4]
iu kin thng phenol c mu hng nht hoc nu sm. Cc sn phm cha
phenol t do trong qu trnh bo qun c mu thay i t hng nht sang nu sm.
Nhit si ca phenol ts=182,10C.
Trng lng ring ca phenol d = 1,0596 g/cm3.
iu kin thng phenol l tinh th c nhit nng chy l 42,3oC, nhit
ho rn l 40,5 40,9oC.
Phenol rt c, vi hm lng phenol rt nh trong khng kh cng gy ng c.
Phenol ho tan trong cc dung mi phn cc: ru, axeton,Tnh tan trong nc ca
phenol ph thuc nhit .
2.1.2.Cc phng php iu ch phenol.

[5]

Phenol t nhin c tch ra t cc sn phm ch bin nhin liu rn nhit

cao. Ngoi ra phenol tng hp c th iu ch bng cc phng php sau:

Phng php sunfua ho: bao gm cc giai on sau:

Sunfua ho benzen to axit benzoic.
un nng chy kim vi axit th hi.
Phn gii phenol bng axit sunfuric v tin hnh chng benzen th.
Nhc im ca phng php ny l c nhiu giai on, tn nhiu xt, axit v

hiu sut phn ng khng cao.

Cc phn ng xy ra trong qu trnh trng hp:

C6H6

H2SO4

C6H5SO3H

C6H5SO3H + NaOH

+ H2O.

C6H5SO3Na + H2O.

C6H5SO3Na + NaOH

C6H5ONa + Na2SO3 + H2O.

C6H5ONa +

C6H5OH

H2SO4

+ Na2SO4

Phng php clo ho:

X l clobenzen bng Na2CO310% theo t l 1:1,25 c mt oxit diphenyl.

lng, tch phenol em chng theo hi nc hoc x l clobenzen bng NaOH10% theo
t l 1:1,25 tng t nh vi Na2CO3.

Phng php Ra-sic: phng php ny gm hai giai on:

Giai on 1: Cho benzen tc dng vi HCl v khng kh nhit 200-230 oC c

mt mui nhm, st. Sn phm thu c cha clobenzen.

Giai on 2: Tch ra clobenzen v thu phn trong l tip xc nhit 350oC
vi xc tc SiO2 hoc Ca3(PO4)2. Ra phenol nhn c v em chng ct.
Cc phn ng xy ra nh sau:
C6H6 + HCl + 1/2 O2
C6H5Cl

C6H5Cl

+ H2O

+ H2O.

C6H5OH + HCl .

Phng php oxy ho trc tip benzen:

Tin hnh oxy ho benzen nhit 800oC, p sut 70at, c mt xc tc HF. Hn

hp sn phm em chng ct nhiu ln thu phenol. Phng php ny t c s dng

do hiu sut thp(30-60%).

Phng php Cu-men:

Tin hnh alkyl ho benzen 850C, p sut 70at v xc tc AlCl3 to

izopropylbenzen:
C6H6

+ CH2=CH

CH3

C6H5CH(CH3)2.

Oxy ho izopropylbenzen nhit 600-650oC c mt khng kh to hydropeoxit:

C6H5CHCH(CH3)2

O2

C6H5C(CH3)2OOH.

Phn gii hydropeoxit bng axit H2SO410% thnh phenol v axeton cng mt s sn
phm ph khc.
C6H5C(CH3)2OOH.

C6H5OH

+ CH3COCH3

Tin hnh chng ct phn on thu phenol. Phng php c xut Lin X
v l phng php kinh t nht hin nay c ng dng nhiu nc trn th gii.

Phng php Dow (Dow Chemiscal):

Tin hnh oxy ho toluen theo hai giai on:
Giai on 1: oxy ho toluen bng khng kh nhit 120-150oC c xc tc Co

to axit benzoic. Phn ng to nhit mnh v c nhiu sn phm ph.: HCOOH,

CH3COOH, C6H5CHO,..
Giai on 2: Decacboxy ho axit benzoic vi xc tc Cu2+:

Qu trnh tin hnh p sut thng, nhit 200-250 oC, Cu2+ s dng dng dung
dch 1-5%.
2.1.3.Mt s phenol khc:[3]
Crezol: CH3C6H4OH.
Crezol c ba ng phn:

o-Crerol.

m-Crerol.

p-Crerol.

Crezol thng tn ti di dng hn hp ba ng phn. nhit si ca hn hp l

185-205oC, trng lng ring 1,044g/cm3. Crezol ho tan trong ru, ete, kim, kh ho
tan trong nc. Crezol nhn c ch yu t sn phm x nhit ca than , than nu, g.
Xylenol: (CH3)2C6H3OH.
Xylenol c su ng phn, xylenol k thut dng lng nht, mu nu,, trng lng
ring 1,035-1,040 g/cm3. Xylenol tan trong dung dch kim 10%. Xylenol cng nhn
c ch yu t x l nhin liu rn.
Resocsin (m-dioxy benzen): C6H4(OH)2.
Resocsin dng tinh th rn, nhit nng chy l 110oC v nhit si l
276,5oC, trng lng ring l 1,285 g/cm3.
2.2.Aldehyt.
2.2.1.Fomandehyt.

Tnh cht l hc ca fomandehyt

[6]

Fomandehyt l cht kh khng mu, mi mnh. Khi lm lnh fomandehyt s ho

lng, nhit si l -21oC, nhit nng chy l

-92oC, nhit 93oC s ng

thnh mt cht tinh th rn trng lng ring l 0,815 g/cm3.

Fomanhehyt thng c s dng dng dung dch vi nc gi l focmalin.
Focmalin cha 33- 40% th tch fomandehyt. Khi lu thy kt ta trng tch ra t
dung dch focmalin l polyme ca fomandehyt (parafooc ). trnh hin tng trn
thng s dng ru metylic 7-12% trong focmalin. Hm lng ru trong focmalin
c th thay i tu thuc nhit mi trng

Cc phng php iu ch fomandehyt:

+ Oxy ho ru metylic bng oxy khng kh c bc tham gia. Phn ng xy ra nh sau:

CH3OH
+ 1/2 O2
HCHO
+
H2O

Hoc phn ng kh hydro ca ru:

CH3OH

HCHO

H2O

Phn ng oxy ho c th tin hnh trong chn khng hoc di p sut.

+ iu ch fomandehyt t metan:
Mtan c iu ch t cc sn phm ch bin du m v kh thin nhin. Oxy
ho kh metan khng hon ton 1400-1500oC xy ra phn ng:
CH4

O2

CH4

CO +
CH

4 H2
CH

+ 3 H2

Metanol c tng hp t hn hp H2 v CO trn v tin hnh oxy ho metanol

nhit 500-600oC c mt xc tc th nhn c fomandehyt.
+ Oxy ho etylen: cho hn hp kh cha 85% etylen v 15% oxy v th tch qua cc
cht tip xc tr nh: t st nung tm H2BO3 hoc H3PO4 375oC hoc i qua thp
cht y bt tm KMnO4 hay KClO3 nhit ln hn 100oC. Hiu sut to
fomandehyt kh cao (70-80%).
2.2.2.Axetandehyt: CH3CHO.
L cht lng c mi kh chu, nhit si l 20,8 oC, nng chy

123,5 oC,

trng lng ring l 0,792g/cm3. Axetandehyt ho tan trong nc ru, ete.

Axetandehyt rt r t trng hp.
2.2.3.Fufurol.
Cng thc ho hc ca fufurol:

L cht lng khng mu, mi d chu. Nhit si l 161,7oC, ng rn 36,5oC,

trng lng ring l1,1598 g/cm3. Fufurol tan trong ru etylic, metylic, ete, axeton.
Trong qu trnh bo qun nu c mt khng kh th fufurol s c mu ti dn v ru
ho. bo qun ngi ta thng cho thm hydroquynol hoc parafooc.
Phng php ch yu sn xut fufurol l thu phn cc ph phm trong nng
nghip: rm, d, li ng,tin hnh thu phn di p sut v nhit ln hn 100oC.
Ngoi ra c th nhn c fufurol bng cch thu phn g hoc than nu.

3.Phn ng tng hp.

3.1.Phn ng tng hp nha rezolic.
Nha phenolic dng rezolic nhn c trong mi trng kim. C ch xy ra trong
mi trng kim xy ra nh sau:

Ion phenolat c kh nng gii to in tch vo vng benzen lm cho mt in t

ti cc v tr ortho v para ca vng tng ln.
Cc ion ny s phn ng vi fomandehyt theo phng trnh:

Trong mi trng kim ion hydroxy metynol phenol bn vng v cc v tr hot

ng cn li ca phenol tip tc phn ng vi fomandehyt to ra cc mono, di, tri
hydroxy phenol.

Hn hp ru phenolic ny s ngng t to nha rezolic:

3.2.Phn ng to nha novolac.

Nha novolac to thnh trong iu kin mi trng phn ng l axit. C ch phn
ng nh sau:

Ion metylol s tn cng vo v tr giu in t ca phenol.

Trong mi trng axit cc metylol phenol khng bn chng tng tc vi ion H+ to

ion metylolphenol.

Hoc chng ngng t vi nhau to cu ni metylen.

3.3. iu kin ngng t nha.

Phn ng ngng t nha ca phenol v fomandehit l phn ng tng bc v vy ta c
th tch cc sn phm v nghin cu cc sn phm ban u tng i n nh. Qua
nhiu th nghim thy rng cc iu kin nh : cu to ho hc ca nguyn liu, t l
cu t, mi trng phn ng nh hng quyt nh n qu trnh to thnh v cc tnh
cht ca nha.
3.3.1. iu kin ngng t nha rezolic.
Nha rezolic to thnh trong iu kin :
Mi trng phn ng l mi trng kim.
T l Phenol / fomandehit > 1 (d phenol).
Phenol phn ng c ba v tr hot ng.
Xc tc cho phn ng:

Cc xc tc thng dng l : NaOH, Ba(OH)2, NH4OH,..

o NaOH: L xc tc mnh , dng vi lng nh (0,1%), NaOH cn c tc dng lm
cho cc sn phm a t ban u d ho tan trong mi trng phn ng. Nhc in ca
loi xc tc ny l cn phi tin hnh trung ho kim cn li trong nha.V cn kim d
trong nha lm gim cc tnh cht k thut ca nha: mu sc, bn nc, tnh cht
cch in,..
o

Ba(OH)2: l xc tc yu hn NaOH nn dng vi lng nhiu hn (1-1,5%),

Ba(OH)2 d trung ho bng CO2, mui tr cn li trong nha khng nh hng n cc

tnh cht k thut ca nha. Do tc dng xc tc yu hn nn d khng ch tc phn
ng ngng t .
o

NH4OH: Thng s dng dng dung dch amoniac 25%. L xc tc ph bin

c s dng tng hp nha rezolic ng dng trong cc lnh vc khc nhau. NH4OH
kt hp vi fomandehit to thnh urotropin v vy ta c th s dng trc tip urotropin
lm xc tc. Hm lng thng ly t 0,5 - 3% so vi phenol. S dng dung dch
amoniac d khng ch tc phn ng nhng c nhc im l sn phm d b rp
trong qu trnh p nng do to kh NH3.

T l cu t:
Trong mi trng kim nu d phenol vn to thnh nha rezolic. y t l cu

t khng khng nh hng quyt nh nh vi nha novolac. Hm lng cc cu t

c ly gn vi ng lng phn t. Khi tng hm lng fomandehit th tnh cht ca
nha cng thay i: tng nhit nh git, tng tc ng rn v gim hm lng
phenol t do trong nha.

Thnh phn ho hc ca cc cu t :
c trng ho hc ca phenol tham gia phn ng ngng t thnh rezolic nh hng

ln n qu trnh a t : tc a t , tc ng rn,..
Cc phenol c ba v tr hot ng ho hc tham gia phn ng rt mnh lit vi
fomandehit v to nha rezolic c nhit rn cao. Nha i t phenol, m-crerol c tc
ng rn cao. Fomandehit thng s dng dng dung dch vi nc gi l
focmalin, nng fomandehit 37- 40%, trong focmalin cha 7- 12% metanol ng vai
tr cht bo qun. S c mt ca metanol lm gim hiu sut ngng t, nng

fomandehit t l vi tc phn ng.V vy hm lng metanol trong focmalin cng

thp, hm lng fomandehit cng cao th tc phn ng cng mnh.
3.3.2.iu kin to nha novolac:
Nha novolac to thnh trong iu kin:
Phenol c 2 hoc 3 v tr hot ng.
T l phenol / fomandehit >1 (d phenol).
Mi trng phn ng l mi trng axit .
Xc tc :[3]
Cc loi xc tc hay dng l : HCl, H2SO4, axit osalic,..
HCl : Nng HCl trong mi trng phn ng l 0,1- 0,3%, PH mi trng phn
ng t : 2,2 1,8. Phn ng a t to nhit ln nn HCl cn a vo thnh nhiu ln.
HCl c u im l khi sy s tch khi hn hp cng vi hi nc nhng nhc im
ca n l n mn thit b.
H2SO4 : Axit ny ch c s dng trong thng hp c bit. Tc dng xc tc
ca axit sunfuric km hn axit HCl v khi sy axit H2SO4 cn li trong nha v vy phi
tin hnh trung ho axit , cc mui tr cn li trong nha lm nh hng n mu sc
ca nha. Axit H2SO4 gy n mn thit b rt ln.
Axit osalic: L axit hu c phn ly yu, hot tnh xc tc km nn c s dng
vi lng ln. Qu trnh phn ng xy ra m di, d iu chnh hn nhng thi gian
phn ng li ln hn rt nhiu so vi axit v c. Nha to thnh c mu sng v bn
nh sng hn.
Axit focmic: Axit focmic lun c trong fomalin nhng hm lng thp khng
m bo tc ph ng cn thit. V vy khi tin hnh a t p sut thng v
nhit si ca hn hp cn phi thm axit m bo PH mi trng xung 2,2-1,8.
Nu tin hnh phn ng p sut v nhit cao th qu trnh xy ra kh nhanh v
khng cn thm axit xc tc.
Trong thc t axit HCl c s dng ch yu sn xut bt p v axit osalic
thng dng sn xut novolac cho cng nghip sn.

T l cu t:

Nha novolac ch nhn c trong iu kin tha phenol. Trong sn xut t l

phenol:fomandehit thng ly l 6:5 hoc 7:6. Lng fomandehit cng gn vi phenol

th nhit chy mm, trng lng phn t trung bnh, ho rn nhit ca nha
novolac to thnh cng cao, lng phenol t do trong nha cng gim ( lng phenol t
do trong nha cng nh nha cng d chuyn thnh nha rezolic).

iu kin sy v a t:

Qu trnh a t nha to thnh khng tan trong hn hp phn ng, c th kt thc

qu trnh a t khi c s phn lp. Nhiu kt qu thc nghim cho thy nu ko di thi
gian a t th phn ng gia phenol v fomandehit trit hn, trng lng phn t
trung bnh v hiu sut to nha cao hn ( phn ng a t tin hnh tng bc).
Qu trnh sy ngoi mc ch tch nc v cc cu t khng tham gia phn ng :
phenol, fomandehit, axit,..cn c tc dng lm cho phn ng tin hnh su hn nhit
cao. Qu trnh sy gm cc giai on sau:
un nng hn hp n nhit si.
Cho bay hi nhit si ca hn hp.
X l nhit : nng nhit cao hn nhit si ca hn hp.
Thi gian x l nhit v nhit nh hng rt ln n nht, nhit chy
mm, hm lng phenol t do.[5]
4.ng dng.

[11]

Nha phenolic c ng dng rt rng ri trong cc lnh vc khc nhau, c bit l

sn xut cht do t nha phenolic lm cc loi vt phm .
4.1.Cht do.
Thnh phn chnh ca cht do l nha phenolic c th dng novolac hoc rerolic
ngoi ra cn c cc cht ph gia : cht mu, cht ho do,Cn c vo ph gia v mc
nghin nh phn thnh cc loi sau: dng bt, dng si, mnh vn v dng lp.
Phng php gia cng thng s dng l phng php p.
Bt p: thng s dng sn xut cc vt phm thng dng hay cng dng c
bit. Bt p c th sn xut bng phng php trc vt, trc cn thng thng. Ph gia
thng dng l mt ca (a phn), si amian nh, bt mica, thch anh.
Theo cng dng phn thnh cc loi bt p sau:
- Bt p lm cc sn phm k thut v dn dng thng t nha novolac c chu
lc, chu nhit, cch in, km.

- Bt p lm cc sn phm cch in: hu ht l t zerolic. Sn phm cch in

chu c in p v nhit tng i cao (20Kv , 200oC).
- Bt p lm cc sn phm c bit c bn nc v chu nhit cao.

Vt liu p lp: Ch yu sn xut vt liu dng tm v dng ng.Tu thuc

ph gia m cht do cc dng khc nhau: testolit ( ph gia l vi, si bng ), thu tinh
testolit ( ph gia l vi thu tinh).
Vt liu si p: Ch yu i t rerolic v ph gia si lm tng mt s tnh cht c
hc: do, chu va p,si lm ph gia c th l si bng, si thu tinh.

Vt liu p vi ph gia th ( mnh vn ): i t rerolic v ph gia l mnh vn:

vi, giy,Sn phn c do v chu va p.

Vt liu p t nha phenolic c nhc im l chu axit km, dn, cc tnh cht
cch in ph thuc nhit . tng cng cc tnh cht ny ngi ta thng s dng
phi hp vi cc nha khc polyvinylclozit, cao su thin nhin.
4.2.Phao-lit.
Phao-lit l loi vt liu chu axit tt, sn xut t nha phenolfomandehit dng
rerzolic c mt cht ph gia. Cc ph gia ch yu sn xut phao-lit l : ct, grafit,
amian antoxilit.
Phao-lit c s dng rng ri trong cng nghip lt v ch to cc thit b ho
hc: thng cha, ni phn ng, thp hp ph,..
4.3.Keo dn.
Nha phenolfomandehit c ng dng sn xut keo dn cho cc loi vt liu
nh : g, kim loi, cht do, gm, s, thu tinh,..Nha rerolic thng s dng dng tan
trong ru hc nh tng trong nc.
Keo phenolic c tnh kt dnh cao, chi c m v cc loi nm mc song c
nhc im l mng keo dn dn, bn mi dn kt cu thp. Hin nay ch yu s
dng keo phenolfomandehit kt hp vi cc loi polyme khc : urefomandehit, epoxy,
polyvinylaxetan, cao su, nilon,..
4.4. Mt s ng dng khc.
Phn ln cc sn phm t nha phenolic c ng dng vo cc lnh vc k trn,
ngoi ra cn mt s ng dng khc nh :

S dng lm cht do bt, sn phm c t trng thp 0,015 0,32g/cm3, c nhiu

c tnh tt s dng trong cng nghip xy dng.
Dng lm nguyn liu sn xut mng sn, vecni.
Bn cnh nha novolac cng c s dng cho cc sn phm :
Chi tit cho ng c, ho tin.
Phanh, lp m mi ni chu nhit > 500oC.
Thit b in dng trong gia nh chu nhit cao.
u ch ho kh.
Np u xilanh ca ng c xe.
S dng phi trn vi cc cht ph gia to ra nhiu loi vt liu c tnh cht tt:
dn nhit cao, vt liu dn t, vt liu bn dn,.. [5]
5. Sn xut nha novolac.
Nha novolac c th c xut theo hai phng php l lin tc v gin on i t
cc nguyn liu u l focmalin, phenol, phenol hn hp vi cc phenol khc. Cc n
phi liu sn xut nha novolac c th khc nhau nhiu tu tng nhn hiu nha
nhng qu trnh sn xut u tun theo qui trnh ngng t.
Qui trnh sn xut nha novolac c th phn thnh cc giai on sau:
a nguyn liu vo thit b phn ng.
Trn hp phenol v fomalin thnh hn hp ng nht.
Cho xc tc vo hn hp phn ng.
Ngng t phenol v focmalin nhit 98-100oC.
Kh nc trong chn khng v x l nhit.
Thm cc cht b tr v tin hnh rt nha.
Trong cng nghip c th sn xut novolac theo phng php khng xc tc v
di p sut cao. Khi axit focmic trong focmalin ng vai tr cht khi u, tc
phn ng p sut cao ln hn so vi p sut thng nhng trong thc t sn xut nng
sut thit b p sut thng cao hn p sut cao. Khi tin hnh trng ngng p
sut cao th phenol phi s dng d nhiu (phenol : fomandehyt l 100:26 theo trng
lng ). Hiu sut khi t 85-92% nhng hm lng phenol t do trong nha vn
cao. khc phc cho thm vo axit osalic th hiu sut t 107% v nhit phn ng
180oC.

5.1. Sn xut nha novolac theo phng php lin tc.

Qu trnh sn xut m hn hp nguyn liu c a vo lin tc sn phm phn
ng cng c ly ra lin tc thng qua mt h thit b ni tip nhau. Trong thi gian
phn ng nng cc cu t trong mt th tch no khng thay i theo thi gian.
Qu trnh sn xut lin tc c th phn thnh: qu trnh lin tc tng bc v qu trnh dng
lin tc.

Qu trnh lin tc tng bc: L qu trnh lin tc xy ra tng bc trong mt dy

thit b ni tip nhau thnh mt h tc dng lin tc. c im ca qu trnh l nng

cc cu t khng thay i trong ton b th tch ca thit b sau khi t n trng thi
n nh. S thay i nng ca cc cu t ban u v sn phm cui cng xy ra tng
bc trong c dy thit b, mi thit b hn hp phn ng v cht lng chy ra c thnh
phn ng nht.
Phng php lin tc i hi tnh ton thit b rt phc tp, trong nhiu trng hp
c th tin hnh phn ng trong cc thp c ngn phn chia, mi ngn tng ng vi
mt thit b ring bit. Hn hp nguyn liu lin tc i vo ngn u tin v lin tc i
ra ngn cui cng. Xc tc thng a vo t ngn u tin, mt s trng hp nhit
phn ng to ra mnh phn phi nhit u trong thit b phn ng th xc tc c
a vo tng ngn.

Phng php dng lin tc: Qu trnh trong nng cc cu t thay i trong

ton b khng gian phn ng cng ging nh trong qu trnh lin tc tng bc, i vi
qu trnh ny nng hn hp phn ng khng thay i trong sut thi gian phn ng.
Qu trnh dng lin tc thng tin hnh trong thit b dng ng.
5.2. Sn xut novolac theo phng php gin on.

Nguyn tc lm vic ca phng php gin on:

Nguyn liu t cc thng cha trong phn xng nh bm bm ln cc thng lng
trng lng ri t i vo thit b phn ng.
Axit t thng cao v a vo thng lng trng lng hoc th tch. Hn hp phn
ng c khuy u, thm xc tc n PH yu cu (1,6-2,5).
un nng hn hp phn ng n 55-60oC sau ngng cp hi v nhit hn hp
phn ng t tng do phn ng to nhit. Khi nhit hn hp t 98-100oC th hn hp
bt u si v ngng khuy, cho nc vo v bc ngoi ca thit b lm lnh nhng

phi m bo hn hp phn ng si nh.Sau mt thi gian ( khong 20 pht ) tip tc

cho khuy v thm xc tc. Duy tr phn ng v tin hnh ly mu kim tra t trng ca
nha ti khi t yu cu.
Trong qu trnh phn ng t khi un nng n lc si, t trng, nht ca hn hp
phn ng thay i khng ng k, do trng lng phn t trung bnh thp tan c trong
fomalin. Cng vi thi gian phn ng nha to thnh c khi lng phn t tng dn,
kh ho tan trong nc, phenol, fomalin khng thm gia phn ng. Sau khi si khong
mt gi lng phenol v fomandehyt khng tham gia phn ng gim khng ng k,
nht ca nha tng ln l do ccc sn phm thp phn t ngng t vi nhau.Giai on
sy nha nhm mc ch kh nc, metanol, xc tc d bay hi, phenol, fomalin v cc
sn phm ph.
Nha c x l nhit bng hi nc c p sut vo v bc ngoi ca thit b. Hiu
sut nha t c105-110% so vi trng lng nha.

Tm li i vi i phng php sn xut u c nhng u im v nhc

im khc nhau. Do vy vic la chn phng php sn xut no tu thuc vo mc

ch, yu cu v sn phm, yu cu v tri ph u t , ..
i vi phng php lin tc i hi h thng thit b rt phc tp, tnh ton rt
chnh xc, nng lng tiu tn nhiu, hiu sut khng cao.Tuy nhin phng php ny
cho nng sut cao.
i vi phng php gin on h thng thit b n gin hn, cho hiu sut cao,
chi ph kinh t t hn phng php lin tc nhng cho nng sut khng cao, ng
u ca sn phm km.Thc t sn xut phng php gin on thng c ng dng
nhiu v tnh kinh t cao, dy chuyn sn xut n gin v c bit l an ton v mi
trng ( hm lng metanol v phenol t do c trong nc thi).
S dy chuyn sn xut nha phenolfomandehit dng novolac theo phng php
gin on (trang bn).

CHNG 2 TNH TON K THUT

2.1. Tnh phi liu v cn bng vt cht.

2.1.1.n phi liu
Nha novolac c sn xut theo phng php gin on, n phi liu nh sau:
Phenol 96%:

100 phn trng lng.

Focmandehyt 37%

70 phn trng lng.

HCl 6N

1 phn trng lng.

2.1.2.Cn bng vt cht

S dy chuyn sn xut nha novlac:

Gi thit tn hoa qua cc cng on nh sau:

Np liu:

0,5%.

a t:

1%.

Lc, tch: 0,5%.

Sy:

0,5%.

ng gi sn phm:

0,5%.

Thi gian lm vic:

Tng s ngy trong nm: 365.
Ngh th by, ch nht: 104.
Ngh l, tt: 7.
Ngh bo dng: 14.
Tng s ngy lm vic trong nm: 365-125 =240 (ngy).
Nng sut thit b trong mt ngy l:

(tn/ngy).

2.1.2.1.Cn bng vt cht cho 1 tn sn phm.

T s lng mt tn sn phm tnh ngc li bit nguyn liu u cn dng.
Cng on ng ngi sn phm:
Cng on ny tn hao 0,5% nn sn lng cn sn xut trc khi a vo cng
on ny l:

(kg).

Lng tn hao l: 1005 1000 = 5 (kg).

Cng on sy:
Cng on ny tn hao 0,5% nn sn lng trc khi sy l:
(kg).
Lng tn hao l: 1010 1005 = 5 (kg).
Cng on lc v tch nc:
Cng on ny tn hao 0,5% nn sn lc cn thit l:
(kg).
Lng tn hao l: 1015 1010 = 5 (kg).
Cng on a t:
Cng on ny tn hao 1% nn sn lc cn thit l:
(kg)
Lng tn hao l: 1025,26 1015 = 10,26 (kg).
Cng on np liu:
Cng on ny tn hao 0,5% nn sn lc cn thit l:
(kg).
Lng tn hao l: 1030,4 1025,26 = 5,14 (kg).
Vy tng tn hao c qu trnh l 3%.
T n phi liu:
100 kg phenol phn ng vi 27 kg focmalin v 1 kg HCl thu c 113 kg nha
Novolac.
Lng phenol 100% cn thit to ra 1030,4 kg nha Novolac l:
(kg)
Lng phenol 96% cn thit to ra 1030,4 kg nha Novolac l:
(kg).