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HYDROCARBONPROCESSING TOLUENE
DIISOCYANATE (TDI)
Toluene diisocyanate (TDI) CH3C6H3 (NCO)2 is an organic compound where two of the six possible isomers - 2,4-TDI and 2,6-TDI - are used in the commercial production of an extensive range of materials. These include flexible polyurethane foams (the largest market for TDI products); rigid foams, which use polymeric MDI as the isocyanate component; and in adhesives, sealants, surface coatings and elastomers.
TDI synthesis is a complex, three-stage process which first requires the
production of toluene diamine (TDA) and phosgene which are then combined and distilled to create TDI, with hydrochloric acid as a by-product. The process, which involves combining a range of toxic materials including hydrogen, chlorine and carbon monoxide, requires high levels of gas analysis for both process control and product purity throughout all three processes.
Servomex is an expert in the supply of analyzers and systems designed to meet all requirements of the TDI process.
With an industry-leading range of analyzer technologies, we offer a turnkey solution for TDI gas analysis that overcomes common process problems including gas cross sensitivity, the highly toxic nature of the process and detecting low levels of chlorine within the TDI product.
Supported by a global network of Service and Support, our expertise in TDI analysis enables us to consult, design and build systems that are safe, reliable, highly efficient and highly productive.
• Proven experience in solving complex TDI analysis issues with full, independently verified SIL reports available
• Servomex analyzers deliver safe surrogate calibrations, eliminating requirement to use highly toxic 100% phosgene
• More than twenty TDI systems installed and supported to a global customer base
CUSTOMER PROCESS BROCHURE
TOLUENE DIISOCYANATE PROCESS APPLICATION MAP
TDA PRODUCTIONHydrogen (H2)from the HyCO process is used for the Hydrogenation of dinitrotoluene (DNT) and the next step is the catalytic reduction of dinitrotoluene under H2 pressure which is subsequently undertaken to produce toluene diamine (TDA). There are a number of measurements to ensure the quality of the Carbon Monoxide (CO) using the SERVOPRO MultiExact 5400 (1), SERVOPRO 4210 (2), SERVOTOUGH OxyExact 2200 (3) and SERVOTOUGH LaserSP 2900 (4), which measure H2, methane (NH4), oxygen (O2) and water (H2O) impurities respectively. The purity of the hydrogen is also measured, with the MultiExact (5) measuring percent H2 and 4210 (6) measuring ppm CO. H2 is also measured as an offgas (7).
PHOSGENE MANUFACTUREPhosgene is made using the CO from the HyCO process and chlorine (Cl2) from the electrolysis of brine. The SERVOTOUGH SpectraExact 2500 (8) provides a critical purity measurement for the supplied CO while the SERVOTOUGH LaserSP (9) monitors for ppm moisture levels in the Cl2 feed.
KEY:APPLICATION TYPES: PROCESS CONTROL QUALITY SAFETY COMBUSTIONEMISSIONS
SpectraExact 0-500 ppm ODCB in HCl
SpectraExact 0-500 ppm COCI2 in HCI
SOLVENTOrthodichlorobenzene
RECYCLE
HCIBy Product
CH4 + H2OCO + 3H2
HYCO
HYDROGENH2
TOLUENEDIAMINE
TDA
CARBONMONOXIDE
CO
CHLORINECI2
PHOSGENECOCI2
PHOSGENECOCI2
DISTILLATION
PHOSGENATION 1
PHOSGENATION 2
REDUCER
DINITROTOLUENEDNT
ELECTROLYSISOF BRINE
1 3
2
MultiExact TCD 0-1% H2 in CO
4210 0-0.1% CH4 in CO
OxyExact/Oxy 0-0.5% O2 in CO
SpectraExact 0-1000 ppm H2O in CO
MultiExact TCD 90-100% H2 in Hydrogen
4210 0-10ppm CO in H2
MultiExact TCD 50-100%H2 in Hydrogen off gas
SpectraExact 90-100% CO in CO LaserSP 0-500 ppm H2O in Cl2
SpectraExact 0-200 ppm Cl2 in COCl2
SpectraExact (2510) 0-15% CO in COCl2
SpectraExact 0-100% COCl2in reaction gas (COC12 + HCI)
SpectraExact 0-100% HCIin reaction gas (COC12 + HCI)
SpectraExact 0-3% CO2
in reaction gas (COC12 + HCI)
SpectraExact/LaserSP 0-500 ppm H20in reaction gas (COC12 + HCI)
SpectraExact 0-500 ppm H2O in ODCB
SpectraExact 0-0.1% NCO in ODCB
SCRUBBERSpectraExact 0-1000 ppm COCI2 in stack
4210 0-100 ppm CO in air
CH3
NO 2
NO2
CH3
NH 2
NH2
O
Cl Cl
C
CH3
NCO
NCO
TOLUENEDIISOCYANATE
TDI
TOLUENEDIAMINE
TDA
1
1 2
5
7
8 9
6 2 3 4
TDI MANUFACTUREThe TDA is then treated with the phosgene under controlled temperature and pressure conditions, with quality ppm measurements of Cl2 (10) and CO (11). This results in a TDI isomer mixture in solution, together with traces of phosgene and HCl. These traces are subsequently separated and recycled. During the phosgenation stages the orthodichlorobenzene solvent is monitored for moisture (12) and NCO (cyanate groups) (13). The phosgene quality is also measured by the SpectraExact for purity (14) and also for impurities including HCl (15), CO2 (16) and moisture (17).
The TDI isomer mixture is then purified by distillation. There is no change to the 80:20 isomer composition during this step. During the distillation process the HCl by-product is monitored for impurities such as phosgene and solvents by the SpectraExact (18), (19). Phosgene emission in the stack and CO emissions are measured by the SpectraExact (20) and 4210 (21) respectively.
KEY:APPLICATION TYPES: PROCESS CONTROL QUALITY SAFETY COMBUSTIONEMISSIONS
TOLUENE DIISOCYANATE PROCESS APPLICATION MAP
SpectraExact 0-500 ppm ODCB in HCl
SpectraExact 0-500 ppm COCI2 in HCI
SOLVENTOrthodichlorobenzene
RECYCLE
HCIBy Product
CH4 + H2OCO + 3H2
HYCO
HYDROGENH2
TOLUENEDIAMINE
TDA
CARBONMONOXIDE
CO
CHLORINECI2
PHOSGENECOCI2
PHOSGENECOCI2
DISTILLATION
PHOSGENATION 1
PHOSGENATION 2
REDUCER
DINITROTOLUENEDNT
ELECTROLYSISOF BRINE
1 3
2
MultiExact TCD 0-1% H2 in CO
4210 0-0.1% CH4 in CO
OxyExact/Oxy 0-0.5% O2 in CO
SpectraExact 0-1000 ppm H2O in CO
MultiExact TCD 90-100% H2 in Hydrogen
4210 0-10ppm CO in H2
MultiExact TCD 50-100%H2 in Hydrogen off gas
SpectraExact 90-100% CO in CO LaserSP 0-500 ppm H2O in Cl2
SpectraExact 0-200 ppm Cl2 in COCl2
SpectraExact (2510) 0-15% CO in COCl2
SpectraExact 0-100% COCl2in reaction gas (COC12 + HCI)
SpectraExact 0-100% HCIin reaction gas (COC12 + HCI)
SpectraExact 0-3% CO2
in reaction gas (COC12 + HCI)
SpectraExact/LaserSP 0-500 ppm H20in reaction gas (COC12 + HCI)
SpectraExact 0-500 ppm H2O in ODCB
SpectraExact 0-0.1% NCO in ODCB
SCRUBBERSpectraExact 0-1000 ppm COCI2 in stack
4210 0-100 ppm CO in air
CH3
NO 2
NO2
CH3
NH 2
NH2
O
Cl Cl
C
CH3
NCO
NCO
TOLUENEDIISOCYANATE
TDI
TOLUENEDIAMINE
TDA
10
12
14
16
18
20
11
13
15
17
19
21
3
SERVICE SYSTEMS
RUGGED PHOTOMETRIC GAS ANALYZER FOR DEMANDING PROCESS APPLICATIONS
Oxy 2200
SE
RV
OT
OU
GH
SpectraExact 2500
MonoExact TCD
SE
RV
OT
OU
GH
SE
RV
OP
RO
AWARD-WINNING DIGITAL O2 ANALYZER
HIGH SPECIFICATION PROCESS O2 ANALYZER
Oxy 1900
SE
RV
OT
OU
GH
DIGITAL SINGLE GAS ANALYZER WITH NEW TCD MEASUREMENTS
HIGH-SENSITIVITY CROSS-STACK TDL ANALYZER
LaserSP 2900
SE
RV
OT
OU
GH
Servomex has a policy of constant product improvement and reserves the right to change specifications without notice. © Servomex Group Limited. 2014. A Spectris company. All rights reserved.
S E R V O M E X . C O M
TDI ANALYSIS SOLUTIONS
EXPERT
NORTH AMERICAAmericas Business, Systems Engineering and Service Center 12300 Dairy Ashford, Suite 400Sugar Land, TX 77478 Tel: +1 281 295 5800 USA Toll Free 1 800 862 0200Fax: +1 281 295 5899Email: [email protected]
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EUROPEEuropean Business, Systems Engineering and Service CentrePO-Box 406, 2700 AK ZoetermeerThe NetherlandsTel: +31 (0) 79 330 1580Fax: +31 (0) 79 342 0819Email: [email protected]
LATIN AMERICA Latin America Business and Service Center(Empresa do Grupo Spectris)Rua Laguna 276, Santo Amaro Sao Paulo – SP – Brasil CEP 04728-000 Tel: +55 11 5188 8166Fax: +55 11 5188 8169Email: [email protected]
INDIAIndia Business Centre and Systems Engineering and Service CentreSpectris Technologies Pvt. Ltd.Plot No.A-168, M.I.D.C. TTC Indl. Area Thane-Belapur Road, KhairaneNavi Mumbai- 400 7099 IndiaTel: +91 22 3934 2700Fax: +91 22 3934 2701Email: [email protected]
MIDDLE EASTMiddle East Business CentreWarehouse Q3 - 197 - SAIF ZonePO Box 8962, Sharjah, UAETel: +971 6552 8073Fax: +971 6552 8074Email: [email protected]
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