Why Gas Leak Detection is Essential in Polyurethane Foam Manufacturing?

Author: Dod Technologiesinc

Polyurethane foam manufacturing is a $12 billion dollar industry. It is used in the manufacture of an array of products, including insulation, shock-absorbing products, cushions, and fluid filtration systems, to name a few. The average factory produces about 8000 tons each year.

This versatile foam is created by mixing diisocyanates and polyols that react and foam, expand, then harden to a desired level of rigidity. Considered to be a complex process, it can be produced in a variety of densities, resilience, and colors. Because of the potential of chemicals that can become airborne during production, an effective gas leak detection system is essential.

Detection of Airborne Chemicals

The production process for polyurethane foam requires combustion, which causes a wide range of airborne thermal degradation chemicals to be released into the air, and includes these gases:

  • Carbon dioxide
  • Carbon monoxide
  • Nitrogen oxides
  • Hydrogen cyanide
  • Isocyanates
  • Isocyanic acid
  • Amines
  • Hydrocarbons

The most common diisocyanates identified in the polyurethane foam production environment include Toluene diisocyanates (TDI) and Methylenediphenyl diisocyanates (MDI), which have exposure levels set by the Occupational Safety and Hazard Administration (OSHA) in order to protect workers.

Setting up an effective gas leak detection equipment system starts with an evaluation of risk exposure in several different areas along the production line. Combining multiple methods of detection for exposure, including badges, portable gas monitors, and fixed systems, allows manufacturers to effectively monitor any areas where there is a chance for potential exposure.

Potential Health Effects

The concentration level of these chemicals vary, but they can cause a variety of health issues. In addition to eye irritation, exposure can result in respiratory tract irritation as well. Symptoms may include watering eyes, running nose, coughing, dizziness, difficulty breathing, and nausea.

Asthma may result from overexposure.

There has been extensive research into the effects of diisocyanates, which are highly regulated through OSHA, the Environmental Protection Agency (EPA), and other local, state, and federal agencies. If companies do not monitor and adhere to mandated emission levels, they could face both civil and criminal penalties for noncompliance.

As long as workers adhere to safety precautions, and effective gas leak detection equipment is in place, polyurethane foam work environments can be protected against employee exposure.

Experienced Analysis Any production environment where workers could be exposed to harmful gases should be tested to determine the levels of exposure. Consult with an experienced, reputable provider of gas leak detection equipment who can suggest the best ways to ensure worker safety.