Enhancing the safety and thermal stability of polyurethane filling materials in the mining industry through expanded graphite-based hydrated salts

The utilization of Polyurethane foaming materials (PUF) to seal coal fissures presents a significant challenge due to the substantial heat generated during the reaction process, potentially accelerating fires. In order to study this issue, we propose a novel low-heat polymerization mechanism by incorporating a hydrated salt phase change composite that efficiently absorbs polymerization heat while encapsulating liquid water using expanded graphite (EG). Our findings demonstrate that integrating 10 % EG-6 leak-free phase change material effectively reduces the reaction temperature to a safer 91.4 °C, ensuring minimal impact on the inherent properties of the material. Thorough analyses via TGA and in-situ IR experiments reveal a noteworthy 17 °C elevation in the modified PUF's thermodynamic characteristic temperature point. Additionally, we developed a mixed combustion model of PUF and coal to investigate the gas generation pattern of polyurethane in the mine-filled state where fire occurs. Specifically, the introduction of PUF reduced O₂ consumption and CO production while increasing CO₂ and C₂H₄ production, which is consistent with the reality of increased carbon hydrocarbon gases being monitored downhole. These findings suggest a synergistic, mutually beneficial relationship between the two during the low-temperature oxidation stage. This research offers perspectives for the development of polymer materials for coal mines and the safe application of actual filling.