Polyurethanes Contributing to. Energy-Efficiency. Chandrakant Nayak Dow Polyurethanes

Transcription

1 Polyurethanes Contributing to Energy-Efficiency Chandrakant Nayak Dow Polyurethanes

2 Agenda Introduction: Trends and Market Drivers Insulation Solutions for More Sustainable Construction Enhancing the Energy Efficiency Profile of Appliances Improved Energy Efficiency in DCP Panel Production Conclusions

3 Introduction Trends and Market Drivers The growing influence of sustainable building initiatives is driving the demand for advanced construction materials that contribute to the energy efficiency of buildings and appliances, helping to reduce their carbon footprint. Energy Efficiency Sustainability Fire Safety HCFC 141b

4 Trends and Drivers Key Drivers in India Energy : Cost and Availability Building Certifications LEED and Green Building Regulations ECBC Codes Implementation and Upgradation

5 Climate Change: Multiple Solutions Required McKinsey & Associates Assessed More than 50 Alternatives for Greenhouse Gas Reduction. Examples: BioFuels, High Efficiency Lighting, Wind Energy, etc. Study shows, For every 1 kg of CO2 used in production of foamed plastic insulation, a Economic assessment: Cost to Implement & Energy Costs Saved lifetime INSULATION savings offered of 233 the kg largest of CO2 economic per kg benefit; of foamed INSULATION plastic offered insulation a positive was Return obtained. on Investment This is a CO2 savings ratio of 233:1 Greenhouse Gas Reduction: Net Impact For each Alternative INSULATION offered 233:1 the largest CO2 reduction among positive ROI alternatives! Source: McKinsey & Associates 2007 Study:

6 Building Insulation Options Building Insulation Materials

7 Market share of Insulation Materials by Geography 2011

8 Global Building Insulation Market Bn $

9 Energy Loss through buildings India Scenario : Roof insulation is the biggest segment for residential and commercial buildings Wall Insulation and Floor Insulation still predominant in Cold Chain only

10 Buildings: The Largest Opportunity Residential & Commercial Buildings Consume Greater Than 40% of Energy in India Buildings are responsible for 40% of energy consumption and 36% of CO2 emissions. Energy performance of buildings is key to achieve the EU Climate & Energy objectives, namely the reduction of a 20% of the Greenhouse gases emissions by 2020 and a 20% energy savings by Source: European Commission, 2010

11 Polyurethanes Insulate Better 37% More Heat Loss 42% More Heat Loss 56% More Heat Loss 58% More Heat Loss 70% More Heat Loss Polyurethane XPS EPS Glass Mineral Cellulose Wool Wool Fibers W/m.k [ W/m.k] W/m.k [ W/m.k] Assumes the same thickness of insulation material W/m.k [ W/m.k] Source: Thermal Insulation Manufacturers & Suppliers Association, UK Typical Lambda Table for Members Insulation, published March W/m.k [ W/m.k] W/m.k [ W/m.k] W/m.k [ W/m.k]

12 Comparison between PU vs Substitutes *Performance-PU vs Substitutes 2.5 cm rigid polyurethane 4.0 cm expanded polystyrene 4.5 cm glass fiber 5.0 cm cork 12.0 cm wood 40 cm bricks

13 Comparison between PU vs Substitutes *Performance-PU vs Substitutes Products PU EPS XPS Glass wool Rock wool Thermal conductivity mw/m.k 18~23 34~40 28~ Flame retardant B2~B1 B3, dripping B3, dripping B2 A Adhesion performance Good average average poor poor Cost High average average low low Density 35~45 15~35 15~35 48~64 100~120 kg/m 3 Compressive strength High average High average average Shelf life Long Average average average average

14 Polyurethanes has best low temperature insulation

15 Polyurethanes has best R value per inch

16 Polyurethanes Offer Superior Performance INSULATION is critical for Global Energy Policy. INSULATION is critical for Global Climate Change. However, INSULATION materials are not equal!

17 Polyurethanes also offer versatile application options Roofing Membranes PolyIso Board Insulation Rigid Panel Insulation Window Frames Panel Adhesives Window Shutters Entry Doors Cold Room Insulation Wood Alternative Spray Foam Insulation Water Proofing & Anti-Skid Surfaces Water Heaters Garage Doors Refrigerated Trucks

18 Flexibility for application and design Spray Foam Insulation Boards (FF DBL) Block Foam Other Insulation Sliding Shutters Doors DCP Construction Panels DCP Construction Panels DBL INSULATION MATERIALS COMPOSITE MATERIALS

19 Insulated Metal Panels for Roofs & Walls

20 Spray Foam Applications of Polyurethanes

21 Improved Energy Efficiency in DCP Panel Production PASCAL TM PRO Technology

22 Construction and Cold Chain Insulation DCP Energy Efficiency and PASCAL PRO Technology Construction and Refrigeration industries can contribute massively to reducing the global energy consumption by making buildings, refrigerated warehouse, cold rooms, reefer containers more energy-efficient. Polyurethane (PU) cored Insulated Metal Panels (IMPs) are the insulation technology of choice in most of the above applications. In order to improve the energy efficiency profile, panel manufacturers are looking at technologies that improve the k-factor of the foam and increase the productivity of high thickness panels. Dow s solution: PASCAL PRO translates Dow s breakthrough PASCAL technology to DCP Production Faster Cycle Time Lower Density Better Thermal Insulation

23 Construction and Cold Chain Insulation DCP Energy Efficiency and PASCAL PRO Technology Sustained quality and design without increasing costs.

24 Appliance Insulation PASCAL TM Technology

25 Appliance Insulation PASCAL TM Technology Concept Processing: Injection under reduced pressure Preferred Material: Polyurethane (PU) Systems PASCAL TM technology is using a controlled reduced in-mold pressure during the PU foam injection. Dow offers PASCAL TM Foam Technology for Appliances as well as PASCAL PRO Technology for discontinuously produced panels (DCP process).

26 PASCAL TM Technology offers mutliple benefits Up to 50% greater PRODUCTIVITY at sustained quality and design.

27 PASCAL TM achieves better insulation and increased productivity Current EU Low k c-p PASCAL TM c-p PASCAL TM Foam Technology vs. current Low k c-pentane formulations offers: 5% density reduction and better density distribution 7% lower k-factor vs. EU c-pentane formulation (5% lower vs. US formulation) 25-30% smaller cell size 30-40% shortened demold time (validated at industrial level) Flow Index 10 Post-expansion, mm 1,45 1,40 1,35 1,30 1,25 1,20 1,39 1,35 1, ,8 6,1 5,8 4,5 Low k EU PASCALTM 1,15 2 1,10 Low k EU Low k USA PASCALTM min 5 min

28 PASCAL TM enhances performance with all Blowing Agents 0,135 0,132 PASCAL TM k-f 50F, btu 0,13 0,126 0,126 0,125 0,122 0,1215 0,12 0,115 0,115 0,11 0,105 Low k Cp EU PASCALTM Cp HFC 245fa LW PASCALTM 245fa PASCALTM Gen 4 BA-A PASCALTM Gen 4 BA- B/Cp At the same amount of CO 2 % within the cell gas composition, we could achieve: c-pentane, same k-f as a low water HFC 245fa blown foam HFC 245fa, further k-f improvement of 3% from 126 to 122 btu Gen 4 BA-A, the lowest k-f achievable, as low as 115 btu Gen 4 BA-B, the best k-f achievable when co-blown with c-pentane

29 PASCAL TM Life Cycle Assessment (LCA) Results Study limited to c-pentane Other aspects of the refrigerator design or use are not included The PASCAL TM Technology allows for a measured 10% reduction in electricity use (all other things remaining the same) which translates to about 10% reduction in all potential cradle-to-grave impacts.

30 Key Take Aways Polyurethanes insulation offers best in class lifetime performance It has lowest thermal conductivity, long shelf life, high compressive strength and good adhesion with variety of substrates Excellent application flexibility and most versatile design capability Polyurethanes offer one of the best options to meet the Energy Efficiency needs of the industry and the nation New advances such as Dow PASCAL and PASCAL PRO are commercially available to further enhance the PU insulation performance as well as to improve productivity for Appliance and DCP Panels Life Cycle Assessment (LCA) demonstrated that PASCAL technology 10% reduction in all potential cradle-to-grave impacts, giving significant advantages in terms of GHG emission reduction and improved sustainability.

31 Thank You Chandrakant Nayak Dow Polyurethanes