Michael Lecourt FCBA. Focus on fibre based insulation materials

Transcription

1 Michael Lecourt FCBA Focus on fibre based insulation materials

2 Presentation topics Market facts The different types Raw materials Processing of wood based insulation boards

3 Situation type of products focused on Insulation materials are distinguished by their matrix Fibrous Mineral wools (stone, glass) Organic fibres Carbon Plastic Cellulose Wood Cellular Expensed glass Expensed plastics Powder or grains calcium silicate perlite

4 Situation type of products focused on Insulation materials are distinguished by their matrix Fibrous Mineral wools (stone, glass) Organic fibres Carbon Plastic Cellulose Wood Cellular Expensed glass Expensed plastics Powder or grains calcium silicate perlite

5 Situation Market Acermi accreditation survey Limited number of companies producing natural product based insulations materials A few number of reference from natural resources Wood based insulation products < 5% of the market

6 Dominating products Resource mainly issue from Oil based products 50% Mineral source 45% Natural source 5% Wood based insulation products are limited to a niche market Oil based Mineral Biosourced

7 Performance of products Such a domination cannot be justified by performances only Synthetic Mineral Agrobased Recycled Animal

8 Impact on the environment Impact on the environment Less environmental impact of natural based insulating products Synthetic Mineral Agrobased Recycled Animal

9 Summary Wood fibre based insulation products are niche products They can be as performant as others Production conditions less impacting the environment / most of other products Nature of dominating product Processing Adjuvants required Different forms are available Fluffed Rigid boards Semi rigid boards

10 The different types of fibre based insulation materials Possibilities are Fluffed Rigid boards Semi rigid boards Choice will depend on application Loft Cavity wall External wall Internal wall Roof

11 Fluffed fibre based insulation materials No cohesion Can be blown Uses: loose fill Flat roof

12 The rigid fibre based insulation materials Rigid panels= non deformable by own weight Can be due to material cohesion to stratification

13 The rigid fibre based insulation materials Benefit are during installation easy to install equipped by profiles no glue- dust no deformation Uses external-internal walls roof

14 The semi-rigid fibre based insulation materials Bended by own weight Application with more constraints Less adhesive/cohesion chemicals Uses roof internal walls

15 Summary Various solutions for using fibre based insulation products depending on use on performance Facilities-equipment for installation Price Type of fibre chosen

16 Raw materials Recycle fibres Textile-cotton Annual plants Virgin fibres

17 Processing of natural fibre based insulation products Depending on raw material and final product, processing will be performed in different ways Recycle fibres Textile-cotton Annual plants Virgin fibres

18 Recycled cellulose Recycled newsprint post-consumer collected sorted to remove plastic, wood and other contaminants. Mix with post-industrial recycling which consists of unsold newspapers. Grinding to make the paper pieces smaller and smaller until Prior to the final stage of fiberizing, the chemical additive is blended with the paper. The amount and type of chemicals added depends on the product being made (all borate, wet-spray or dry attic blown-in insulation). Mix is heated up and put through the fiberizer together which embeds and distributes the chemical through each fibre of the paper This process ensures that the chemicals can never separate out and cause any dust or other concerns. It also ensures that the cellulose always performs it best in slowing the spread of fires, deterring insects and rodents and preventing mould and mildew Recycled cellulose available as loose fill

19 Cotton Cotton insulation consists of 85% recycled cotton and 15% plastic fibres that have been treated with borate -- the same flame retardant and insect/rodent repellent used in cellulose insulation. Cotton insulation is available in bats. Costs about 15% to 20% more than fiberglass bat insulation.

20 Long fibre from annual resource Straw-Hemp-Jute-Miscanthus fusing straw into boards without adhesives Panels are usually 5 to 102 mm thick and faced with heavyweight Available as Bats with kraft paper on each side. Boards with multiple-layered structures

21 Animal Fibre Insulation Materials Sheep s Wool For use as insulation, sheep's wool is also treated with borate to resist pests, fire, and mould. It can hold large quantities of water, which is an advantage for use in some walls, but repeated wetting and drying can leach out the borate. Plums

22 Virgin fibres Two types of process Wet process Dry process

23 Wet process From chips or shavings from softwood Grounding into wood fibre pulp via defibration. Water is mixed with the pulp and paraffin or latex added Formation of a continuous fibre mat. Pressing for water removal Drying in a circulating air dryer to final moisture content at 160 up to 200 C. Maximum attainable ply thickness is 25 mm Thicker boards are comprised of multiple plies, which are glued together with white glue

24 Wet process

25 Dry process From chips or shavings from softwood Grounding into wood fibre pulp via defibration. Fibres are sprayed with paraffin and discharged through a drier via warm forced air. Dried fibres are sprayed with resin solution (4% PU or pmdi) or mixed with textile fibres Fibre mat is formed Conveyed for curing where resin hardens through its exposure to a mixture of air and water vapour. The dry process produces single-ply insulation boards in up to 240 mm thickness.

26 Dry process

27 Exemple at Pavatex World Largest producing unit

28 Comparison of processes Wet processing Dry processing Defibering at 3-8 bars Dilution into water up to 98% Adjuvants addition Fourdrinier formation Pressing for water removal Hot pressing for cohesion Tunnel drying (120m long) Mat formation on a table Cohesion by heating Textile fibres Adhesives polyurethane Isocyanates honey moon

29 Comparison of processes - Examples of manufacturer Wet processing Steico, Homatherm Pavatex. Actis, Buitex Sotextho Gutex, Hofatex, Isoroy Knauf insulation Saint Gobain, (mix with glass fibres) Dry processing Pavatex Swiss plants Steico

30 Wood based boards Several producers are from Germany groups. Main producers are: Steico, Homatherm Pavatex. Some French are: Actis, Buitex (brand Isonat), Sotextho, Effiréal. Other companies are Gutex, Hofatex, Isoroy and Knauf insulation (brand Heraklith). Mixes of natural fibres and glass fibres are developed (Saint Gobain, brand Isovert).

31 Comparison of products Wet processing 4 % white glue for the lamination of the various plies in a single board 2 % paraffin for hydrophobic fibreboard 5 % latex to sarking and plaster baseboard to improve strength 89 % wood Maximum thickness 25mm Dry processing 4 % polyurethane resin binding agent 1.5 % paraffin for hydrophobic fibreboard 94.5 % wood 240mm

32 Adjuvants required for wood fibre based insulation products Fire proof Insect proof

33 Conclusion on fibre based insulation materials A growing market High performance products Thermal and delay in temperature transfer Acoustic Good environmental footprint Room for improvement Processes under development Isotrope products Low technology combination Adjuvants needed Habits and uses Installation protocols Constraints of storage