8 a Conferenza di Responsible Care. La sostenibilità dell industria Chimica, della sua filiera e dei servizi indotti
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1 8 a Conferenza di Responsible Care La sostenibilità dell industria Chimica, della sua filiera e dei servizi indotti
2 An Example of Sustainability Project FEDERCHIMICA
3 Una nuova tecnologia per la produzione di schiume poliuretaniche eco-efficienti per l industria della refrigerazione FEDERCHIMICA
4 LIFE+ Project: 3 partners Dow Italia S.r.l. Owned by The Dow Chemical Company DOW offers a broad range of chemical products and services to the European Market, mainly: Polyurethanes Systems, Polyester Polyols, Ion Exchange Resins for water treatment, Styrene Butadiene Latex for the paper industry Cannon Group The group s main fields of activity are plastics processing technologies (for polyurethane, thermoplastics, composites and thermoforming), equipment for energy and ecology. Federchimica FEDERCHIMICA
5 Why Polyurethane for Appliance Insulation? With one injection it fills complex cavities and items Strength of Polyurethane foam gives structural properties Rigid Polyurethane foams have the best insulating properties
6 Rigid PU foam insulating properties 2.5 cm rigid polyurethane 4.0 cm polystyrene 4.5 cm glass fiber 5.0 cm cork 12.0 cm wood 40 cm bricks
7 The Appliance Industry Challenge Energy improvement Cost control Environment sustainability
8 Reducing the Household Energy Consumption
9 The Energy label A
10 Development of energy demand in Europe kwh/year/100 litre Electricity demand (cold appl.) refrigerator fridge-freezer upright freezer chest freezer (A+) Data source: Öko-Institut e.v., 2005 year of manufacture
11 Energy labels globally Energy labelling did help Electricity saving down by 45% from 1972 to 1997 in the USA 45% from 1980 to 2000 in the EEA However continued technical improvements led to significant energy saving have been offset by increase of use
12 The Energy legislations worldwide
13 The Blowing Agent Issue Once upon a time... CFC-11 HCFC s Today Hydrocarbons HFC s CO 2 (waterisocyanate reaction)
14 Climate change Global efforts are needed to resolve the Climate Change Challenge Global warming due to GHG (Green House Gas) emissions, Energy Consumption reduction for many Industries is a need Graph from IPCC Fourth Assessment Report on Climate change 2007: Intergovernmental Panel on Climate Change
15 The project idea Offer an unique solution to the Appliance Industry Challenge: Energy improvement Cost control Environment sustainability
16 The Novel Dow Polyurethane Chemistry
17 The rigid PU foam process Rigid PU foams have closed cells structure, Fine cells show better insulation properties, Fast reactive foam process show the finer cell, and thefore the best insulation!
18 Rigid Polyurethane foaming process Time: 0 sec 23 sec 35 sec 46 sec Start Rise End of reaction
19 High performing PU foam
20 ENERG-ICE Project targets 10% Energy consumption improvement vs. the best in class A, A+, A++ refrigerators using the greenest blowing agent, cyclopentane, having ODP=0 and very low GWP (=5-11 based on models) adopting a single injection methodology offering a valid alternative technology to the non environmental friendly HFC s (GWP>1000), so reducing the carbon footprint offering an economically attractive solution for new lines or plants» reducing polymerization time» increasing productivity» making a safer working environment» offering additional working area (space)» producing refrigerators using less Energy (less CO2)
21 Project Technical Targets
22 ENERG-ICE: Breakthrough Appliance Technology New PU Foaming Technology for the Cold Appliance Industry Addressing All Needs: Cost-Efficient Energy Saving Breakthrough PU Foaming Technology Lowest Refrigerator Energy + Lowest Total Cost Option + Environmental friendly BA Fine Novel Polyurethane Chemistry Combined New Process and Fixture: Vacuum assisted New PU Foaming Technology - Long Term Sustainable Combined with High Productivity and Ease of Process
23 Objectives Qualitative objectives include the demonstration of a novel breakthrough Polyurethane foam technology for the insulation of Cold Appliances employing hydrocarbon blowing agents showing: Technical: enhanced insulation performance vs. best in class products available in the market as requested by the Directive 2006/32/EC. Environmental: more environmental friendly and sustainable manufacturing process throughout the whole refrigerator life cycle (up to the end-of life disposal) Policy and Market: up to 10% Energy consumption reduction vs. best in class refrigerators produced today worldwide Specific technical objectives include the development and industrial validation of an innovative, high quality PU insulating foam for Cold Appliances blown with Cyclopentane offering a foam Thermal Conductivity of W/m.K (measured at 10 C) a breakthrough, cost-efficient vacuum-assisted technology for injecting the innovative PU insulating foam for Cold Appliances, assuring safer working conditions than standard technologies in a cost-efficient way
24 Environmental objectives The potential reduction of the Energy Consumption of Cold Appliances up to 10% i.e kwh/yr equivalent to 0,018-0,021 BOE/yr (Barrel of Oil Equivalent) per sold working unit on the average, with a correspondent reduced carbon footprint of 0,008-0,009 tco2eq/yr. The potential impact in Europe of such Energy Consumption reduction, assuming only a 20% market share on 22.5 million units produced (refrigerators and freezers) sold in 2015 in the EEA is estimated at a minimum of 135,3 GWh/yr equivalent to BOE/yr or tco2eq/yr Obtain a high-performing insulating PU foam by using hydrocarbon blowing agents saved (Cyclopentane) having low GWP100 ( 11) without damaging the stratospheric ozone layer (meaning having zero-odp) The potential impact of replacing HCFC s and HCF s blown foams worldwide with Cyclopentane assuming only a 4,5% market share on nearly 100 million units sold in 2015 (rounded down estimation) on the worldwide market is estimated in nearly» tco2eq/yr saved: i.e. 160 times greater than the benefit resulting from energy savings in Europe.
25 The Novel Cannon Process and Fixture
26 The refrigerators making process Foaming face-up Foaming face-down
27 Polyurethane development goes on Responsible Care Conference Auditorium Via Veneto Rome, June 23rd,2010
28 The movie criosgb.mpg Responsible Care Conference Auditorium Via Veneto Rome, June 23rd,2010
29 Foaming fixture new design Responsible Care Conference Auditorium Via Veneto Rome, June 23rd,2010
30 End of presentation Thank you for your attention FEDERCHIMICA Responsible Care Conference Auditorium Via Veneto Rome, June 23rd,2010
31 Environmental objectives The potential reduction of the Energy Consumption of Cold Appliances up to 10% i.e kwh/yr equivalent to 0,018-0,021 BOE/yr (Barrel of Oil Equivalent) per sold working unit on the average, with a correspondent reduced carbon footprint of 0,008-0,009 tco2eq/yr. The potential impact in Europe of such Energy Consumption reduction, assuming only a 20% market share on 22.5 million units produced (refrigerators and freezers) sold in 2015 in the EEA is estimated at a minimum of 135,3 GWh/yr equivalent to BOE/yr or tco2eq/yr Obtain a high-performing insulating PU foam by using hydrocarbon blowing agents saved (Cyclopentane) having low GWP100 ( 11) without damaging the stratospheric ozone layer (meaning having zero-odp) The potential impact of replacing HCFC s and HCF s blown foams worldwide with Cyclopentane assuming only a 4,5% market share on nearly 100 million units sold in 2015 (rounded down estimation) on the worldwide market is estimated in nearly» tco2eq/yr saved: i.e. 160 times greater than the benefit resulting from energy savings in Europe. Form
7/3/2013 ENERG-ICE LIFE08 ENV/IT/000411
1 Dow Italia (The Dow Chemical Company group), Afros and Crios (Cannon Group), and Federchimica are partners in the Energ-Ice Project funded by LIFE, the EU Community financial instrument supporting environmental
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