FEIPUR 2012 Opportunities and Challenges to Replace HCFC141b in Rigid Foams. November 2012 Paulo Altoe - Dow Brasil

Transcription

1 FEIPUR 2012 Opportunities and Challenges to Replace HCFC141b in Rigid Foams November 2012 Paulo Altoe - Dow Brasil

2 HCFC141b Consumption in PU Foams Brazil 2009 HCFC141b Consumption in PU Foams - Brazil 2009 Distribution Percentage per Application - Total PDO = 617 t 3,03 1.Domestic Refrigeration 32,63 6,54 0,71 2,05 0,82 2.Panels -Continuous 3.Water Heaters 4.Thermoware 7,13 5.Pipe in Pipe 8,17 6.Packaging 7.Panels- other 20,17 6,70 9,97 8.Block 9.Commercial Refrigeration 10.Transportation 11.Spray 2,08 12.Flexible + Integral Skin 2

3 Estimated HCFC141b Consumption in PU Rigid Foams Brazil 2011 Estimated Consumption of HCFC141b in PU Rigid Foams - Brazil 2011 Distribution Percentage per Application - Total PDO ~ 330 t 16,94 14,20 4,41 6,92 11,10 6,42 4,35 1,49 1.Domestic Refrigeration 2.Panels -Continuous 3.Water Heaters 4.Thermoware 5.Pipe in Pipe 6.Packaging 17,32 15,12 1,73 7.Panels- other 8.Block 9.Commercial Refrigeration 10.Transportation 11.Spray Opportunities for non validated technologies represent ~68% of HCFC141b consumption 3

4 HCFC141b Phase Out Alternative Blowing Agents 4

5 HCFC141b Phase Out Alternative Blowing Agents Zero ODP - Low GWP H2O HCs Methyl Formate Ecomate Methylal HFOs HCFC 141b Zero ODP HFCs Moderate to High GWP Page 5

6 Page 6 HCFC 141b Phase Out Comparison of Selected Blowing Agent Alternatives GWP and k-factor of Zero ODP BAs vs. 141b Red = Flammable Blue = moderate to high GWP Green = Low to zero GWP GWP < ~30 very low-gwp ( ultra-low 1) GWP < ~100 very low-gwp GWP < ~300 low-gwp GWP < ~1000 moderate-gwp GWP < ~3,000 high-gwp GWP < ~10,000 very high GWP GWP > ~10,000 ultra-high GWP 3500 Blowing Agents wih Zero ODP Source: UNEP 3000 HFC 227ea Very Low GWP c-pentane GWP /227 93/7 365/227 87/13 HFC 134a HCFC 141b HFC 365mfc HFC 245fa 500 Met Formate C-Pentane CO Methylal HFOs GWP TDCE Methyl Formate HFO Methylal CO2 k-factor (mw/mk) Sources: API 2003, Utech 2006, Rapra 2007, CPI k-factor (mw/mk)

7 HCFC141b Phase Out What must be considered for its Application? Environment & Sustainability Foam Cost Applied Density Processing Machinery Investment Mold Investment Temperature Controls Energy Efficiency Flammability 7

8 HCFC141b Phase Out Comparative Systems - All Zero ODP HCFC141b Phase out - Comparative Systems with medium reactivity Voracor * Systems Lambda Mold Dens C. Strength C. Strength Gel GWP % Bl. Ag mw/mk kg/m3 kpa Sec GWP Rel% Mixing Head 100% HCFC 141b H20, Gen ~ 0.0 NA H20, Gen ~ 0.0 NA HFC 365/227 Low [ ] C-pentane Solstice Low [ ] Solstice Formacel 1100 Low [ ] Formacel

9 CS, kpa Mold Dens, kg/m3 HCFC141b Phase Out Comparative Systems Alternative Blowing agents for HCFC141b Replacement Molded Density and Compressive Strength kg/m3 kpa 50,00 48, , , , , , , , , ,00 9

10 24 C HCFC141b Phase Out Comparative Systems Alternative Blowing Agents for HCFC 141b Replacement 24 C, mw/mk

11 Opportunities for HCFC141b Elimination in PU Rigid Foams Applications [ Technology not validated yet by UNDP) Panels (Others) Blocks Commercial Refrigeration Transportation Spray Page 11

12 2 nd Generation of Water Blown Rigid PU Foams Page 12 Comparative evaluation between WB G2 and HCFC 141b Customer test Process information HP Machine Injection Point = 1 S2 S1 Injection Time = 4 secs S4 Mold Temperature = 45 C Volume m3 Molded Density = kg/m3 B1 S3 Injection Point Demold Time = 8 min

13 2 nd Generation of Water Blown Rigid PU Foams Page 13 Overall Molded Density : 38,7 Kg/m 3 9,50Kg (WB G2) Test S-1 S-2 S-3 S-4 B-1 Units Methods Core Density 36,80 37,80 36,9 38,0 38,2 kg/m3 ASTM D 1622 Creep test , Bar Adhesion 1,39 1,46 1, ,46 KgF/cm2 Friability % ASTM C 421 Thermal conductivity, 24 C 24,0 24,0 23,8 24,0 23,7 mw/mk ASTM C 518 Dimensional stability Linear 48h / -20ºC Dimensional stability Linear 70h / + 70ºC % ASTM D % ASTM D2126 Compressive strength, 10% kpa ASTM D-1621

14 2 nd Generation of Water Blown Rigid PU Foams Enviromental and Technical Aspects VORACOR TM ZERO ODP and zero GWP VORACOR TM ZERO flammable blowing Agent VORACOR TM Easy handling and storage VORACOR TM Excellent physical properties VORACOR TM Non-corrosive to equipments and final products VORACOR TM Mold temperature range should be from 45 o C to 55 o C VORACOR TM Can be used in existing equipments, low investment is required. 14

15 2 nd Generation of Water Blown Rigid PU Foams Challenges Requires accurate temperature control Critical for adhesion High lambda that is typical for water based systems Aging can be affected if foam is not properly sealed Higher density than HCFC141b 15

16 Low GWP Foam - Combining HFCs and High Water Page 16 Comparative evaluation between HCFC 141b and Low GWP with HFCs (365/227) HAND MIX Unit 141B Based Low GWB Cream Time S 8 8 Gel Time s FRD kg/m Proc. Condition Ratio (I/P) 100: :145 Temp C Pressure Bar HPM DCP (Discontinuous Panel) Cream Time s 6 5 Gel Time s MD kg/m Spray HAND MIX Unit 141B Based Low GWP Cream Time s 2 2 Gel Time s 8 8 FRD kg/m Proc. Condition Ratio (I/P) 1:1 1:1 Temp C Pressure PSi HPM Cream Time s 2 2 Gel Time s 6 6 MD kg/m

17 Low GWP Foam - Combining Low HFC and High Water Enviromental and Technical Aspects - DCP and Spray VORACOR TM ZERO ODP and very low GWP VORACOR TM ZERO flammable Blowing Agent VORACOR TM Easy handling and storage VORACOR TM Excellent physical properties VORACOR TM Non-corrosive to equipments and final products VORACOR TM Mold Temperature range should be from 35 o C to 50 o C VORACOR TM Can be used in existing equipments, low investment is required. 17

18 Low GWP Foam - Combining Low HFC and High Water Challenges Lambda just slighly better than water based systems Incremental foam cost due to HFC addition that is more expensive Higher molded density than HCFC141b 18

19 HFOs (Hydrofluorolefins ) blown Foam for HCFC141b Replacement High Concentration of Solstice LBA and Formacel 1100 Validated in Cabinets Remarks ZERO ODP and ~ zero GWP Easy Handling and Storage Superior Mechanical Performance Similar Molded Density Trade offs Not yet available Cost versus benefit not applicable to all PU Rigid Applications Better Lambda and Better Energy Efficiency (2-4% ) Drop in Solution for HCFC 141b, Technically Possible to all Applications 19

20 HFOs blown Foam for HCFC141b Replacement Low Concentration of Solstice LBA and Formacel 1100 combined with High Water Not Validated in the field yet Remarks ZERO ODP and ~ zero GWP Easy handling and storage Good mechanical performance Cost effective solution to overcome limitations of water blown systems Drop in solution for HCFC 141b Can be used in existing equipments, low investment is required 20

21 HCFC141b Phase out - Timeline and Technical Alternatives HCFC141b Hydrocarbons (Methylal, Me Formate) H2O HFCs HFOs

22 Conclusion Water based systems can be applied in commercial refrigeration. Due to limited adhesion its implementation in Panels-Other and Spray is most unlikely. C-pentane is a well known alternative to replace HCFC141b. Flammable Requires high investment for plant modification and machinery Applicable for high consumption of PU Systems. Good balance of foam cost and performance Not applicable for spray and limited application in Panels-Other and Transportation Utilization of HFCs combined with water. Non Flammable Needs to be considered as interim and feasible alternative while HFOs are not available. High Spectrum of Application due to good balance of foam cost and properties HFOs can be considered as drop-in solution for HCFC141b replacement. Appropriate concentration of blowing agent can reach good balance of cost versus performance Applications that require better energy efficiency are most recommended 22

23 Thank you Paulo Altoe * Trademark of The Dow Chemical Company ("Dow") or an affiliated company of Dow

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