VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES

Transcription

1 SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, CREATING TOMORROW'S SOLUTIONS

2 OVER 90 YEARS OF SUCCESS Wacker Chemie AG Founded in 1914 by Dr. Alexander Wacker Headquartered in Munich WACKER Group (2009) Sales: EBITDA: R&D: Investments: 3.72 billion 607 million 164 million 740 million Employees: 15,618 Saulat Khan, Wacker Chemie India P.L, , Slide 1

3 AGENDA WACKER Why to Insulate and current situation of cold stores in India Insulating Materials Recommended thickness of Insulating Materials IS-661:2000 VINNAPAS, its working and advantages Insulation boards application Technical requirement, Role of VINNAPAS and Required Tests Summary Saulat Khan, Wacker Chemie India P.L, , Slide 2

4 WHY TO INSULATE AND CURRENT SITUATION OF INSULATION IN COLD STORAGES IN INDIA VINNAPAS Conserve energy and save money Increase profitability 90% of existing cold storages are using inappropriate insulation material (as per NHB expert committee report 1.1.1) level of insulation are very low (as per NHB expert committee report 1.1.1) 13 bil$ of fruits and vegetable get wasted annually (as per ISHS) NHB= National Horticulture Board ISHS= International Society for Horticultural Science Saulat Khan, Wacker Chemie India P.L, , Slide 3

5 PU, MINERAL WOOL & PF BOARD AS INSULATING MATERIALS VINNAPAS PU Boards: Insulation effect much better than with conventional EPS boards Thermal conductivity 0,022W/mK brittle material - low impact strength low flammability but highly toxic gases in case of fire Phenol Formaldehyde Boards: Thermal conductivity 0,022 W/mK Insulation effect much better than with conventional EPS boards comparable to PU boards brittle material low impact strength severe shrinkage very sensitive against water! Mineral Wool Mineral wool has a extremely open structure, high water vapor permeability Saulat Khan, Wacker Chemie India P.L, , Slide 4

6 RECOMMENDED THICKNESS OF INSULATION FOR WALLS IS-661:2000 (As reaffirmed in year March 2008) (For Different Storage Temperatures with Design Ambient Temperature of 40 Degree Celsius and 50 % Relative Humidity) Name of Material Minimum Density kg/ cu. m -30to to -15 Insulation Thickness in mm, Temperature Range in C -15 to -4-4 to +2 2 to to 16 >16 Rigid Polyurethane foam Rigid Phenolic Foam Expanded Polystyrene Bonded Rockwool Bonded Slagwool Bonded glasswool Saulat Khan, Wacker Chemie India P.L, , Slide 5

7 FILM FORMATION PROCESS OF VINNAPAS Filmformation Evaporation of water Particle deformation Coalescence of particles and filmformation Saulat Khan, Wacker Chemie India P.L, , Slide 6

8 POLYMER FILMS OF A VINNAPAS IN A CEMENT MORTAR MATRIX Polymer films based on Vac/E VINNAPAS within a cement mortar matrix and at the interface Saulat Khan, Wacker Chemie India P.L, , Slide 7

9 SEM PICTURES OF INSULATION BOARD MORTAR INTERFACE 1= INSULATION BOARD (2) (3) 2= cement mortar (2) 3= polymer (3) film (1) (1) Saulat Khan, Wacker Chemie India P.L, , Slide 8

10 WITH VINNAPAS, YOU SET THE STANDARD! FOUR STRONG PERFORMANCE FEATURES VINNAPAS 1.Improved adhesion to all substrates (polystyrene boards, mineral wool, concrete, bricks, old renders/coatings ) 2.Increased flexibility and improved impact resistance 3.Excellent hydrophobicity 4.Durability and long-term performance Saulat Khan, Wacker Chemie India P.L, , Slide 9

11 VINNAPAS GRADES FACILITATE COMPLIANCE WITH ETAG 004 GUIDELINES. VINNAPAS Formulation basics for cementitious thermal insulation adhesion components with requirements according to ETAG 004 guideline Base Coat / Requirements Adhesive Embedding Mineral Top Coat Mortar dispersible polymer powder 2-4% 2-4% % 5044 N 5044 N 5044 N VINNAPAS DP 5046 T 7037 T 5046 T 7037 T 7031 H 8031 H 8034 H LL 3030 H 7031 H 8031 H 8034 H LL 3030 H Saulat Khan, Wacker Chemie India P.L, , Slide 10

12 INSTALLATION (FIXING OF THE INSULATION PANELS) Fixing the insulation panels with a polymer modified cement mortar Saulat Khan, Wacker Chemie India P.L, , Slide 11 Pictures: Lugato manual

13 INSTALLATION (APPLICATION OF THE BASE COAT AND FIBER MESH) Application of the base coat (polymer modified cement mortar) + glass fiber mesh Saulat Khan, Wacker Chemie India P.L, , Slide 12 Pictures: Lugato manual

14 TECHNICAL REQUIREMENTS FOR THE MORTARS (MOST IMPORTANT) Exposure of system under practical conditions: from - 40 C up to +70 C Adhesive mortar: good adhesion (high tensile adhesion strength) on various substrates Base coat mortar: high impact resistance, high flexibility and good adhesion on various substrate) Finishing coat mortar: low water absorption and high impact resistance, good adhesion to the base coat The technical performance depends on dosage (amount) and type of polymer used in combination with cement Saulat Khan, Wacker Chemie India P.L, , Slide 13

15 TENSILE ADHESION STRENGTH [N/MM²] OF ADHESIVE MORTARS WITH DIFFERENT AMOUNTS OF VINNAPAS ON DIFFERENT TYPES OF INSULATION PANELS Substrate: insulation panel 1 Substrate: insulation panel 2 Saulat Khan, Wacker Chemie India P.L, , Slide 14

16 TENSILE ADHESION STRENGTH [N/MM²] OF BASE COAT MORTARS ON INSULATION BOARD) BY PULL-OFF TEST VINNAPAS Saulat Khan, Wacker Chemie India P.L, , Slide 15

17 HARD BODY IMPACT TEST FOR BASE COAT base coat mortar with 4% dispersible polymer powder base coat mortar without dispersible polymer powder Saulat Khan, Wacker Chemie India P.L, , Slide 16

18 IMPACT RESISTANCE [J] WITH 1 KG STEEL BALL OF A CEMENT BASED MORTAR DEPENDING ON THE VINNAPAS Test at 23 C Test at 23 C Test at 23 C Test at 0 C Saulat Khan, Wacker Chemie India P.L, , Slide 17

19 DETERMINATION OF THE WATER ABSORPTION OF INSULATION SYSTEM BASE COATS AND TOP COATS Determination of the water absorption Substrate Base coat Water T e s t p ro c e d u re a c c o rd in g to G e rm a n s ta n d a rd D IN Saulat Khan, Wacker Chemie India P.L, , Slide 18

20 TENSILE ADHESION STRENGTH, FLEXURAL STRENGTH AND WATER ABSORPTION OF A CEMENT BASED FINISHING MORTAR Polymer used: VAc/E (Tg 12 C) VC/E/VL (Tg 0 C) Dispersible polymer powder dosage [%] Tensile adhesion strength [N/mm²] on concrete slab (storage 28 days sc) 0,22 0,38 0,49 0,57 0,34 0,52 0,58 Flexural strength [N/mm²] (storage 28 days sc) 1,50 2,25 2,30 2,30 2,20 2,30 2,30 Coefficient of water absorption [kg/m²h 0,5 ; 24 h] 2,50 2,25 2,10 2,00 0,08 0,06 0,04 Saulat Khan, Wacker Chemie India P.L, , Slide 19

21 TECHNICAL REQUIREMENTS ACCORDING TO EOTA REGULATIONS (ETAG 004) Requirements EOTA (ETAG 004) requirements for EIFS - tests Laboratory tests: Bond strength adhesive on substrate (tensile adhesive strength [N/mm²]) Storage 28 d sc (sc = 23 C/50% R.H.; d = days) Storage 28 d sc + 2 d in water + 2 hours sc Storage 28 d sc + 2 d in water + 7 d sc Bond strength adhesive on insulation board (tensile adhesive strength [N/mm²]) Storage 28 d sc (sc = 23 C/50% R.H.; d = days) Storage 28 d sc + 2 d in water + 2 hours sc Storage 28 d sc + 2 d in water + 7 d sc After hygrothermal wall test according to EOTA (ETAG 004), composite system on the test rig (6x2,5x2 m) Bond strength (tensile adhesive strength [N/mm²]) Hard body impact resistance [J]; three classes > 0,25 N/mm² > 0,08 N/mm² > 0,25 N/mm² > 0,08 N/mm² > 0,03 N/mm² > 0,08 N/mm² > 0,08 N/mm² < 3 J / 3-10 J / > 10 J Saulat Khan, Wacker Chemie India P.L, , Slide 20

22 ARTIFICIAL WEATHERING TESTING ACCORDING TO EOTA TEST CONDITIONS (HYGROTHERMAL WALL TEST; TEST RIG 6X2,5X2 M) Test conditions hygrothermal wall test for the whole EIFS: Heat rain cycles: 80 cycles 70 C (rise for 1 h, maintaining for 2 h at 70 C and 10-15% R.H.) + spraying 1 h water (temperature 15 C; 1 l/m² min) + leave for 2 h at normal conditions Heat cold cycles: 5 cycles of 24 h 50 C (rise for 1 h, maintaining for 7 h at 50 C and 10% R.H.) + exposure to -20 C (fall for 2 h, maintaining -20 C for 14 h) Saulat Khan, Wacker Chemie India P.L, , Slide 21

23 TEMPERATURE VARIATIONS INSIDE THE MODEL HOUSES WITH AND WITHOUT INSULATION DURING THE COLD AND THE HOT SEASON IN CHINA Temperature [degr. C] During coldest month time/d During the hottest month time/d with EIFS, west wall temperature no EIFS, west wall temperature outdoor air temperature Saulat Khan, Wacker Chemie India P.L, , Slide 22

24 COMPOSITION OF VINNAPAS MODIFIED DRY-MIX MORTARS FOR THE ADHESIVES, BASE COAT, TOP COAT sand cement Polymer binder = dispersible powder Just add water Additives Saulat Khan, Wacker Chemie India P.L, , Slide 23

25 SUMMARY - VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES -The use of dispersible polymer powder in the cement based mortars on suitable insulation material in order to achieve the following features even under extreme conditions - Good adhesion on substrate and polystyrene panels - High deformability and flexibility - High impact resistance - low water absorption Saulat Khan, Wacker Chemie India P.L, , Slide 24

26 THANK YOU FOR YOUR ATTENTION.. Saulat Khan, Wacker Chemie India P.L, , Slide 25

27 XPS and EPS AS INSULATING MATERIAL Name of the sample (XPS) (EPS) Characteristic Density(Kgs/m3) Compressive strength at 10 % deformation (kpa) Water vapour permeability (per inch) Thermal conductivity (W/m.K) Flammability Moisture absorption (%) B2 class < 1 Self extinguish Saulat Khan, Wacker Chemie India P.L, , Slide 26