TECHNOLOGY DEVELOPMENTS IN THE FOAM SECTOR

Transcription

1 TECHNOLOGY DEVELOPMENTS IN THE FOAM SECTOR Mike Jeffs & Miguel Quintero FAs DC

2 SECTORS WHERE HCFCs ARE USED Rigid Insulation Foams Polyurethane building and appliance insulation Extruded Polystyrene building insulation Polyurethane Expanded Elastomers Integral Skin automotive and furniture Microcellular Elastomers shoe soles FAs DC

3 DRAFT FOAMS HPMP STRATEGY Control measure Impact vs. BAU 5%) Freeze to 2009/2010 levels 10% reduction 35% reduction Cut by ~20% Cut by 40+% Cut by 50 to70% Likely near end of foam use of HCFCs FAs DC

4 PROVEN HCFC-FREE TECHNOLOGIES & LIMITATIONS RIGID PU FOAMS Hydrocarbons (pentanes) Low GWP Low unit costs Highly flammable conversion cost barrier for SMEs not suitable for spray foam Acceptable foam properties HFCs High GWP High unit costs Non-flammable or low flammability Good foam properties CO 2 (water) Low GWP, non-flammable High foam cost Inferior foam properties FAs DC

5 NON-HCFC TECHNOLOGY BY APPLICATION Refrigerator/freezer HC Pre-insulated pipes Boards/panels Discontinuous panels, Display units, etc. US Refrigerator/freezer CO 2 (water) Spray foam HFC FAs DC

6 TECHNOLOGY UPDATE SINCE LAST OORG MEETING HC/HFC Blends Blends of HC(cyclopentane)/HFC-245fa improve foam insulation value by 1mW/mK (ca 6%) may help meet tightening appliance energy standards Lambda: (mw/m. o K) % weight of HFC-245fa 10 C 15 C 22.5 C Improved CO 2 (water technology) Density and jig dwell time reduction via formulation optimisation Density reduced from 44-46kg/m 3 to 41-43kg/m 3 Mould temperature reduced from 45+ C to C Addition of Formic acid Improved flow, density distribution, but. Issue of corrosion in equipment FAs DC

7 MLF-SUPPORTED DEMONSTRATION PROJECTS Evaluation of safety of pre-blended cyclopentane-containing formulations to reduce costs (China) Equipment delivery 2/2011, installation during 3/2011 Information being sought from pre-blended HC use in EU Evaluation of supercritical CO 2 for spray foams (Colombia) Programme expected to take place in Q FAs DC

8 WHAT NEXT? Technical requirement low cost, low GWP and non-flammable blowing agent FAs DC

9 EVALUATION PROGRAMME FOR A NEW BLOWING AGENT FOR RIGID INSULATING FOAM Toxicology and ecotoxicology testing Processing characteristics: Solubility in polyols Stability in polyol blends Flash point/flammability of polyol blend Flow properties Reaction times including jig dwell times Atmospheric concentrations during processing and comparison with flammable limits in air Effects on equipment seals and metal parts Physical & Fire properties Closed cell content Density/strength relationships Dimensional stability versus temperature and ageing using accelerated methods Thermal conductivity versus temperature and ageing using accelerated methods Foam friability Adhesion to different substrates Compatibility with contact materials Fire code testing for construction industry foam-based components Water vapour transmission Cell gas analysis Trials under commercial production conditions and long term testing of articles FAs DC

10 TECHNICAL PERFORMANCE OF METHYL FORMATE (MF) IN RIGID INSULATING FOAM Toxicology and ecotoxicology testing Existing chemical GRAS (US) and REACH registered Processing characteristics To retain a flashpoint in the polyol above 35 C (non-flammable rating) the MF content has to be below 2-3% - depending on the polyol MF in foam cells hydrolyses to formic acid, CO and CO 2 leading to corrosion of the components of production equipment including dispensers Lack of comprehensive data on atmospheric concentrations of MF during processing Physical & Fire properties Initial foam insulation values inferior to those with HCFC-141b and pentane The loss of MF due to hydrolysis leads to deterioration in thermal insulation MF is a strong solvent for the PU matrix and at contents of 2-3% and above the foam shrinks unless the density is increased; adhesion to steel panels facers is poor At contents below 2-3% (with co-blowing with CO 2 (water)) there is no advantage over 100% CO 2 (water)-based foam In appliance applications the thermal insulation is inferior to that with cyclopentane and jig dwell times are long There is a lack of systematically developed data on long term thermal insulation and dimensional stability The tailoring and optimisation of foam systems based on MF is challenging Trials under commercial production conditions and long term testing of articles Lack of data and documented experience FAs DC

11 TECHNICAL PERFORMANCE OF METHYL FORMATE (MF) IN RIGID INSULATING FOAM Toxicology and ecotoxicology testing Existing chemical GRAS (US) and REACH registered Processing characteristics To retain SUMMARY a flashpoint in the polyol below 60 C (non-combustible rating) the MF content has to be below 2-3% - depending on the polyol MF in foam There cells are hydrolyses several to technical formic acid, performance CO and CO 2 leading issues to corrosion with of the components of production the use equipment of MF (dispensers) in rigid insulating foams Lack of comprehensive data on atmospheric concentrations of MF during processing Physical The & Fire use properties of MF is unproven, particularly for long term applications The loss of MF due to hydrolysis leads to deterioration in thermal insulation;initial insulation values inferior to that of HCFC-141b and pentane At contents The of development 2-3% the foam of shrinks formulations unless the density based is on increased; MF is adhesion challenging to steel and panels is poor additional technical support would be required At contents below 2-3% (with co-blowing with CO2(water)) there is no advantage over 100% CO 2 (water)-based foam In appliance Experience applications with the the thermal use insulation in integral is inferior skin to and that flexible of cyclopentane moulded and jig dwell times are long foams is growing There is a lack of systematically developed data on long term thermal insulation and dimensional stability The tailoring and optimisation of foam systems based on MF is challenging Trials under commercial production conditions and long term testing of articles Lack of data FAs DC

12 PROPERTIES OF EMERGING BLOWING AGENTS OVERVIEW OF MAIN CHARACTERISTICS Blowing Agent GWP (100 Year ITH) BP (ºC) MW GAS λ-value C) Flammable Limits In Air (% Vol) Potential Producer HFO-1234ze None Honeywell HBA-2 < <T<30 < HFC- 245fa 12.5 None Honeywell HFO-1336mzz (FEA-1100) None Dupont AFA L1 <15 10<T<30 < HFC- 134a 10 None Arkema FAs DC

13 UPDATE ON LOW GWP OPTIONS HFO-1234ze Toxicology testing complete no issues Some use in EU: One Component Foams (OCF) XPS Production level semi-commercial FAs DC

14 UPDATE ON LOW GWP OPTIONS HBA-2 Toxicology testing nearly complete no issues Evaluations in three main foam types (in comparison to HFC-245fa) including thermal conductivity & dimensional stability versus time, compressive strength, adhesion and compatibility with contact materials: Spray foam Typical data: Refrigerators/freezers Foam (initial) thermal conductivity 17.5 mw/mk Good compatibility with HIPS (plastic liner) Exceeded performance of HFC-245fa in DoE energy tests Discontinuous panels Foam λ-value (mw/mk at 10 C) Foam thermal conductivity 19.0 mw/mk (versus 20.3 for HFC-245fa) Commercialisation expected 2014/5 Initial 6 months aged HBA HFC-245fa FAs DC

15 UPDATE ON LOW GWP OPTIONS HFO-1336mzz (FEA-1100) Toxicology testing completed no issues US SNAP approval being applied for Extensive studies of polyol solubility/miscibility Evaluation in spray, discontinuous panel, boardstock and appliance formulations* typical data (hand mixed foams): Foam λ-value (mw/mk at 24 C) Initial 290 days aged HFO-1336mzz HFC-245fa Good compatibility with plastics, elastomers and metals Molecule is CF 3 CH=CHCF 3 Commercialisation expected 2014/5 *Manich, sucrose, polyester and TDA-based polyols, respectively FAs DC

16 UPDATE ON LOW GWP OPTIONS AFA-L1 Toxicology testing in progress no issues so far Systems development choice of co-components Foam thermal conductivity ageing extended to 12 months discontinuous panel foam Foam λ-value (mw/mk at 10 C) Initial 12 months aged AFA HCFC-141b HFC-245fa Spray foam system development wall system initial λ-value at 10 C 19.8 mw/mk roof system initial λ-value at 10 C 20.9 mw/mk Good material compatibility with plastics and metals Commercialisation 2014/5 FAs DC

17 SUMMARY OF FINDINGS FOR LOW GWP OPTIONS - HFOs Toxicology testing well advanced/completed no issues so far Good solubility/miscibility with polyols Non-flammable; equipment drop-in for HCFC-141b replacement Foam thermal conductivity similar/superior to HFCs Extensive evaluations in progress (including with major system houses) formulation optimisation expertise being assembled Commercialisation 2014/5 FAs DC

18 EQUIPMENT MODIFICATIONS FOR FORMIC ACID Formic acid is a break-down product from methyl formate or from direct addition to CO 2 (water) co-blowing systems But. Formic acid is corrosive to standard foam dispensers and other equipment resulting in: Metering efficiency loss, nozzle wear and mixing problems Problem is worse if polyol blend stagnates in equipment over time low systems usage Solutions from machinery suppliers: Corrosion resistant pump, nozzles, epoxy resin coating of preblended polyol tank Cost $7,000 to $20,000 FAs DC

19 DRAFT FOAMS HPMP STRATEGY Control measure Impact vs. BAU 5%) Freeze to 2009/2010 levels 10% reduction 35% reduction Cut by ~20% Cut by 40+% Cut by 50 to70% Actions Take low-hanging fruit Use HC where possible Use of +25% C/E ($9.79/kg) for low GWP Pentane pre-blends Likely near end of foam use of HCFCs Use new low GWP blowing agents including blends FAs DC