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gl bal insulation MAGAZINE

Global insulation news Passive+ homes Process optimisation Insulation for oil and gas Monolithic silica gel

ISSUE 2 2010

globalinsulation.com

Ad IndexContents
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4 Global Insulation news

7 Diary dates

11 Innovative technology for building materials of the future

12 Introducing the Scantron Proscan MasterTrak

14 Denmark's rst Passive+ house inaugurated

16 Huntsman's technology helps create one of the mostenergy-effi cient homes in America

17 Global Gypsum Conference 2010

21 Flexible insulation solutions for the oil and gas industry

24 A new envelope with highly energy-effi cient insulation

30 Industrial insulation - A forgotten technology

33 The Last Word34 Advertiser index and reader enquiry

CONTENTS ISSUE 22010

This issues front cover...

The MP1 is a downsized conventional multipack machine with

lm curtain. The footprint is considerably smaller because the

packs/rolls enter directly into the compression chamber with no

charge accumulation. Because of the design, there is no need

for overhead support conveyors. The machine is designed for

very wide packages up to 1200 mm.

The end result is a machine much less expensive than other

multipack machines, but with the same compression force

and exibility.

Contact Details:

Seelen A/S, Morsoegade 10, DK-6700 Esbjerg

Ph. +45 75 12 01 99

Fax +45 75 12 91 84

[email protected]

www.globalinsulation.comExclusive Offi cial Magazine for

Global Insulation Conference, Global Gypsum Conference,Global Boards Conference, Global Fuels Conference,

Global Slag Conference

ISSN: Pending

Published by:

PRo Publications International Ltd

First Floor, Adelphi Court1 East Street, Epsom, Surrey, UK KT17 1BBTel: +44 (0)1372 743837

Fax: +44 (0)1372 743838

Editor Dr Robert McCaffrey [email protected]

Deputy Editor Dr Peter Edwards

[email protected] Margaret Masson [email protected]

Administrative assistant Lisa [email protected]

Commercial director Paul [email protected]: (+44) (0)776 747 5998

The Editor welcomes editorial contributions (letters,

articles etc). For full details on article submission, please

see: www.propubs.com/global-insulation

http://www.propubs.com/global-insulation

globalinsulationMAGAZINE Issue 2 - 2010 3


Dear Readers,

Welcome to Issue 2 o Global Insulation Magazinein 2010. Te issue coincides with the 5thGlobal Insulation Conerence and Exhibition, which will be held in London on 4-5 October.

Te event has established itsel as perhaps the only insulation-dedicated event to bring to-gether participants rom every branch o the industry, whether they are slag-wool producers,XPS users, VIP researchers or equipment producers. Te participants don't always see eye

to eye and there is ofen a robust debate about the merits or otherwise o different insulation

options and systems.

It seems to me though that every type o insulation has its niche - some are better in someapplications than others. I a cold-eyed appraisal o the situation is undertaken, then one

type or another will come out on top. I you eel that your product is at a disadvantage in thatniche, then the solution is obvious: either choose a different niche to compete in or changeyour product so that it can compete. Tat sounds harsh, but there are any number o addi-

tives that can be used to alter product properties and which can be very cost-effective. Weshall hear about a number o them at the conerence.

I you are attending, we hope that you enjoy the conerence. Over the course o the meeting,participants will be able to make contacts rom around the world and rom

all major branches o the industry. We hope that you enjoy this issue oGlobal Insulation Magazine. In the uture, you will be able to keep up with

all the latest news on developments in insulation via our redesigned andredeveloped web site, www.Global Insulation.com.


Globalinsulationnews Passive+ Homes Process Optimisation

ISSUE22010

globalinsulation.com

Dr Robert McCaffreyEditor

Ad Index


4/36

NEWS

4 globalinsulationMAGAZINEIssue 2 - 2010

US DOE cool-roof policy

US: The Department of Energy (DOE) announced on

19 July 2010 a series of initiatives to more broadly im-

plement cool-roof technologies on DOE facilities and

buildings across the US. As part of the new efforts DOE

will install a cool roof whenever cost effective over the

lifetime of the roof during construction of a new roof or

the replacement of an old one at a DOE facility.

As an example of a project already underway, the

National Nuclear Security Administration (NNSA), a

separately organised agency within DOE, has already

installed more than two million square feet of cool and

white roofs at NNSA sites across the country. Through

the Roof Asset Management Program, NNSA currently

saves an average of US$500,000/yr in energy costsand expects to save more than US$10m over the next

15 years.

Owens Corning on Dow Sustainability Index

US: Owens Corning has been added to the Dow Jones Sus-

tainability World Index in recognition of its industry-leading

sustainability initiatives.

The Index is a highly recognised sustainability index comprised of

leading sustainable companies from around the world. Inclusion on

this list means that the company ranks in the top 10% of the biggest

2500 companies worldwide based on long-term economic, environ-

mental and social criteria.

We are pleased to be recognised as the only US-based construction

and materials company on the DJSI World Index, said Frank OBrien-

Bernini, Owens Cornings chief sustainability offi cer. This ranking is

a true reection of Owens Cornings commitment to our customers,

employees, communities and the environment. Sustainability is a core

business strategy and it will continue to guide our efforts for years

to come.

One example of Owens Cornings contribution to environmental

sustainability is its insulation products which make homes and build-

ings more energy-effi cient worldwide. In the rst year of use, Owens

Corning insulation products save 12 times the energy it takes tomanufacture them. Owens Corning is also one of the largest users of

recycled glass in the world.

The DJSI follows a best-in-class approach and includes sustain-

ability leaders from industries worldwide, serving as an important

guide for investors to assess a given companys sustainability portfolio.

Selection to the DJSI is based on an in-depth analysis of a companys

economic, environmental and social aspects with a focus on long-term

development of corporate values. Listed companies are considered to

demonstrate continuous improvement year-on-year, as judged by a

panel of Dows judges.

The listing comes shortly after Owens Corning released its fourth

annual sustainability report, which outlines the companys progressin reducing its environmental footprint, greening its product lines,

providing energy-effi ciency solutions for the built environment and

supporting renewable energy sources.

Our fourth annual sustainability report demonstrates our commit-

ment to setting and meeting aggressive goals related to greening our

products and greening our operations, said OBrien-Bernini. We have

made solid progress with our sustainability efforts and remain focused

on continuously improving.

Knauf binder patent

US: US Patent number 7,772,347 was issued on 10

August 2010 and assigned to Knauf Insulation Gm-

bHs local subsidiary in Shelbyville, Idaho. A Binder

and Fibre Glass Product from Maillard Reactants was

invented by Brian Lee Swift, Ruijian Xu and Ronald

E Kissell.

According to the abstract released by the US

Patent & Trademark Offi ce, The present disclosure

is directed to cured and uncured binders useful in

the fabrication of products from loosely assembled

bres. For example, the disclosure describes cured

and uncured binders useful in the fabrication of

products from loosely assembled glass bres. The

disclosure also describes methods of fabricating

products from loosely assembled bres utilising the

aforementioned binders.

Russian insulation market is strong

Russia: The Russian market for insulation materials

has returned to record growth. By way of illustration,

Rockwool says that despite operating 24 hours a

day, its plants in the country cannot keep up with

demand. It reports that it is now importing mate-

rial from Poland, the Czech Republic, Hungary

and Germany.

Rockwool revises estimate upwards

Denmark: Rockwool put in a strong performance inthe second quarter of 2010, with a turnover growth

of 10% year-on-year and an earnings before interest

and tax margin of 5.8%, compared with 4.1% in the

second quarter of 2009.

At the same time Rockwool has raised it net results

forecast for the whole of 2010 from US$52.5m to

US$70.0m. A gure of US$35m was reported for the

rst half 2010.

Big increase in output for Lenzing

Austria: In the rst half of 2010 Lenzing AG increased its consolidated

sales by 44% to Euro847m. It was enabled by higher bre quantity

and the price dynamics of global markets. It was also helped by

rst-time full consolidation from early May of 2010 on, of its pulp pro-

duction site Biocel Paskov in the Czech Republic, which it acquired in

April 2010.

The startup of new viscose bre capacity in Indonesia in the rst

half of 2010, investment in debottlenecking in China and the expan-

sion of lyocell in Heiligenkreuz, Austria put Lenzing in a position to

make optimum use of the expected bre market dynamics.

Sales of segment bres grew by 46.3% to Euro741m. Higher pro-

duction capacity along with full utilisation at all sites and signicantly

higher prices were the reason for this development. Its business units

Textile Fibres as well as Non-woven Fibres performed excellently. Inparticular its special bres Lenzing Modal and Tencel met with broad-

based success due to innovative applications.

Ad IndexContents


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http://www.ode.com.tr/


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NEWS


Business saved by former managerUS: Brandon Gallegos, the former branch manager for

G&G Insulation in Boise, Idaho, recently acquired the

trade name and is operating as G&G Insulation LLC.

He acquired the trade name from United Subcon-

tractors Inc., a Minnesota-based company that exited the Idahomarket in late July 2010, closing facilities in Boise, Twin Falls and

Idaho Falls.

Its a huge honour for me to continue a local business, Gal-

legos said. I denitely feel there are still opportunities here. Our

customer base and knowledge give us good opportunities.

Gallegos started with G&G Insulation in 1992 and later left toown and operate Gem State Insulation. He returned to G&G in

1996, working as an installer, estimator, sales manager, assistant

manager and branch manager. He is joined at G&G by estimator

Ken Farmer, son of the founder of the original company.

Beacon acquires Posi-Slope Enterprises

US / Canada: Beacon Roong Supply, Inc, a US based

distributor of roong materials and complementary

building products, has acquired Posi-Slope Enterprises,

Inc., a Canadian company engaged in the design and

fabrication of tapered roof insulation systems. The trans-

action also includes the acquisition of Posi-Pentes, Inc.,

the sister company of Posi-Slope Enterprises.

The acquisition enables Beacon Roong to expand its

presence in the Province of Ontario and to better serve

its existing commercial roong customers and to enter

into the Canadian tapered design market.

India slaps anti-dumping duty on

Chinese glass-bre

India: The Indian government has imposed anti-dumping duty of

up to 41% on Chinese glass bre, which is used as a reinforcement

material, to protect the domestic industry in India. The restrictive

duty on glass bre will impact shipments from 13 Chinese manu-

facturers, according to the Department of Revenue.

The anti-dumping duty imposed under this notication shall be

effective up to 13 January 2011 and shall be payable in Indian cur-

rency, taking into account the combined cost, insurance and freight

value of the products.

The principle of anti-dumping duty, a WTO compatible tool, is

to prevent dumping, to ensure fair trading practices and to create a

level playing eld for domestic producers vis-a-vis foreign producers

and exporters.

Knauf receives Eurons indoor air award

Europe: Knauf Insulation has become the worlds rst company

to receive the coveted Eurons indoor air comfort gold standard.

The gold standard certicate was awarded to Knauf Insulations

revolutionary new mineral-wool products made with Ecosetechnology and provides a strong endorsement of the enhanced

environmental performance of Knauf Insulations product range

using that technology.

Speaking after the award, Dr Roland Augustin, director of

certication for chemical safety at Eurons, said, We com-

mend Knauf Insulation for leading the charge toward a more

sustainable future. Dr Augustin continued by explaining, Knauf

Insulations unfaced glass mineral wool with Ecose technology

product range has met all of the dened requirements of Euro-

ns indoor air comfort gold standard and is therefore certied as

an outstanding material according to the VOC (volatile organic

compounds) indoor air quality emissions regulations.

Today were celebrating the rst part of our product range

to become certied through this programme. We intend over

time to seek Eurons certication for our complete mineral wool

product range, said Tony Robson, CEO of Knauf Insulation.

The move towards greater energy effi ciency in buildings is

expected to lead to buildings that are much more air tight and

use signicantly more insulation. This in turn is leading to greater

demands on products to achieve strict requirements related to

indoor air quality as well as a growth in the number of manda-

tory and voluntary product regulations being set-up. With the

Eurons indoor air comfort certication programme combining

the criteria of mandatory and voluntary product regulation into

one trusted label, it provides manufactures and customers alikewith a consolidated view of the products performance in rela-

tion to indoor air requirements.

Acoustical Solutions adopts Ecose brand

US: Acoustical Solutions Inc has announced the adop-

tion of Knauf Insulations Ecose brand breglass in the

AudioSeal Sound Blanket line. The new green breglass is

actually brown in colour and will help projects to meet greenbuilding standards.

The Ecose breglass is manufactured from naturally occurring

and/or recycled raw materials and bonded using a bio-based

technology, free from formaldehyde. It is 70% less energy inten-

sive than traditional petroleum-based bonding agents. Ecose

breglass is itself 100% recyclable and it contains a minimum of

30% post-consumer recycled bottled glass.

The AudioSeal Sound Blanket line offers maximum noise re-

duction on any application by combining sound absorption and

noise barrier materials. AudioSeal Sound Blankets are available

in an absorber only, with a sound-blocking barrier backing or

barrier septum conguration. Audioseal sound blankets utilise

a variety of quilted breglass absorbers and exible noise bar-

riers, which offer a combination of both sound absorption and

sound blocking.

These versatile Sound Blankets can be used in many applica-

tion types. They can be custom-sized and supplied with track

systems for indoor sound enclosures, or they can be custom cut

for various OEM manufacturing applications. They can also be

used outdoors for environmental noise control at construction

sites and community noise problems. The blankets have been

used in many high-prole settings including Bostons Big Dig

and at the site of the twin towers in New York City.

Acoustical Solutions sales manager David Ingersoll said, Out

of all of the enhancements we have made to our line of Audio-Seal Sound Blankets over the last 20 years, this is the one that I

am most excited about.


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NEWS


Australian insulation left out in the cold

Australia: The insulation services industry has been left out

in the cold, suffering a 24.1% drop in revenue growth during

2010 after the withdrawal of federal government subsidies in

the home insulation scheme and school building program.

The industry is expected to suffer a 56% fall in job growth.

Once insulated by government support, the insulation

services industry stands alone now, making it vulnerable

to a number of competitors, including special construction

trade contractors and humble do-it-yourself enthusiasts,

said Robert Bryant, general manager of the industrial analyst

IBISWorld.

Knauf Steele River plant plan pulledAustralia: Knauf companys plans for an insulation plant

at Steel River were formally abandoned in June 2010 after

going on hold earlier in 2010. Knauf Insulation had planned

a US$158m glass-wool manufacturing plant, but its Sydney-

based construction manager wrote to Newcastle City Council

to say the project will now not proceed.

Knaufs decision was apparently linked to European eco-nomic conditions and Crown Projects said earlier that troubles

with the federal governments insulation programs had not

been a factor.

New VP at Gaco Western

US: Gaco Western, manufacturer of elastomeric coatings and

polyurethane spray foam for the construction and water-

proong industries, has announced that Dan Nelson will lead

its research and development arm as the new vice presidentof R&D at its manufacturing facility in Waukesha, Wisconsin.

As a company were continuously focused on product in-

novation and advancement. Assembling a world-class R&D

team is paramount to that, said Peter Davis, president and

CEO of Gaco Western. Dans extensive experience leading

technology and research in the coatings industry speaks for

itself. Hes going to make a signicant contribution to our fu-

ture growth.

Gaco Westerns 60,000ft2 facility at Waukesha, Wisconsin

was only recently opened. It replaces a 18,000ft2facility that

was built in 1985. In addition to regional offi ces and manufac-

turing, the new site includes a high-tech research facility andtechnical training program for customers.

Products manufactured in Waukesha include polyurethane

spray foam insulation and Gacos line of silicone, acrylic, epoxy

and urethane coatings.

Czech Knauf plant to produce Ecose bresCzech Republic: Knauf Insulation Praha (KIP) in Prague, Czech

Republic is launching a new-generation mineral insulation

material based on glass bre. The material is manufactured by

the Ecose Technology developed by Knauf. Ecose Technology

uses a binder made of natural or recycled raw materials. Ecose

Technology is environmentally friendly because it does not use

chemicals such formaldehydes, phenols and acrylics.

Johns Manville technology patent

US: Daniel Elden Near of Littleton, Colorado has developed

a nozzle assembly, delivery system and method for convey-

ing insulation material. The inventor was issued US Patent

Number 7,735,755 on 15 June 2010, which was assigned to

Johns Manville of Denver, Colorado.

According to the abstract released by the US Patent &

Trademark Offi ce, A nozzle assembly for conveying a ow of

particles of insulation material suspended in air to a substrate

to form an insulation product on the substrate is provided,

including: a nozzle body, dening a ow-path for accommo-

dating the ow of particles of insulation material suspended

in air, wherein the nozzle body comprises an inlet for receiving

the ow of particles of insulation material suspended in air; an

outlet for propelling the ow from the nozzle assembly and at

least one expansion section in which the cross-sectional area

of the nozzle body expands in the direction of ow, the ex-

pansion section being effective to reduce the velocity of theparticles owing therethrough; and at least one binder outlet

for providing a binder to the ow of particles of insulation

material propelled from the outlet.

Rockwool snaps up CSRs Asian interests

Denmark / Australia: The building products group CSR has

agreed to sell all of its Asian businesses to the Rockwool Group

for a total of US$120m. Rockwool will take charge of CSRs insu-

lation, panels and trading businesses across Asia.

The transaction covers three mineral wool factories in China,

Malaysia and Thailand, a sandwich panel plant at the premises

of the Chinese insulation plant, as well as representation of-

ces in the Philippines, Vietnam and Singapore. The acquired

operations will complement Rockwools existing Asian busi-

ness, which is based in Malaysia.

The acquisition enables Rockwool to put further weight

behind its growth strategy in Asia by establishing a strong

foothold in the Chinese market, said CEO Eelco van Heel.

CSR building products chief executive offi cer Rob Sindel

said the deal was in line with CSRs decision to focus on the

building products markets in Australia and New Zealand

where it owns brands such as Gyprock, Bradford and the glass

maker Viridian.

Rockwool to invest in Russian plantRussia: Danish insulation materials producer Rockwool plans

to invest US$50m in Russias Troitsk Mineral Wool Panel Plant

in the Chelyabinsk Region. The plant is currently controlled by

the Russian Minplita group.

Turkish market for insulation worth US$4bnTurkey: In Turkey new energy effi ciency regulations should

increase the total domestic demand for insulation materi-als. Industry sales rose from just US$300m in 2002 to around

US$2bn in 2008. It is estimated there was a further 15-20% rise

in 2009. Market volume could reach as much as US$4bn in the

near future.


9/36
http://www.remakre.com/


10/36

NEWS

Gamma Meccanica in Russia and UAE

Russia: A high capacity (6t/hr, 2400mm wide) stone-wool

production line is currently being supplied to the Russian

Federation by Gamma Meccanica. The line is designed for

the production of rigid boards for sandwich panels and in-

cludes a dedicated line for lamellas and the production of

standard boards.

UAE: The construction of a high-speed, exible stone-woolline at the Fujairah Rockwool Factory is almost complete. The

line will have a capacity of 4t/hr and will produce rigid boards,

roll felts, loose wool and stitching mattresses. Commissioning

is expected by the end of October 2010.

Premier Tech acquires Forberg assets

Europe: Premier Tech has announced the acquisition of the

commercial and technological assets of the mineral wool bag-

ging division of Forberg, a leading supplier to the insulation

industry in Europe.

Through its business unit in Europe, Chronos BTH, PremierTech is now in a position to serve a larger clientele and even

extend its product lines with technologies for feeding, convey-

ing, palletising, automation and load securing. Chronos BTH is

now in a position to offer turnkey systems from the feeding of

the product to the wrapped pallets.

Chronos BTH is the sister-company of the Canadian-based

Premier Tech Chronos which started its industrial venture

in 1990 making compressible products such as rockwool,

breglass insulation, cellulose, sphagnum peat moss and

wood shavings.

Owens Corning patents

US: William R Cooper of Johnstown, Ohio, William E Downey of

Granville, Ohio, Harry B Cline of Heath, Ohio, and Liang Chen ofNew Albany, Ohio, have developed a recovery system for breglass

production.The inventors were issued US Patent Number 7,754,020

on 13 July 2010, which was assigned to Owens Corning Intellectual

Capital LLC of Delaware.

According to the abstract released by the US Patent & Trade-

mark Offi ce, A recovery system recycles the washwater used to

clean excess binder and debris from the production components,

including a forming hoodwall constructed of non-corrosive materi-

als for manufacturing breglass insulation. A separate closed-loop

recovery system is provided for the forming hoodwall in which

the binder-containing washwater is screened and then recycled

back to the forming hoodwall without further chemical treatmentto change the pH level. A binder reclamation system is coupled

to the hoodwall washwater recovery system to divert the low pH

washwater when the supply of binder needs replenished at the

forming hoodwall. The binder reclamation system introduces an

acid solution to the cleaned washwater to lower the pH from about

3.5 to about 2.5. The other production components share a bulk

washwater recovery system in which a base solution is introduced

to raise the pH to approximately 8.0 or above to reduce corrosion

in the other production components.

US: Owens Corning has also been awarded a patent for a loose-ll

insulation distributing machine.

According to the abstract posted by the World Intellectual

Property Organisation, A machine for distributing loosell insu-

lation is provided. The machine includes a shredding chamber

having an outlet end. The shredding chamber includes a plurality

of shredders congured to shred and pick-apart the loosell insu-

lation. A discharge mechanism is mounted at the outlet end of the

shredding chamber. The discharge mechanism is congured for

distributing the loosell insulation into an airstream. The discharge

mechanism includes a shaft mounted for rotation within a hous-

ing. The shaft includes a plurality of vanes extending radially from

the shaft. A plurality of seals is mounted to the shaft and to the

vanes. The seals are congured to seal against the housing as the

shaft rotates. A blower is congured to provide the airstream ow-ing through the discharge mechanism. The shaft and the vanes are

a one-piece structure.

Relocation and expansion for Evonik

Austria: On 17 June 2010 Evonik Fibres GmbH, Lenzing, inaugu-

rated a new plant at Sching. The partial relocation of production

of the polyimide bre P84 into the joint production and storage

building was necessary because the previous site in Lenzing was

not suitable for an optimal production ow, according to general

manager Dr Herbert Greisser.

Of the 66 employees currently working in Lenzing, around

half will be relocated to the 8000m2site in Sching during the

period to 2013.

Evonik Fibres is the only producer of P84 polyimide bres

worldwide. Their areas of application reach from lter media for

the separation of dusts from hot ue gases in waste incineration

plants of coal-burning power plants to seals, ame-retardant

clothing and thermo-insulation materials.

Distribution International changes hands

US: Audax Group, a private equity rm, has acquired

Distribution International, Inc., a distributor of industrial,

commercial and marine insulation and related specialty

fabricated products from the private equity rm Grey

Mountain Partners, LLC.

GE Antares Capital has provided senior debt nancing

and PNC Mezzanine Capital has provided mezzanine debt

nancing to support the transaction.

Superglass trading enables expansion

UK: Superglass Holdings plc, an independent manufac-

turer of environmental insulation products, has reported

that trading in recent weeks has been broadly in line

with its expectations. Its board expects the rm to meet

market expectations for the 12 months ending on 31

August 2010.

Repairs have been completed at one of the furnaces at

its Stirling plant and the plant is again fully operational.

The repairs have improved the operational performance

of the furnace and will extend its working life, deferring a

planned rebuild of the unit, at an estimated capital costof between Euro1.76m and Euro2.35m, by at least 18

months from the original mid 2011 date.



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globalinsulationinsulationMAGAZINE

globalglobalinsulationinsulationMAGAZINEMAGAZINEIssue 2 - 2010 1111

Energy effi ciency with a new type of brick

Te brick-making industry reacts to these special de-

mands with the development o a new product that not

only meets the required thermal transmittance values,

but exceeds them - A brick lled with mineral wool.

Another essential advantage o this new type o brick is

a signicant improvement in sound insulation.

For the industrial production o this new product,

Grenzebach Maschinenbau GmbH, a German company

situated in Asbach-Bumenheim, Bavaria, has now de-

veloped a brick lling station which can be integratedinto existing production lines.

Operation of the production equipment

Mineral wool stacks in commercially available di-

mensions o approximately 2000mm x 1000mm are

provided or line eed-in. Te mineral wool meets de-

termined requirements regarding density, quality and

thickness tolerance.

At the beginning o the process, a ork-lif truck loads

the stack, o more than 2m in height, onto a rotating

platorm. Te platorm rotates by 180 and transports

the stack into the eeding area. Here a gripper rame at-

tached to a gantry unit takes off a single sheet rom the

stack and puts it onto a table positioned next to it where

it is exactly aligned and moved through a longitudinal

saw by the line gantry. Several saw blades separate it into

longitudinal strips. Te sheet tolerance can be adjusted

by a lateral milling cutter and excessive material is cut

and removed. It can be sucked, collected and later re-

injected into the board production process.

Te strips are then separated cross-wise and cut into

the requested dimensions. For this purpose, a carriage

with carrier rame at the gantry transports the mineral

wool strips cycle-by-cycle through a saw that is moving

cross-wise to the main transport direction. Tis crosssaw can be equipped with several saw blades to achieve

a high output.

In the ollowing special conveyor, the mineral wool

blocks are set up vertically and are thus in the posi-

tion required or lling them into the bricks. Already

here, they are arranged in groups according to the

bricks dimensions.

Another gantry is equipped with a carriage with

stripping ngers and pushes the row o mineral wool

blocks rom the conveyor into a provisioning and

separating station. Afer separation o the mineral wool

blocks, these are pushed through special channels into

the bricks. Te ller is moved into several bricks at a

time. First the lower row o holes in the brick is lledand afer lifing the pre-channels, lling o the upper

row o holes in the brick is perormed.

Feeding o the bricks is perormed by a chain con-

veyor coming rom the brick production line. Te

bricks are stopped in a holding position and aligned or

the lling process.

Structure of the equipment

At a capacity o 800 bricks/hr, 160 mineral wool pel-

lets per minute are lled into the bricks. Tis indication

reers to a brick length o 36.5 cm and twelve holes to

be lled.

Te Grenzebach equipment has a modular design

and various concepts or sawing, sorting and lling are

available so that individual customer requirements can

be met. From simple systems with low-level automation

and perormance to high-perormance equipment ll-

ing up to 1400 bricks per hour and using mineral wool

bricks o different dimensions within the same brick,

the user will get solutions matching exactly his specic

production needs.

In a brickworks, this equipment can be ully inte-

grated into the production process. Te lled bricks are

re-ed into the production line where they are stacked

and nally packed.Te equipment is also available as a stand-alone

solution. Here the lling system is not integrated into

the production process.

Karl Hertle Grenzebach Maschinenbau GmbHKarl Hertle, Grenzebach Maschinenbau GmbH

nnovative technology for buildingInnovative technology for buildingmaterials of the futurematerials of the futureEnergy saving and the use of effi cient, insulating building material will be signicant factors in

future building construction. Legal and energy saving regulations on thermal insulation have

already been launched. In achieving these goals, production of modern building material is of

vital importance.

Above:Grenzebach

Maschinenbau GmbHs

new machine, which can

ll mineral wool into

brick cavities.

Ad Indexontents


12/36


1212 globalglobalinsulationinsulationMAGAZINEMAGAZINEIssue 2 - 2010

he Masterrak product range has been designedspecically or insulation boards, at extrusionprocesses and other continuous, on-line, non-contact

measurement and process control applications.

Scantron provides its customers with complete meas-

urement and control systems which are all designed,

manuactured, delivered and commissioned by its expe-

rienced team all over the world. All systems supplied by

Scantron have a virtual private network (VPN) connec-

tion that enables Scantron to install sofware upgradesand check perormance on a regular basis wherever the

system is operating.

Manuacturing industries are always looking or

ways to increase effi ciency, reduce costs and improve

their competitiveness, all o which can be achieved

with the introduction o a Scantron measurement and

control system. Proscan Masterrak systems can make

a big impact.

Proscan MasterTrak

Te Proscan Masterrak is a complete solution or the

continuous monitoring o product thickness or width.

Te system uses the latest laser technology to measure

the product by a non-contact method. Te operator

interace provides real-time measurement and trend

graphing with alerts or out-o-control and out-o-tol-

erance conditions. Statistical and productivity reporting

is also provided, which can be logged to a hard drive or

printed on demand. A range o industrial interaces are

included to enable connection to external PLCs, host

computers or other hardware devices. A proportional

eedback control acility is available to automatically

regulate the process line reducing human intervention

and improving the process capability and stability.

System overview

Te system comprises an O Frame and a Display Sys-

tem, positioned next to the line.

The O-Frame

Te O-Frame is constructed to provide both a secure

and rigid structure. Te rame is designed not to distort

with temperature but to remain parallel between the

upper and lower rail at all times. Te lasers travel across

the width o the production line and are mounted on

precision rails. A motor controls the movement o the

sensors and an encoder tracks their positions.

Sensor and actuation control systemTe actuators and sensors are managed by a control

computer running Scantron ProControl sofware on a

real time operating system. Te top and bottom sensors

Above: MasterTrak II in

operation at a Kingspan

insulation board line.

Lars-H Lindstrand Scantron Industrial Products LtdLars-H Lindstrand, Scantron Industrial Products Ltd

ntroducing the ScantronIntroducing the ScantronProscan MasterTrakProscan MasterTrak

Scantron, the UKs leading supplier of non-contact laser scanning and measuring systems, has

expanded its well-known range of Proscan products with the introduction of the MasterTrak family

of products.

Right:MasterTrak IV.

Right: MasterTrak II.

Ad IndexContents


13/36

sample at exactly the same time and report a displace-

ment gure to ProControl. It then calculates the actual

thickness at a specic position on the web and sends

this value to the Masterrak sofware. Tus, the accu-

racy is maintained even i the product moves up and

down during the process.

Display system

A robust line side cabinet is the primary operator in-

terace. Te system PC runs Microsof Windows and

Masterrak, communicating with ProControl Sofware

via CP/IP.

General principle of operation

A pair o laser triangulation sensors is connected

together in master/slave mode. Te master gauge

synchronises the measurement and calculates the di-

erential thickness measurement. Te synchronisation

o the sensors ensures a correct measurement even

when there is vertical movement o the product. Te

width is determined rom the encoder positions ateach side where the laser triangulation sensors detect

the edge o the product. ProControl controls and reads

the laser triangulation sensors, an optional temperature

sensor and the position encoder as it moves the sensors

back and orth across the material and creates a data le

o the readings.

Masterrak accesses these readings to display them

as charts and/or in numerical ormat. It compares read-

ings with control and tolerance limits and adjusts the

display colours accordingly. Masterrak then compares

the readings with programmed control limits and dis-

plays the readings in green or in tolerance, yellow or

within control limits and red or outside tolerance

limit. Examples o screen shots rom a scan o a wedged

product with 13 prole lines across the width and the

average width measurement are

shown.

Te standard Masterrak sof-

ware includes a graphic display

o thickness cross section prole,

a numeric display o thicknesso user dened positions across

the width, a numeric display o

average cross section thickness, a

numeric display o product width,

a numeric display o product

thickness, a colour-coded alarm

and pre-alarm on screen indica-

tion and trend graphs.

Other features

Other eatures include the auto-

matic generation and printing o summary report or

each product run, containing product ID, date, time,

target thickness and summary statistics or each run

including minimum and maximum thickness, standard

deviation, range, CP, CPK and the percentage o

product that is out o specication.

In addition, all measured data saved to disk is in

CSV ormat, which can be imported directly in MS

Excel or other computer systems or urther analysis

or custom report generation.

Te products library/prole editor allows instant

set-up when changing rom job to job, holding all

o the products specications, allows the operator

to speciy nominal values and tolerances or variousproducts and the controls limits or process regula-

tion can be administrator level protected.



Left: Example of screen

hot from scan on wedged

product with 13

prole lines across the

width and the average

width measurement.

Left: Numerical screen

hot from scan on wedged

product with 13

prole lines across the

width and the average

width measurement.

Left: Schematic

representation of the

ProControl / MasterTrak

control system.

Left: Example screen-

hot of a top and bottom

prole scan.


14/36



Zero energy bills or even a positive balance on theaccount. It sounds almost too good to be true, butthis will be the reality or Kalle Christensen and his

amily. Te Danish Minister or Climate and Energy,

Lykke Friis, inaugurated Denmarks rst Passive+house on 24 June 2010. Te green leap orward was

taken in Northern Europes largest low-energy area,

Stenlse South.

Lykke Friis said, Buildings are responsible or a sub-

stantial proportion o our CO2emissions. Since the UN

Climate Change Conerence 2009, our task has been to

demonstrate via practical solutions that green transor-

mation is possible and that reducing our consumption

and becoming independent o ossil uels goes hand-in-

hand with competitiveness and green jobs. Te Passive+

house is not just a good initiative on Danish soil. Te

projects prospects are ar-reaching in terms o job crea-

tion, exports, the climate and the consumer.

Housing designed to meet future EU

requirements

Within the Rockwool Group, which has contributed to

the construction o the house, this product is viewed as

an important step towards green exports o the uture.

France already has plans to introduce energy plus

housing standards, says Eelco van Heel, CEO o Rock-

wool International. Germany and Great Britain are

also about to introduce energy requirements or new

buildings that will put Denmark on the back-oot. Also,

the EU has just agreed on requirements or near-zeroenergy buildings beore the end o 2020. I we want to

succeed in the international clean-tech market, it is vital

or construction rms to take a visionary approach and

acquire in-depth experience o building energy-effi cient

buildings. Tese are solutions that we can export and

which can secure important green jobs in the uture.

Stenlse low-energy zone

It is no coincidence that this ground-breaking house

has been built in Stenlse. It is the building site o

what is arguably Northern Europes largest low-energy

development and it has already attracted international

attention. In the past year several hundred journalists

and political decision-makers rom all over the world

have visited the Egedal Municipality. Tey are eager to

pick up know-how rom the visionaries who are build-

ing popular housing that is equipped or uture energy

costs and climate challenges.

As Mayor Willy Eliasen said, Here in Stenlse South,

we have proved that its possible to build better homes

that save more than enough expensive energy to offset

the little extra monthly mortgage costs. So why wait

to introduce super low-energy requirements in uture

building regulations? When that happens, people in this

area will automatically increase the energy effi ciency o

their homes by a urther 25%. Other municipalities can

easily ollow our example. Tis is benecial to domestic

energy bills and to Denmarks clean-tech exports.

Behind the scenes

Te man behind the Passive+ house is Finn Christensen

rom the construction company Passivhus Design ApS,

which has recently developed an innovative designmodel or passive house construction. Now hes taking

it a step urther and has built a ully-insulated passive

house, which will be upgraded to a home with a positive

Finn Christensen, Passivhus Design ApS Thomas Nordli, Rockwool International A/SFinn Christensen, Passivhus Design ApS & Thomas Nordli, Rockwool International A/S

Denmarks rst Passive+Denmarks rst Passive+house inauguratedhouse inauguratedThe rst Passive+ house in Denmark has been inaugurated by Lykke Friis, the Danish Minister for

Climate and Energy. It is paving the way for new constructions, producing more power than

it consumes.

Above: Danish Minister

for Climate and Energy

Lykke Friis cuts the rib-

bon at the inauguration

of Denmarks rst

Passive+ house.

Ad IndexContents


15/36

energy balance, with just a moderate solar cell system.

I see it as a challenge to build a house that will

remain strong into the uture rom an energy point o

view and that also offers international potential. Tats

what I think the Passive+ concept offers, he said.

About the house

Te Passive+ house in Stenlse has an area o 172m2

and cost Euro336,000 to construct. It is studded with

insulation and a new solar-cell system will ensure an

annual surplus o renewable energy, which will be sold

to the power grid.

Te effi cient insulation and super low-energy win-

dows optimise the building envelope, and it also has

effi cient ventilation and heat pumps. Te nucleus is

a passive house certied in accordance with PHPP

(Passive House Planning Package).

Solar cells

Te solar cell device made by Racell is barely 46m2and

not only does it reduce electricity and heating bills tozero, it actually produces surplus energy. In the win-

ter nearly 80% o the buildings energy production is

used or electricity and heating but during the warmer

months o the year only around 20% o the energy

produced by the solar cells is used. Tis means that the

house produces more energy than it consumes and the

energy company transers this power back to the grid.

As Christensen explains, We planned the house

so that it produces the maximum amount o green

surplus energy that the energy company is willing to

take back rom a single amily dwelling annually. Tats

6000kWh. Tis produces an annual saving o 5.75tin CO2emissions. In countries such as Germany and

France, cheap loans or substantial nancial subsidies

are allocated to well-insulated super low-energy houses

and energy+ dwellings. Te situation is not yet like this

in Denmark. While our Danish energy companies pay

the same or a kilowatt hour o solar power that we pay

or a kilowatt hour produced rom a pollutant carbon

source, German solar panel owners receive three and a

hal times more money or the eco-riendly solar energy

than is delivered to the supply network. I the goal is to

make Denmark independent o ossil uels, we will not

achieve this unless we create greater incentives to build

plus energy homes here.

Roof, walls, windows and ventilation

Te insulation in the roo and walls were built using

500mm Rockwool Super FlexiBatts insulation, which

has a high insulating capacity.

Te windows are a new type o super low-energy

product, the Svare model rom Vrgum. Tey are com-

pletely aluminium-ree, and contain no external wood.

Instead, they eature 6mm energy-effi cient reinorced

glass. o minimise wear and the need or maintenance,

wood is only used internally.

Te ventilation device is a Paul product, certied bythe Passive House Institute in Darmstadt. Te Stiebel-

Eltron heat pump has an effi ciency o 4.5. In other

words, the home-owner obtains our and a hal times

more energy or heating than the kilowatt hours that

are put into the device. Low-temperature oor heating

is used or heating and the equipment incorporates the

Rehau geo-thermal tubes that pre-heat the supply air in

winter and provide cooling in summer.

No gaps or leaks

Te new Passive+ house is very well-sealed with a single

load-carrying structure which was specially developed

by Passivhus Design Aps. Tere are rafers all the way

round with suffi cient space or the powerul insulation.

Cables and pipes are installed internally so that the

building envelope remains complete and unpunctuated,

except or the openings that t the windows and doors.

Tis reduces heat-loss and the risk o condensation and

mould. o ensure the best possible exploitation o solar

gain, the building aces south and the roo is angled at

43 degrees.

Certication

PHPP is a calculation tool developed by the interna-tionally renowned Passiv Haus Institut in Germany.

Consulting engineers Ellehauge & Kildemoes carried

out sophisticated energy calculations and managed

the certication process in accordance with the pas-

sive house standard. Actual certication is always

undertaken by an independent body, which checks

the energy calculations or the certication in order

to ensure a high quality. According to the interna-

tional standards established by PHPP, the annual

heat consumption o a passive house should be less

than 15 kWh/m2.

Meet the neighbours

Kalle Christensen, the lucky

owner o the Stenlse Passive+

house said, My wie Anne and

I helped to decide what our

home should look like, down to

the smallest detail, both inside

and outside. Te most impor-

tant thing or us was to build a

home where we had better con-

trol o our heat consumption.

Tats why we initially chose to

build a passive house.

ogether with Passivhus

Design, we were able to take the

nal step and build a passive

house that is actually a dwelling

with a plus on its energy bal-

ance. One o our requirements,

however, was that the house

needed to t in with the style o

the neighbouring housing. We

have been delighted to move in,

and enjoy a comortable indoor

climate. And were certainlyhappy to wave goodbye to elec-

tricity and heating bills.



Below: Inside the

hristensens

Passive+ house.


16/36


1616 globalglobalinsulationinsulationMAGAZINEMAGAZINEIssue2 - 2010

CertaSprayM Closed Cell Foam Insulation from

Certaineed Corporation, which is based on

Huntsmans SPF technology, was featured in a homelocated in Beverly, Massachusetts, built by Cleantech

Homes, LLC. Te home is being evaluated for a LEED

Platinum Home rating,1and is currently being utilised

as a teaching centre that showcases sustainable building

techniques and design as well as new products and con-

struction materials used in high-performance homes.

During the construction phase, a two-pound

CertaSpray foam insulation was used for the homes

interior thermal insulation. CertaSpray foam insula-

tion was applied on the walls, roof underlay and attic

to protect the home against heat, cold, air infiltration,

moisture and sound.

CertaSpray foam insulation offers outstanding en-

ergy effi ciency and contributes to a healthy indoor air

quality, enhanced moisture management and excellent

acoustical control, all of which are critical factors in

green building projects, said Lionel Rossignol, product

manager for Certaineed Insulation. CertaSpray foam

insulation was a natural choice for the homes interior

insulation, and we are honoured to have our product in

a home built by Cleantech Homes.

In addition to thermal barrier protection, homes

insulated with CertaSpray foam insulation will typically

use 30% to 50% less energy when compared to under-

insulated homes. Tis can lead to a reduction in a homesheating, ventilation and air conditioning (HVAC)

systems and an overall reduction in HVAC equipment

costs in new home construction. Homeowners that use

CertaSpray foam insulation can also take advantage of

an existing energy tax credit of up to US$1500 under

the American Recovery and Reinvestment Act.oday energy effi ciency is at the forefront of new

home construction and home retrofit projects. Archi-

tects and builders are looking for innovative ways to

build more energy effi cient homes and consumers are

looking for ways to reduce their energy bills. Tis home

clearly demonstrates how consumer demand can be sat-

isfied with innovative construction materials, including

SPF, said Monica Ntiru Karamagi, marketing manager

at Huntsman Polyurethanes.

Te energy saving measures along with other

features found in the home helped contribute to its

LEED Platinum Home application, meaning it will

achieve the highest level within the LEED for Homes

rating systems.

Developed by the US Green Building Council

(USGBC), the LEED rating system is a US-wide third-

party certification system that recognises leadership

in green building. LEED for Homes was launched

in February 2008 and measures green homebuilding

performance based on numerous categories including

site selection, water effi ciency, material and resource ef-

ficiency, energy and atmosphere, indoor environmental

quality, location and linkages, awareness, education,

and innovation. Te home will be open to the public

until the end of December 2010.

1. LEED is a registered trademark of US Green

Building Council (USGBC).

Contents Ad Index

Above: One of the most

energy- effi cient and

sustainable houses in

America will be open to

the public until the end

of December 2010.

Huntsman Polyurethanes CertainTeed InsulationHuntsman Polyurethanes & CertainTeed Insulation

Huntsmans technology helps createHuntsmans technology helps createone of the most energy-e cient homesone of the most energy-effi cient homesin Americain America

Technology developed by Huntsman Corporation of Woodlands, Texas, USA has been used to

create one of the most energy-effi cient and sustainable homes in America.


17/36

CONFERENCE & EXHIBITION2010

10thgl balgypsum

Organised by:

gl bal gypsum MAGAZINE

PRo PublicationsInternational Ltd

r sest ma g

o mo ess na s

- t sa ever!

Issues covered:

Market trends

Production technology

New developments

Who should attend?

Product manufacturers

Equipment suppliers Cement producers

Researchers

Academics

Technology companies

Plant managers

Market analysts

Shippers & traders

www.propubs.com/ggc

Versailles Congress Palace,

Rue de la Chancellerie,

Versailles

Newdevelopments

in gypsum

2526 OCTOBER 2010 Paris (Versailles), France

Sponsored by:

Syngenta

Ad IndexContents
http://www2.syngenta.com/en/products_brands/materials-protection.htmlhttp://www2.syngenta.com/en/products_brands/materials-protection.htmlhttp://www.ocvreinforcements.com/http://www.jm.com/http://www.gypsumtechnologies.com/http://www.henry.com/http://www.grenzebach.com/http://www.erisimmak.com.tr/


18/36

Te 10th Anniversary Global GypsumConference & Exhibition is set to bethe largest and most successful gypsumconference yet. With the headquartersof several of the worlds largest gypsumcompanies within easy reach and fantasticconnections to every part of the world,this is also set to be the most internationalGlobal Gypsum Conference so far, withdelegates expected from over 40 countries.

Te event takes place in Versailles, literallynext to the famous Versailles Palace and justa short distance from central Paris.

If your business is gypsum, you should bethere.... See you in Paris!

Post-conference tour to Loire Valleyitinerary subject to change

28 OctoberDepart for the city of Saumur, orientation tourof the city, dinner.29 OctoberA visit to Ackerman-Rmy Pannier vineyardsand tasting cellars. A cruise on a traditionalLoire boat through the UNESCO World Heritagesite.30 OctoberA visit to the wine making centre at Puy deNotre Dame. Lunch is a medieval banquet.In the afternoon a visit to the Chteau deMontreuil Bellay.

31 OctoberA visit to the Perrires Cathedrals and Troglo-dyte Caves as well as the Troglodyte village ofRochmenier.1 NovemberTravel back to Paris

Register your interest for the tour now!For more details please seewww.propubs.com/ggc

2526 OCTOBER 2010

Conference Programme (subject to change)

Sunday 24 October 2010

16.00 Registration opens

19.00-21.00 Welcome reception in the exhibition area - sponsored by

Erisim Makina

Monday 25 October 2010

08.00-09.00 Registration, coffee and networking

09.00 Conference opening and introduction: Robert McCaffrey,

conference convenor

Session 1: Global gypsum trends

09.10 Global gypsum megatrends: Does the past predict the future?

Bob Bruce, Innogyps

09.40 Production and international trade trends in the global gypsum

industry, Rob Crangle, U.S. Geological Survey (to be conrmed)

10.10 Conrmed presentation by Isabel Knauf, Knauf Gips KG

10.40-11.30 Coffee and networking in the exhibition area

11.30 European long-term trends in recycled gypsum usage, Henrik

Lund-Nielsen, Gypsum Recycling International.

12.00 Marketing strategies and revenue growth opportunities for solar-

produced drywall, Rod MacGregor, GlassPoint Solar

12.30-13.30 Lunch and networking

Session 2: New technical developments

13.30 The cooling and stabilisation of calcined gypsum, Alfred Brosig,

Grenzebach

14:00 The NuGyp LoCal process, Charlie Blow, NuGyp Corporation

Session 3: Additives for improved performance and protability

14.30 Novel rheological modiers, Dennis Mahoney, Henry Company

15.00 New dispersants for gypsum wallboards; Dr. Michael Bru, Dr.

Michael Schinabeck, Dr. Frank Dierschke, Dr. Silke Flakus; BASF

15.30 Latest evolutions in new generation uidisers for plaster, OlivierMalbault, Chryso

16.00 Meet the delegates session I

16.30 Coffee and networking in the exhibition area

Session 3: Additives for improved performance and protability,

continued

17.00 EH&S impact of common MR additive technologies in gypsum

wallboard, Mark Adams, Henry Company

CONFERENCE & EXHIBITION2010

10thgl bal gypsum


19/36

The programme is subject to change.

The conference language is English.

Dress code for the conference is smart casual or

business suit.

Please visit the event website

www.propubs.com/ggc for moreinformation and an updated version

of the conference programme.

Paris (Versailles), France

List of exhibitors

(Exhibition sold out)

1. Limab

2+3. Monterde SA

4. Borregaard Lignotech

5. Unger Functional Materials

6. SEMIN

7+8+9. Erisim Makina

10. Maschinenfabrik Mllers GmbH

11. Aumund Group

12. Derco Gypsum

13. Schenck Process

14. SICIT 2000 S.p.A.

15+16. Gyptech

17. J.C. Steele & Sons, Inc.

18. Alstom Power / Air PreheaterCompany, Raymond Operations

19. Claudius Peters Technologies

20. Chryso

21+22. Gupsos

23. Haver&Boecker24. WTW / MHC

25. Johns Manville

26. Gebr. Pfeiffer AG

27+28. Henry Company

29+30. Grenzebach

31. Shandong Sanjin Glass MachineryCo. Ltd

32. Fives North American CombustionInc.

33+34. Gypsum Recycling International

35. Sensortech Systems

36. Alphaplatre

Sponsorship opportunities

Sponsor the event to reach yourtarget audience and get yourcorporate message through.Sponsorship opportunities

available include the Farewellparty at the Eiffel Tower, lunchesand the Global Gypsum Awards.

For further information pleasecontact Paul Brown

Tel: +44 (0)1372 840950Mobile: +44 (0)7767 475998

email: [email protected]

17.00 Inuence of the gypsum raw material on the performance of PCE-based

HRWRA during gypsum board production, Markus Mller, Sika Services AG

18.00 Board buses for a dinner dance cruise on the Seine, onboard a luxurious yacht.

Gala Dinner kindly sponsored by Henry Company. We will enjoy romantic views of

Paris at night. Return by 24.00.

Tuesday 26 October 2010

08.00-09.00 Coffee and networking, exhibition area

Session 3: Additives for improved performance and protability, continued

09.00 New approaches to increase water resistance of gypsum-based building

materials, Dr. Thomas Aberle, Dr. Laurent Herschke, Paul Emmenegger, Dr. Franck

Vale; Elotex, AkzoNobel Functional Chemicals

09.30 Foaming agents for use in gypsum wallboard, Lawrence Munie, Stepan Company;

Mike Blezard, Stepan UK Limited

10.00 Controlling set time and rheology: pH to the rescue, Ian Wilkes, Freeform

Construction Ltd

10.30 Meet the delegates session II

11.00 Coffee and networking in the exhibition area

Session 4: Quality control, handling, storage and dispatch of gypsum

11.30 In situ optical microscopy and in situ ultra sonic measurements for quality

assurance in gypsum plants, Christian Pritzel, Yilmaz Sakalli, Prof. Dr. Reinhard

Trettin; Institute for Building and Materials Chemistry; University of Siegen

12.00 On-line monitoring and optimisation of abatement system operations to reduce

operating costs and minimise particulate emissions to air, Volker Schmitz, PCME

ltd UK

12.30 Handling and storage of FGD gypsum at a cement plant in Slovenia as well as at

the British Gypsum plant in Yorkshire, Andr Tissen, Aumund

13.00-14.00 Lunch and networking

Session 4: Quality control, handling, storage and dispatch of gypsum, continued

14.00 Bed storage and blending applied to gypsum, Simon Wintz, Claudius Peters

Technologies S.A. France

14.30 The use of live bottom feeders in the gypsum wallboard industry, Richard Steele,

JC Steele & Co15.00-15.30 Meet the delegates session III

15.30-16.00 Coffee and networking in the exhibition area

16.00 Cost-effi cient and sustainable packaging of gypsum with Billeruds QuickFill,

Mikael Peterson, Billerud

16.30 The future of gypsum packaging is palletless, presenter to be conrmed, Mllers

17.00 An introduction to the largest producer of phosphogypsum in India, Ranjit Misra;

Paradeep Phosphates Ltd

18.00 Board buses for Farewell Party at the Eiffel Tower. Return by 21.00.

Te Global Gypsum Conference in Versailles is located just 20 minutesout of Paris and is of course the home of the Palace of Versailles, which

is an absolute must-see experience and offers an extensive range oftours of its architectural heritage, rare collections of objets dart, special

exhibitions, concerts and much more.


20/36

brochure

2526 OCTOBER 2010 Paris (Versailles), FranceConference Information

Accommodationhe delegates are responsible for booking and guaranteeingtheir own accommodation. A number of rooms have beenreserved at a special rate in Hotel Pullman Versailles Chateau(2 bis avenue de Paris, Versailles). We strongly recommend thedelegates to stay at this hotel, which is conveniently located,and within a short walk from the conference and exhibition

venue (Versailles Congress Palace).Please refer to the conference website www.propubs.com/ggcfor instructions on how to book. All the bookings must bemade using the provided reservation form.

Conference feeshe conference fee includes attendance at the conference andexhibition, conference proceedings volume and presentationson memory stick, conference briefcase, lunches and drinksreceptions.

Registration fee discountsPRo Publications offers a (A) 5% discount for attendees of any

previous Global Gypsum Conference; (B) 10% discount forgypsum producers/users; (C) for third and subsequent del-egates from the same company; (D) for delegates younger than35 or over 65 years; (E) for delegates employed full time byuniversities; (F) 20% discount for attendance on one day only(Gala Dinner not included).

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Global Gypsum Conference & Exhibition

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GIM Issue 2 - 2010


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his article will give an overview on available tech-nologies or thermal and acoustic elastomericinsulation in the oil and gas sector, its restrictions and

benefits as well as uture potential. Very recent and

novel developments regarding extreme applications or

elastomers will be introduced.

Introduction

Flexible insulation in the oil and gas industry is able

to provide either thermal insulation against heat and

cold, acoustic insulation or both. Novel insulationsystems have been developed that can both protect the

environment rom noise and energy loss and can damp

or even prevent vibration and heat or cold build-up

that would otherwise affect essential constructions,

such as pipe work and valves. Formerly considered as

niche products these materials and systems now spread

across the industries and have become standard or

many applications.

Flexible oam insulation is mainly provided by mate-

rials based on elastomers known as exible elastomeric

oam (FEF). In standard applications, such as building

and construction, FEF products show a lot o benefits

over oamed thermoplasts and thermosets, such as

polyethylene, melamine oams and phenolics.

Te major advantage o Armaex FEFs is the

combination o exibility with other properties,

such as chemical and thermal stability and good

insulation perormance.

Te exible product will allow planners and speci-

fiers to more easily draf and decide on aspects o the

design o pipework, tanks and other key components.

An outstanding advantage proved or decades in heat-

ing and cooling applications is Armaexs built-in

vapour barrier which prevents condensation in humid

applications and thus can halt corrosion.

Flexible insulation materials

As the pure insulation material itsel is only one part o

the whole insulation system, Armacell is also offering

compounds or adapting the tube/sheet and its mount-

ing to the individual requirements.

Historically, easy mounting and handling has ofen

been claimed as the major advantage or even as the only

advantage o FEFs. However, there are a number o ad-

ditional benefits, as detailed in able 3.

In act Armaex systems can satisy specifications

as well or even better than other materials. However, it

has also to be said that there are limits, such

as resistance to very high temperatures, ag-

gressive media, weathering and aspects o

sound absorption. Some o these issues can

be overcome by protective measures, or

example by applying claddings, but some

are intrinsic to the material. High and

low temperature resistance and sound/vi-

bration damping thereore were a majortarget o our development efforts, which

lead to the invention o some interesting

new materials.

Dr Mark Swift Jim Ford, Armacell International Armacell Limited, Mnster, GermanyDr Mark Swift & Jim Ford, Armacell International & Armacell Limited, Mnster, Germany

lexible insulation solutions for the oilFlexible insulation solutions for the oiland gas industryand gas industryElastomers are widespread within the exploration, onshore and offshore industry and are found in

seals, gaskets, hoses, etc. However, other interesting features of elastomer foams have only partially

been acknowledged. In recent years more and more exible foam applications have provided

solutions to problems that could not be solved suffi ciently by other materials, especially when it

comes to insulation needs.

Left - Table 1: Arma ex

versatile insulation materials

Product Characteristics Applications

AF/ArmaexHigh-performance, high vapour

barrier material

Cooling/chilling insulation

From -50C to +105C

NH/ArmaexNon-halogen balanced property

prole material

Safety applications / Stainless steel

equipment

HT/ArmaexHigh temperature material with

balanced property prole

Elevated temperatures in industrial ap-

plications from -100C to +150C

ArmaexLTDLow and cryogenic temperature ma-

terial with balanced property prole

Elevated temperatures in industrial

appplications from -200C to +125C

Product Characteristics

ArmaChek Grey Rubber/fabric protective cladding

ArmaChek BlackHigh-performance ame-retardant

rubber cladding

Left - Table 2: Other parts of

the Armaex

system family.

Ad IndexContents


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Insulation solutions for the oil & gas industry

Cryogenic insulation

High and low temperature resistance cannot be

achieved by single and simple methods with elastom-

ers. Cryogenic temperatures are very challenging to

the developer, as even the best elastomers will usually

reeze and become brittle by around -100C, with many

becoming brittle much earlier. However, one has to

keep in mind that glass or PUR/PIR based solutions arealready rozen at room temperature.

A purpose o our development work thus was

to maintain the elastomeric exibility at room tem-

perature to acilitate mounting on the one hand, whilst

preventing the material rom becoming brittle at very

low temperatures. Tis was achieved by creating the

compound, Armaprene LD, which is patent pending.

It does reeze at certain low temperatures, but it does

not crystallise and thereore does not become brittle.

Tis compound and its oamed vulcanisate Armaex

LD is part o the Armaex Cryogenic system. Coupled

with the development o new materials, new methods,techniques o installation and the correct combinations

o materials are used to ensure a harmonious relation-

ship between the substrate and the insulation material.

High temperature insulation

Armaex H will insulate up to a constant temperatiure

o 150C. It has remarkable ozone and weathering resist-

ance. Figure 1 summarises the temperature perormance

range o Armaex industrial insulation systems.

Acoustic insulation

Closed-cell FEF materials have long been recognised

or their beneficial thermal insulation properties. Until

recently, their acoustic insulation perormance had

not been ully explored. Extensive studies by Armacell

demonstrate that Armaex layers can be combined to

achieve excellent vibro-acoustic insulation perorm-

ance suitable or noise-control on industrial process

pipelines. In contrast to traditional layers o mineral

wool and metal cladding, these new systems contain

highly exible layers with closed cell structure. Tese

layers can serve simultaneously as a thermal insulation

system, an acoustic insulation system and integratedwater vapour barrier. In this way the internal (pipe) and

external (surrounding air) are reliably isolated acousti-

cally, thermally and rom uid ingress.

It has been shown that the vibro-acoustic perorm-

ance o these systems can be increased by combining

Armaex with the open-cell, porous layer ArmaSound

RD, which has careully designed micro-structural and

visco-elastic properties. Standard acoustic tests show

that these new insulation systems meet the required

perormance levels outlined in the new ISO15665

standard or pipe acoustic insulation specification.

Performance targets met

Tis work has revealed that not only are these new sys-

tems compliant with the industry acoustic standards,

but perormance targets are met and even exceeded with

substantially reduced thickness and weight compared to

traditional insulation systems. o illustrate this, Figure

2 compares the typical make-up o a) traditional sys-

tem based on mineral wool and metal jacketing, with

b) Armacells offering. Both are compliant to an ISO

15665 Class B acoustic perormance. Figure 3 shows the

acoustic insertion loss (noise reduction) capabilities o

the two insulation systems measured independently to

ISO 15665.



Left - Figure 1 : Summary of

Product Foamed glass Glass bre PUR/PIR Thermoset materials FEF

Thermal conductivity ++ ++ (with foaming gas still in cells)

~(with air in cells)~ +

Vapour barrier - - - ~ - + +

Additional vapour barrier Essential Essential Strongly recommended Essential Not required

Additional cladding Essential Recommended Recommended Recommended Optional

Flexibility None Limited None Limited High

Brittleness Very high Acceptable Medium Medium Low

Flammability (SBI-test) Very high A (standalone), B-C (system) B-C B-C B-C

Smoke creation Medium (system) Medium (system) High High Medium

Right- Table 3:

Comparison of

insulation materials.


23/36

Combinations

In the case o cold acoustic insula-

tion design, Armacell offers a unique

proposition. Te historical approach

adopted by engineering specifiers is

to separate the thermal and acous-

tic requirements. In this case the

process lines are treated or thermal

reasons first and acoustic insulation

is applied directly on top as and

when required.

Tis practice is justified on the

basis that traditional materials, such

as PIR and cellular glass that are used

or thermal insulation do not exhibit

any acoustic unction.1 Similarly,

mineral wool, which is open-cell and

offers the acoustic unction, would

not normally be used on the inner

layers o a thermal insulation or cry-

ogenic application. As a result, the combined insulationthicknesses and weights can become very substantial.

Armacells offering is unique because its systems are

based on specially ormulated, exible closed cell oam

technology, which remain acoustically exible at lower

temperatures as compared to other FEF and non-FEF

closed cell oams. Maintaining exibility at low temper-

atures is crucial rom an acoustic perspective because

it has a direct inuence on the mass isolation perorm-ance o the outer jacketing. Figure 4 demonstrates the

concept in a combined thermal/acoustic system or a

typical cryogenic process line such as ethylene or LNG.

It compares a traditional cold thermal/acoustic system

and an Armacell cold thermal/acoustic system.It can be seen that although an identical thickness o

thermal insulation may be required, with the Armacell

system, the last 25mm layer o thermal

insulation acts as the first layer o the

acoustic, as seen in Figure 2. Te com-

bined insulation layering is thereore

urther simplified.

o the process-piping engineer, the

benefits o lighter and thinner insulation

systems are clear. Tese relate mainly

to financial savings in the design and

number o pipe supports, and also inracking space requirements or multiple

process lines. In addition, the proven

greater perormance o Armacell acous-

tic systems over traditional systems mean

that the length o pipework requiring

acoustic treatment is also significantly

less, in many cases by up to one third.

It means that sound power level targets

o the process acility can be met by

insulating a smaller proportion o the

total pipework.

Te benefits o closed cell, thermal

insulation materials that remain acous-

tically exible at low temperatures is

clear. Work is currently being carried

out to demonstrate new opportunities

or acoustic insulation systems based on

Armaex LD. Te exibility at low-

temperatures offered by this technology

will help to reduce urther the total thickness o ther-

mal/acoustic insulation systems. It is believed that with

such technology, Armacell will be in a strong position

to offer a truly combined thermo-acoustic insulation

solution as a single solution.

1. ISO 15665: Acoustics, Acoustic insulation or

pipes valves and anges. International Organisation or

Standardisation. 2003.



Left - Figure 2: ISO 15665

Class B compliant acoustic

insulation systems.

a )Traditional Acoustic System B

(Density = 18.7kg/m2)

b )Armacell Acoustic System B


Mineral wool

Metallic or non-metallic jacketing

Armaex

Armasound

Metallic or non-metallic jacketing

Left - Figure 3: Acoustic

insertion loss results for

Armacell System B and ISO

Class B system based on

traditional mineral woolnd metal jacketing.

Left - Figure 4: Cold

thermal / acoustic insulation

system comparisons.

a) Traditional Acoustic System B


b) Armacell Acoustic System B


ArmaexArmaex LDTArmasound RD240Metallic or non-metallic jacketing

Mineral woolPIR / Cellular GlassMetallic or non-metallic jacketing


24/36



One o the major challenges or architects today isthe insulation o buildings with a view to achiev-ing energy-effi ciency that provides not only economicand environmental savings but also improves user com-

egi-issue2-nonsub global insulation magazine

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