polyurethanes contributing to...

Polyurethanes Contributing to

Energy-Efficiency

Chandrakant Nayak

Dow Polyurethanes

Agenda

• Introduction: Trends and Market Drivers

• Insulation Solutions for More Sustainable Construction

• Enhancing the Energy Efficiency Profile of Appliances

• Improved Energy Efficiency in DCP Panel Production

• Conclusions

DOW @ Indian PetroChem: Polyurethane Contributing to Energy -Efficiency

Introduction

Trends and Market Drivers The growing influence of sustainable building initiatives is driving the demand for advanced construction materials that contribute to the energy efficiency of buildings and appliances, helping to reduce their carbon footprint.


Energy

Efficiency

Sustainability Fire

Safety

HCFC

141b

Trends and Drivers


Key Drivers in India

• Energy : Cost and Availability

• Building Certifications – LEED and Green Building

• Regulations – ECBC Codes Implementation and Upgradation

Climate Change: Multiple Solutions Required

McKinsey & Associates Assessed More than 50 Alternatives for

Greenhouse Gas Reduction. •Examples: BioFuels, High Efficiency Lighting, Wind Energy, etc.

Economic assessment: Cost to Implement & Energy Costs Saved

•INSULATION offered the largest economic benefit;

•INSULATION offered a positive Return on Investment

Greenhouse Gas Reduction: Net Impact For each Alternative

•INSULATION offered the largest CO2 reduction among

positive ROI alternatives!

Source: McKinsey & Associates 2007 Study:

Study shows, For every 1 kg of CO2 used in

production of foamed plastic insulation, a

lifetime savings of 233 kg of CO2 per kg of

foamed plastic insulation was obtained. This is

a CO2 savings ratio of 233:1

233:1


Building Insulation Materials


Building Insulation Options

Market share of Insulation Materials by Geography


2011

Global Building Insulation Market

Bn $

Energy Loss through buildings


India Scenario :

• Roof insulation is the biggest segment for residential and

commercial buildings

• Wall Insulation and Floor Insulation still predominant in Cold

Chain only

• “Buildings are responsible for 40% of energy consumption and 36% of CO2 emissions. Energy performance of buildings is key to achieve the EU Climate & Energy objectives, namely the reduction of a 20% of the Greenhouse gases emissions by 2020 and a 20% energy savings by 2020.”

Buildings: The Largest Opportunity

Source: European Commission, 2010

Residential & Commercial Buildings Consume

Greater Than 40% of Energy in India


Polyurethanes Insulate Better


Polyurethane XPS EPS Cellulose

Fibers

37% More

Heat Loss

42% More

Heat Loss

70% More

Heat Loss

Source: Thermal Insulation Manufacturers & Suppliers Association, UK

“Typical Lambda Table for Members’ Insulation”, published March 2007

Glass

Wool

56% More

Heat Loss

0.0375 W/m.k [0.031-0.044 W/m.k]

Mineral

Wool

58% More

Heat Loss

0.038 W/m.k [0.034-0.042 W/m.k]

0.034 W/m.k [0.030-0.038W/m.k]

Assumes the same thickness of insulation material.

0.033 W/m.k [0.029-0.037W/m.k]

0.024 W/m.k [0.022-0.038W/m.k]

0.041 W/m.k [0.039-0.043 W/m.k]

Comparison between PU vs Substitutes

2.5 cm rigid polyurethane

4.0 cm expanded polystyrene

4.5 cm glass fiber

5.0 cm cork

12.0 cm wood

40 cm bricks

*Performance-PU vs Substitutes


Products PU EPS XPS Glass wool Rock wool

Thermal conductivity

mw/m.k

18~23 34~40 28~40 42 42

Flame retardant B2~B1 B3, dripping B3, dripping B2 A

Adhesion

performance

Good average average poor poor

Cost High average average low low

Density 35~45 15~35 15~35 48~64 100~120

kg/m3

Compressive

strength

High average High average average

Shelf life Long Average average average average


Comparison between PU vs Substitutes

*Performance-PU vs Substitutes

Polyurethanes has best low temperature insulation


Polyurethanes has best R value per inch


INSULATION is critical for Global Energy Policy.

INSULATION is critical for Global Climate Change.

However, INSULATION materials are not equal !

Polyurethanes Offer Superior Performance


Polyurethanes also offer versatile application options

PolyIso Board Insulation

Rigid Panel Insulation

Spray Foam Insulation

Cold Room Insulation

Refrigerated Trucks

Roofing Membranes

Window Shutters

Window Frames

Panel Adhesives

Garage Doors

Entry Doors Wood Alternative

Water Proofing & Anti-Skid Surfaces

Water Heaters


COMPOSITE MATERIALS

Flexibility for application and design


INSULATION MATERIALS

Spray Foam

Other

Insulation Block Foam

Doors DCP

Sliding

Shutters

Insulation

Boards

(FF DBL)

Construction

Panels DCP

Construction

Panels DBL

Insulated Metal Panels for Roofs & Walls


Spray Foam Applications of Polyurethanes


Improved Energy Efficiency in

DCP Panel Production

PASCALTM PRO Technology


Construction and Cold Chain Insulation | DCP

Energy Efficiency and PASCAL™ PRO Technology

• Construction and Refrigeration industries can contribute massively to reducing the global energy consumption by making buildings, refrigerated warehouse, cold rooms, reefer containers more energy-efficient.

• Polyurethane (PU) cored Insulated Metal Panels (IMPs) are the insulation technology of choice in most of the above applications.

• In order to improve the energy efficiency profile, panel manufacturers are looking at technologies that improve the k-factor of the foam and increase the productivity of high thickness panels.

• Dow’s solution:


PASCAL™ PRO translates

Dow’s breakthrough

PASCAL™ technology to

DCP Production

Faster Cycle Time

Lower Density

Better Thermal Insulation

Construction and Cold Chain Insulation | DCP

Energy Efficiency and PASCAL™ PRO Technology


Sustained quality and design without increasing costs.

Appliance Insulation

PASCALTM Technology


Appliance Insulation

PASCALTM Technology Concept


Processing: Injection under reduced pressure

Preferred Material: Polyurethane (PU) Systems

PASCALTM technology is using a controlled reduced in-mold pressure during the PU foam

injection. Dow offers PASCALTM Foam Technology for Appliances as well as PASCAL™ PRO

Technology for discontinuously produced panels (DCP process).

PASCALTM Technology offers mutliple benefits

• Up to 50% greater PRODUCTIVITY at sustained quality and design.


PASCALTM achieves better insulation and increased productivity


PASCALTM Foam Technology vs. current Low k c-pentane formulations

offers:

• 5% density reduction and better density distribution

• 7% lower k-factor vs. EU c-pentane formulation

(5% lower vs. US formulation)

• 25-30% smaller cell size

• 30-40% shortened demold time (validated at industrial level)

Current EU Low k c-p

PASCALTM c-p

8,8

5,86,1

4,5

0

1

2

3

4

5

6

7

8

9

10

3 min 5 min

Low k EU

PASCALTM

Post-expansion, mm

1,39

1,35

1,21

1,10

1,15

1,20

1,25

1,30

1,35

1,40

1,45

Low k EU Low k USA PASCALTM

Flow Index

PASCALTM enhances performance with all Blowing Agents


At the same amount of CO2% within the cell gas composition, we could achieve:

• c-pentane, same k-f as a low water HFC 245fa blown foam

• HFC 245fa, further k-f improvement of 3% from 126 to 122 btu

• Gen 4 BA-A, the lowest k-f achievable, as low as 115 btu

• Gen 4 BA-B, the best k-f achievable when co-blown with c-pentane

0,132

0,126 0,126

0,122

0,115

0,1215

0,105

0,11

0,115

0,12

0,125

0,13

0,135

Low k Cp EU PASCALTM Cp HFC 245fa LW PASCALTM

245fa

PASCALTM

Gen 4 BA-A

PASCALTM

Gen 4 BA-

B/Cp

PASCALTM k-f50F, btu

PASCALTM Life Cycle Assessment (LCA) Results


The PASCALTM Technology allows for a measured 10% reduction in electricity

use

(all other things remaining the same) which translates to about 10% reduction in all

potential cradle-to-grave impacts.

• Study limited to c-pentane

• Other aspects of the refrigerator design or use are not included

Key Take Aways


• Polyurethanes insulation offers best in class lifetime performance

• It has lowest thermal conductivity, long shelf life, high compressive strength and good

adhesion with variety of substrates

• Excellent application flexibility and most versatile design capability

• Polyurethanes offer one of the best options to meet the Energy Efficiency needs of

the industry and the nation

• New advances such as Dow PASCAL™ and PASCAL™ PRO are commercially

available to further enhance the PU insulation performance as well as to improve

productivity for Appliance and DCP Panels

• Life Cycle Assessment (LCA) demonstrated that PASCAL™ technology 10%

reduction in all potential “cradle-to-grave” impacts, giving significant advantages in

terms of GHG emission reduction and improved sustainability.

Thank You

Chandrakant Nayak Dow Polyurethanes

polyurethanes contributing to...

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