Zero ODS Low GWSEliminate HCFC with alternate blowing agents

Processing issues and challenges for the foam sector

Presented by Arun K Singh

Our Social Responsibilities

Save Ozone layer Save Environment byUsing ZERO ODS LOW GWS Blowing agents

Objectives

Phase out production & consumption of HCFC in accordance to the Protocol Phase out schedule Stage 1

Achieving Montreal protocol target stage 1 establishing base line consumption respectively @ 10% reduction of baseline volumes from 2015

Phase out production and consumption of HCFC in accordance to the protocol total phase out schedule 2030 Stage II

Adhere to Stage II Protocol reduction target 2020 -2025 and total phase out 2030 with a allowance on servicing @ 2.5% from 2030 to 2040

Phase out HCFC like OSD/GWS subsistence with the alternate ZERO ODS/LOW GWS

Ozone layer Protection

Need of hour phase-out HCFC to protect Ozone layer

Montreal Protocol on ODS

Turn off production tap of ODS & GWS materials & improve public health environments

ProductOverview

• Insulating Foams

• Construction

• Transportation

• Piping

• Flexible foam

• Shoe soles

• Micro cellular

• Integrals skinned • Spray Foam

Use of HCFC in Polyurethane Foam

Role of the Blowing agent

Desired Characteristics blowing agents

Available options to replace HCFC Mature technologies Emerging Technologies

PU Industry Growth in Middle East & KSA

HCFC consumption scenario in the reason

Awareness Among stake holders

• Identification of the stake holders• Initiation of interaction with the

stakeholder at regional & divisional level

• Awareness to Stake holder over environmental concerns due to HCFC usage .

• Ensuring Participation of Key stake holders/ industries/ SMEs /contractors /Associations/NGOs/ Research Institutions/ End users/concern departments , Ministries etc.

Actions

Establishing supply demand Scenarios

• Arrange awareness on HPMP work shop

• Reach Out to Stake Holder at Divisional / Regional Level

• Carry out surveys • Collection of Data on HCFC

Production & consumption • Establish over all Growth in volume

of HCFC consumption with respect to National GDP & Economic Growth.

• Developing demand & supply scenario

Actions

Regional Specific Strategy

• Division Specific Group need to formed which includes Industries, Associations, Users , Research institutes & all concern Stake holders.

• Identification of the applications Division or sub -Division wise

• Identified Division specific consumption Their growth and freeze the volumes .

• Assessment of the specific data of the application

• Evaluate the energy efficient economic viable alternative Technology

• Suggest Individual industry specific viable Alternate

Actions

Data Collection & Survey

Description of methodology for data collection & validation of data(Name /address/ source/resources /stake holder involved in consumption HCFC

Information on HCFC infrastructure Importer/distributer/Consumer/end Users

Overall view on HCFC user Their Production/Import/ Export Their use and consumption Forecast on HCFC volume with respect to Regional Growth

Availability of alternate to HCFC with price

Actions

Role of the blowing agents

Physical expansion of the foam -Generation of Co2 by iso with water reaction -Evaporation of external gases (Blowing agents) with the reaction of the PU System

Contribution to Thermal performance -forms close cell structure remain into the cells -Lowest Thermal conductivity

Thermal Insulation Properties

• Overall reaction profile of foam• Cell size , Close cell %age,

Distribution (material flow) & Orientation balances.

• Composition of the cell gas• Initial lambda factor (thermal

efficiency)• Aging lambda factor (Age K value)• Compressive Strength• Density control of the foam• Processing / storage factors

Factors that influence energy efficacy of thermal insulation so the design of the products is critical

Blowing Agents in Rigid PU

HCFC 141b ?Hydrocarbons (pentanes )ButanesCO2HFCHFA-L1HBA- 2FEA-1100HFOMethyl FormateWater

Phase – Out HCFC

Concerns over selection on Alternate blowing agents

• Zero ODP & Low GWS

• Easy Handling

• Mechanical & Chemical Properties

• Fire Retardency

• Thermal & Aged Thermal Stability

• Non Toxic

• Technically Proven with commercially viable alternate blowing agent

Technology

Reasonable Cost

Environmental acceptability

System durability

Energy Efficiency

Safety

Easy management for change

Phase – Out of Ozone Depleting Substances : Their Remaining challenges and uncertainties

• Key issues in Phasing out HCFCs

• Period of change over is short addressing all reduction targets

• 30 to 40% reduction in consumption (2013 to 2015)

• Technical options are still immerging may not be the long term solutions

• HFC look as main available option which cater all application solutions but have high GWS

• Still has to find Zero ODP Zero GWS blowing agent

• Eliminate of 10,000 MT HCFC use in the sector with the right substitute

• Working adoption ,Equipments renewals cost of changes .

Default substitute still (High GWS) HFCsBoiling point HFCs a issue at high ambient conditionsHydrocarbon are highly flammables Low GWP blowing agents need to be promoted

Available Technologies

Water Cell Regulation Problem Skin formation Problem High Boiling point Bonding issuesCO₂ skin formation Problem Foam flowbility Problem Bonding Issues'HFC Higher operating cost ,high High GWP ,low boiling PointPentene High Flammability issues High Investing cost Not feasible for SHEsMethyl A patented Technology by Formate Foam supplier HFO Excellent lambda value & other properties with a little extra cost

Blowing agent characteristics

Easy to use Solubility with Polyol Down Trend Flammability

Smooth Rising Boiling PointFoam Reaction cycle

Perfect Curing Should be tact free Foam while de molding

De - Molding Cycle should complete within allocated time broadly independent

Mechanical Properties Enhance Mechanical / Physical /Chemical values

Performance Gas thermal conductivity through close cell wall Enhance overall performance of the Foam

Zero ODPLow GWSLow Toxicity Chemically & Physically Stable Lower “K” values Improve Energy efficiency Batter Thermal stability Proven & validated Technology Commercially available Economically Viable

Mature Technology

• Most Popular blowing agent improving performance day by day

• “K” Value slightly better compare to even HFCs

• All Mechanical Properties are good• Flame Retardency slightly Poor to HCFC

but better to Cychlopentane • Medium Safety risk (Fire hazards) • No Capital investment cost ( storage

tank, Pre blend units, sensors ,Alarms/ leak detection systems, Ventilation system and a core training need)

• operating cost slightly higher (Current Price is High for BA)

• suitable for SMEs specially Foam spray applications , Application of FJ

A

HFO

Mature Technology

• Favorable to Energy Efficiency • Good lower Lambda value• Non flammable so enhance fire

retandency • Low operating cost( No major

change in equipments or technology)

• BA cost is high • Mechanical Properties are excellent .• High GWP is a negative point

Protocol adherence• Low boiling point also not permit to

use this BA in high ambient Temp. conditions

BSaturated HFCs

Mature Technology

• Can be use as co blowing agent in all formulations

• Poor Lambda values “K” Value high• Poor Energy Efficiencies because off

Poor aging lambda value • Poor cell Structure Lower the close

cells• Adhesion issues due to Foam

friability• Poor density control high material

consumption high application costing.

• Use for Spray/ joint filling like applications

CCO₂ from Water

New TechnologyMolecular Weight 60

Boiling point ◦C 31.3

Gas Thermal conductivity(Mw/Mk @ 25 C)

10.7

GWP(100 yr ITH) Negligible

Patented technology with a minor retro fit into the equipments

Now the cost is little high 10% higher to HCFC

DMethyl FormateRelative new BA options

Other Emerging Technologies

Methylal HFO1234-ze

FEA-1100

HBA-2 AFA-L1

ChemicalFormula

CH₃OCH₂OCH₃ Trans-CF-CH₃=CHF

Undisclosed Undisclosed Undisclosed

Molecular Weight 76.1 114 undisclosed Undisclosed undisclosed

Boiling Points ᴏC

42 -19 >25 >32 >30

Gas Conductivity(mW/mK@10 ᴏ C)

Not Disclosed 13.0 10.7 Yet to know 15.9

Flammable limit in air 2.2 to

19.9None to 28

None None None

GWP in 100 years horizon

<25 6 5 <15 <15

ODS Zero Zero Zero Zero Zero

E

Other Emerging options

Initial summery on Emerging BA

• Methylal - Use as co- blowing agent with hydrocarbons & HFCs

- Major Pilot Trails having encouraging results

• Saturated HFCs - Most are liquid at room temperature

- Thermal performance very promising results

- High operating cost

- Liquid HFCs will be commercially available in2 to 3

Years Time

Findings

Summary

• All Mature Technologies have restriction at Risk , safety cost & performance

• HFO• Hydrocarbons although most popular

technology but required high capital investments carry the risk can not be use in Spray foam application

• Methyl Formate Becoming established in Integral skinned Foam, Commercial Refrigerators, Thermo wares, sandwich panels

• HFCs Having higher operating cost with high GWS

• CO2 High Lambda Value Skin problem˳ New Technologies of BA, HCFs under

developments˳ Time of essence Lets aware about serious

Environmental concerns , lets freeze the volume use of HCFC s