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Montreal, 06.04.2008
Experiences and potentials in replacing rigid foam manufacturingequipment in Article 5 countries
Dipl. Ing., MBA Jens Kompe Dipl. Ing. Rolf BohländerKraussMaffei Technologies GmbH Hennecke GmbHExport Manager Reaction Technology Project Manager Refrigerated Appliances
Process requirement Pentane driven PUR-systems
Pentane
Polyol
Isocyanate
25 °C
25 °C
25 °C
N2 N2
Exhausting system
open closedmould operation
Storage facilities Pre-mixing Work tanks Mixhead and operation station
Metering machine
Process requirement 245fa driven PUR-systems
Polyol
Isocyanate
12 °C
12 °C
245fa
12 °C
open closedmould operation
Pre-mixing Work tanks Metering machine Mixhead and operation station
Storage facilities
Insulated piping system
pressure work tank
Modified sealing materials
Foam distribution Pentane and 245fa driven PUR-systemCabinet production process
Pentane driven PUR-systemstandard conditions
Fluid pouring process
245fa driven PUR-systemwithout optimized temperature control
Frothed pouring process
Foam distribution Pentane and 245fa driven PUR-systemPipe insulation process
Pentane driven PUR-systemstandard conditions
pipe length up to 16.000 mm
Fluid pouring process
245fa driven PUR-systemwithout optimized temperature control
pipe length up to 16.000 mm
Frothed pouring process
Current physical blowing agents
CO2
HCFC 22
HFC134a
HCFC 141b
Preis(€/kg)
2
4
6
8
10
0,2
ODPOzoneDepletionPotential
GWPGlobal
WarmingPotential
0
0,05
0,10,2
0,05
0,1
0,30,4
0,30,4
0,5
0,6
0,70,8
0,91,0
0,50,6
0,7
0,80,9
1,0
Aceton
Methylen-chlorid
HFC365mfc
HFC245fa
HFC 152a
HCFC142b
CFC 11
C-Pentan
Important when using pentane
• Pentane will form, together with air, an explosive mixture (Between 1,7 to 7 Vol-% pentane in the air)
• Poly- Pentane mixture is a liquid categorized as an A1 hazard (similar to petrol)
• Safety measures have to be taken when processing pentane
Basic principle :Avoiding the formation of a flammable, explosive mixture of pentane and air
V o lu m e p e rc e n t P e n ta n e in a ir
M ix tu re to o c o n c e n tra te d - n o t e x p lo s iv e
O E GU E L (U p p e r E x p lo s io n L im it )
4 0 % o f L E L : p la n t s h u td o w n
M ix tu re to o le a n - n o t e x p lo s iv e
2 0 % o f L E L : a u d ib le v is u a l w a rn in g
%
7 ,0
0 ,5 6
0 ,2 8
0
Sens
or m
aesu
ring
rang
e
1 ,4
H a z a rd o u s a re a , e x p lo s io n h a z a rd
U E G 1 0 0 %L E L 1 0 0 % (L o w e r E x p lo s io n L im it)
Primary Explosion Proofing is achieved bymonitored air changinggas warning systemneutralization of daytanks and moulds with inert nitrogenequipotential bonding (earthing)
Primary Explosion Proofing is essential!
Secondary Explosion Proofing is achieved byAvoidance of ignition sourcesUse of explosion proofed parts with certification according to ATEX
Design of a pentane metering plant
A plant for processing pentane as a blowing agent for PUR-systems consists of the following components :
• Pentane storage• Polyol storage• Premixing unit for the mixing of polyol and pentane • Metering unit for the high-pressure metering and mixing of the
polyol-pentane blend and isocyanate (assuming LP machines will not be used for pentane)
• Working and foaming area
Pentane supplies via hazardous Goods Container
• Interchangeable vessels (100 - 1000 l)• Refilling from standard 200l Pentane drums•• Expansion tank with level control• Storage outside of the plant• System approved by German TÜV and used since more than 10 years
Premixing station for meteringpentane into polyol
• Enclosure incl. doors, leakage pan and ventilation duct
• Metering units, consisting of high pressure pumps for polyol and pentane
• Static mixer
Realized Projects: Technical aspects defining costs
• Part information• PU-System data• Information of the plant location• Information dry and wet side• Information foaming stations• Raw material supply• Requirements human resources, civil work• Minimum scope of supply machine manufactures
Example: New Line for District Heating Pipes in Latvia, 2005
KraussMaffei’s delivery: 260.000 €• Pentane Tapping System• Premixing Unit 40 l/min• Metering Machine 300 kg/min• Safety Equipment incl.
Nitrogen Inerting• Installation/Commissioning/
Training
Customers delivery:• Exhaust System: 20.000 €• Grounding: 3.000 €• Civil Construction: 0 € No Housing of plant necessary
Example: Retrofit of Line for District Heating Pipes in Romania, 2007KraussMaffei’s delivery: 150.000 €• Pentane Tapping System• Premixing Unit 40 l/min• Retrofit of Metering Machine 150 kg/min, consisting of:
• Stirrer for day tank with Magnetic Coupling• Magnetic Coupling for Metering Pump• Ex-Proof pressure switches
• Safety Equipment incl. Nitrogen Inertisation• Installation/Commissioning/Training
Customers delivery:• Exhaust System: 10.000 €• Grounding: 5.000 €• Civil Construction: 5.000 € No Housing of plant necessary
Example: New Foaming Line for Production of Refrigerator Cabinets and Doors in Vietnam, 2007KraussMaffei’s delivery: 650.000 €• Pentane Tapping System• Premixing Unit 40 l/min incl. 2 x 1.000 ltr. Buffer tanks• 2 Metering Machines 40 kg/min for foaming of cabinets• 1 Metering Machine 30 kg/min for foaming of doors • Safety Equipment incl. Nitrogen Inertisation• Exhaust System (excluding ducts)• Installation/Commissioning/Training
Customers delivery:• Exhaust System: 30.000 €• Grounding: 8.000 €• Civil Construction: 0 € Installation in existing building
Example: Retrofit of Refrigerator Line in Chile, 2007
KraussMaffei’s delivery: 320.000 €• Pentane Underground Storage System• Premixing Unit 40 l/min• Retrofit of Metering Machine 80 kg/min with 6 Mixing Heads• Safety Equipment incl. Nitrogen Inertisation• Installation/Commissioning/Training• Exhaust System
Customers delivery:• Civil Construction: 20.000 €
In Total more than 100 Pentane References of KraussMaffei all over the world
Example: New line for the production of household doors, Iran, dd. 2005
Hennecke’s delivery: 260.000 €• Pentane storage system (400 l)• Premixing unit Pentamat 30• Metering machine 1300 g/s• Pentane safety system• Exhausting fansCustomers delivery:• Exhausting ducts: 15.000 €• Piping works: 3.000 €• Grounding, interface
to PPT-safety system: 5.000 ۥ Nitrogen (gas cylinder)No Housing of plant necessaryNo Electricity Backup necessary
Example: New line for pipe fittings (insulation), Germany, dd. 2006
Hennecke’s delivery: 230.000 €• Premixing unit Pentamat 30• Metering machine 1300 g/s• Safety system incl. Pentane
sensors and monitoring• Exhausting fans• Inertisation systemCustomers delivery:• Storage (container): 20.000 €• Grounding, interface
to PPT-safety system: 15.000 €• Exhausting ducts: 12.000 €• Nitrogen generator: 22.000 €No Housing of plant necessaryNo Electricity Backup necessary
Example: Pentane conversion of a production line for pipe insulation, Ukraine, dd. 2007
Hennecke’s delivery: 400.000 €• Retrofitting of 2 metering
machines, each 300 kg/h,with totally 8 foaming stations
• Premixing unit Pentamat 30• Pentane safety system incl.
Pentane sensors and monitoring• Pentane supply by drumsCustomers delivery:• Exhausting system: 15.000 €• Grounding, interface
to PPT-safety system: 15.000 €• Nitrogen generator: 22.000 €No Housing of plant necessaryNo Electricity Backup necessary
In Total more than 250 Pentane References of Hennecke all over the world
• 245fa harmful to the climate (according to Swiss “Federal Office for the Environment FOEN” 800 - 1000 more harmful than CO2)
• 245fa already forbidden in countries like Sweden• Combustion of 245fa creates toxicological substances• Handling of 245fa not as easy as oftenly assumed• λ-value of 245fa almost similar with Pentane• 245fa much more expensive• Out of NAFTA region 245fa only used at customers with very small consumption• Simple Pentane Storage Equipment available and proven• Oftenly (depending on the design of the exhausting system) no housing
necessary• Pentane technology accepted and implemented worldwide since 1993• Retrofit of Low Pressure machines to Pentane not efficient • Costs for retrofit of High Pressure machines depending on local situation
Resumee
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