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4387 Rider Trail N. | Earth City, MO 63045 | 1.800.325.4875 | +1.314.344.3330www.foamsupplies.com | www.ecomatesystems.com
TITLE:ecomate® – A Multi-Faceted Blowing Agent
AuThoR:John Murphy, Foam Supplies, Inc.
ABSTRACT:Since its introduction into the foam market as a new blowing agent, ecomate® has been successfullytrialed in many different venues. We will outline below difficult applications that have been successfullymet using ecomate.
Ecomate® seems the ideal replacement for HCFC 14 Ib in integral skin foams because ecomate has the ideal combination of boiling point and solubility to mimic the solubility and boiling point of 14 lb.Additionally it has about half the molecular weight of 14 lb making it even more economical for thisapplication. Combining this efficiency and economy of use with the environmentally friendly nature of ecomate [zero ODP, zero GWP, and VOC-exempt] there is no doubt that it is highly appealing to this market.
Another market having a difficult transition from 14 lb has been the spray foam market. The use of HFC 245fa is fraught with problems because of high drum vapor pressures causing ratio issues in the field. HFC 365mfc [while not available in North America] would have better drum pressures, but has difficulty with cold substrates; and has such a high MW as to be less than economical. HC’s are problematic because of solubility and flammability issues, and are losing some of their cost advantage due to recent price increases. We will show how ecomate can help mitigate the application problems of spray foam blowing agent transition both neat and in combination with other physical BAs.
Finally we will show how ecomate® can be used in pour foams to make economical foams having good dimensional stability, with excellent flammability, at low densities.
ABSTRACT
A Multi-FacetedBlowing Agent
API Salt Lake City 2006
ecomate® advantages A True LIQUID Blowing Agent Patented: US 6,753,357 w others Pending To Replace HCFC’s, HFC’s, HC’s SNAP Approved ZERO ODP, ZERO GWP, VOC Exempt Economically Advantageous Good Solubility Low Volatility Good Foam Properties Good Foam Flammability Resistance
ecomate® Blowing AgentProperties
Clear, Colorless, Flammable Liquid
Boiling Pt Flash Point LEL \ UEL LAMBDA, gas ( 25 °C)
Vapor Pressure ( 25 °C)
Auto Ignition Temp Specific Gravity Molecular Weight
88.7 F 31,5 C-26 F -32 C
5 - 23% 5 - 23%0.074 10,7
11.4 psig 586 mm
>840 F >450 C
0.982 0,98260 60
BA COMPARISONecomate 141b 245fa 365mfc 365/227
93 / 7n-C5 cC5
Mol wt 60 117 134 148 149,6 72 70
Bpt, C 31,5 32 15,3 40,2 30 36 49
Sp Gr 0,982 1,24 1,32 1,25 1,28 0,62 0,75
Lambda 10,7 10 12,2 10,6 10,7 14* 11*
LEL/UEL 5,0 – 23,0 7,6 – 17,7 n/a 3,5 – 9,0 3,8 – 13,3 1,4 – 17,8 1,4 – 8,0
Cost Efficiency
Blowing Agent $/LB Mol Wt Factor
HCFC-141b ** 117 1.00HFC-245fa ***** 134 1.15HFC-365/227 **** 149 1.27cC5 ** 70 0.60nC5 * 72 0.62
ecomate® ** 60 0.51
Cost Efficiency
Blowing Agent $/LB Mol Wt Factor $/mole
HCFC-141b ** 117 1.00 RefHFC-245fa ***** 134 1.15 +350%HFC-365/227 **** 149 1.27 +380%cC5 ** 70 0.60 - 45%nC5 * 72 0.62 - 70%
ecomate® ** 60 0.51 - 65%
Integral Skin
Integral Skin ecomate – best alternative to 141b Solvates all Raws currently used BPt. just above ambient [like 141b]
Permits good skin formation Allows fast demold times
Environmentally Benign Economical – Mol Wt HALF of 141b US EPA SNAP Approved
Flexible FoamsMolded & Slab
Good Solubility Fine Cells Safer than
Hydrocarbons Non-VOC Excellent Hand
Rigid Applications Moulded Roof Panels Pipe-in-Pipe
Insulation Spray Foam
SPRAY FOAM Like other foams – except: Faster Reacting Prolonged Shelf Stability > 3 mos. 1:1 by volume Uncontrolled Application Environments
Two routes PUR & PIR
SPRAY FOAM Blend of Polyols Ester - Cost & Fire Properties Amine - Reactivity & Can Stability Mannich - Adhesion & Can Stability Sucrose - Strength & Char
What is the Best Combination ?
D-Optimal MixtureDESIGN EXPERT 6.0
ESTER, 184 Eqwt
MANNICH, 178 Eqwt
SUCROSE, 152 Eqwt
AMINE, 94 Eqwt
20 – 50 Parts 20 – 40 Parts 0 – 30 Parts 0 – 25 Parts
D-Optimal MixtureDESIGN EXPERT 6.0
ESTER, 184 Eqwt
MANNICH, 178 Eqwt
SUCROSE, 152 Eqwt
AMINE, 94 Eqwt
FIRE RETARDANT ecomate WATER
20 – 50 Parts 20 – 40 Parts 0 – 30 Parts 0 – 25 Parts
15 Parts 6 % 2.5 %
System Flash PointPOLYOL TYPE
3035404550556065707580
2.50% 3.50% 4.50% 5.50% 6.50%
ECOMATE PCT
FLAS
H PT
, C
POLYOL 1POLYOL 2POLYOL 3POLYOL 4POLYOL 5POLYOL 6
D-Optimal Mixture 20 RUNS Adjusted for constant DENS, REACTIVITY
DESIGN RUNSRun ESTER SUCROSE MANNICH AMINE
% % % %
1 25 30 20 25
2 35 0 40 25
3 31 23 26 20
4 43 23 33 0
5 50 10 40 0
6 20 23 40 18
7 50 0 33 18
8 20 23 40 18
9 29 30 29 12
10 42 22 20 17
DESIGN RUNSRun ESTER SUCROSE MANNICH AMINE
% % % %
11 34 14 40 12
12 25 30 20 25
13 50 30 20 0
14 50 5 20 25
15 43 13 30 14
16 30 30 40 0
17 50 5 20 25
18 50 30 20 0
19 33 13 28 25
20 35 0 40 25
D-Optimal Mixture 20 RUNS Adjusted for constant DENS, REACTIVITY
EFFECTS Monitored: INDEX FLAME SPREAD SMOKE
ISOCYANATE INDEX ALL Foams 1:1 by Volume
Index range: 104 - 119 Normal for sprays
FLAME SPREADDESIGN-EXPERT Plot
FLAME SPREADDesign Points
X1 = A: ESTER: 20 - 50X2 = B: SUCROSE: 0 - 30X3 = C: MANNICH: 20 - 40
Actual ComponentD: AMINE = 12.50
A: ESTER67.50
B: SUCROSE47.50
C: MANNICH67.50
20.00 0.00
20.00
FLAME SPREAD
3540
45
50
55SUCROSE Levels worsen FS
SMOKEDESIGN-EXPERT Plot
SMOKE Design Points
X1 = A: ESTER: 20 - 50 X2 = B: SUCROSE: 0 - 30X3 = C: MANNICH: 20 - 40
Actual ComponentD: AMINE = 12.50
A: ESTER67.50
B: SUCROSE47.50
C: MANNICH67.50
20.00 0.00
20.00
SMOKE
550600
650
700
750
800
850
AMINE Levels worsen SMOKE
SMOKEDESIGN-EXPERT Plot
SMOKE Design Points
X1 = A: ESTER: 20 - 50X2 = B: SUCROSE: 0 - 30X3 = C: MANNICH: 20 - 40
Actual ComponentD: AMINE = 0.00
A: ESTER80.00
B: SUCROSE60.00
C: MANNICH80.00
20.00 0.00
20.00
SMOKE
450 500
550 600
650
2
AMINE Levels worsen SMOKE
DESIGN RESULTS FLAME SPREAD worse w Hi SUCROSE SMOKE worse w Hi AMINE DESIGN-EXPERT 6.0 OPTIMIZED: 45 FS / 400 SMOKE ESTER 50 SUCROSE 29 MANNICH 21 AMINE 0
POUR FOAMS ecomate system gets HIGHEST Fire Resistance FSI’s eco1 System
UL 723 – 25 FS / 300 smoke @ 6 inches [ASTM E-84] FM 4880 – Lg. Scale Corner Test – Passed
ecomate excellent for PIR Boardstock Laminator approval obtained.
System shipping possible w/o ‘Flammable’ tags Foam recycling / disposal w/o environmental
impact.
CONCLUSIONS INTEGRAL SKIN ecomate - a perfect fit
solubility, ideal BPt, Lo MW, environmentally benign
SPRAY GOOD PROPS, CLASS 1 & 2, 3+ MOs STABILITY
POUR EXCELLENT PROPS, HIGH FIRE RESISTANCE
ecomate® advantages A True LIQUID Blowing Agent SNAP Approved Good Solubility Low Volatility Good Foam Properties Good Flammability Resistance Cost Competitive TRY IT….YOU’LL LIKE IT !
Contacts - EUROPE BOC Specialty Gases Zoë Sturdy 10 Priestly Rd Guildford, Surrey GU2 7XY ENGLAND TEL: +44 (0)1483 244 088
Contacts – S/C America PURCOM Quimica Ltda Gerson Silva Rua Aeroporto n° 83/115 06419 260 Barueri, SP, BRAZIL TEL:(+55 11) 4161 8902
Contacts - ROW FOAM SUPPLIES INC Todd Keske 4387 North Rider Trail Earth City, MO 63045 USA TEL: 314-344-3330
The Next Generation Blowing Agent