International Seminar
Organized by:
Ministério do Meio Ambiente-Brazil, UNDP and Ministerio Dell’ Ambiente-Italy
Governement
Alternatives to HCFCs in Foams Sector - Technology Options and Equipment
Chapecó-Santa Catarina - Brazil - July 2014
Hydrocarbons and water as blowing agents to replace HCFC141b
in Polyurethane Rigid Foams
Paulo Altoe’ - Product Technology Manager - Dow Brasil S.A [email protected]
Rodnei Abe – Product Technology Manager - Dow Brasil S.A [email protected]
Marcelo Fiszner – Marketing/R&D Director - Dow Latin America [email protected]
Blowing Agents Evolution
• The evolution of BAs technologies, driven by regulation and market trends moved far from 1st
generation BAs (CFCs)
• Uses of Gen 1 and 2 is regulated by Montreal protocol (Ozone Depletion Potential ODP)
• HFCs � high GWP substances are currently not regulated. However market trends indicate that
they will be probably in the future
• On top of Hydrocarbons (HC) and water, HFO ����Gen 4, Hydrofluorolefines will represent a viable
Low GWP alternative to HFCs
Gen1 Gen 2 Gen 3 Gen 4
High ODP
High GWP
Low ODP
High GWP
Zero ODP
High GWP
Zero ODP
Low GWP
CFC-11 HCFC-141b HFC 134aHFC 245fa
HFC365mfc/227ea
HFO
HC and Water
Blowing Agents - Properties
Not commercially available
Table 1
Performance Overview - Different Blowing Agent Technologies
• Zero ODP and Low GWP � Water, Hydrocarbons , Formic Acid, Methylal , Methyl Formate and HFOs
• Zero ODP ���� HFC-134a, HFC365/227ea , HFC245fa
Blowing Agents - Selection by Performance and Application
• The general properties reported in Table 2 can be considered as a guidance for the
choice of the right blowing agent for each application
• In fact each application will have its own peculiarity and set of most important
properties, and this will guide the choice
• For example, for those applications driven by thermal insulation, a full water blown
solution will not be the most effective one
HCFC141b Elimination - Blowing Agents Alternatives
Laboratory data also validated in production
HCFC141b Elimination – BA Alternatives
Applications
• Panels : Continuous and Discontinuous
• Walk-in Cold Rooms
• Blocks; Commercial Refrigeration
• Insulated Trucks, Reefers
• Pipes, Tanks
• Thermal wares, boilers
• Spray
• …
HCFC141b Eliminations – Criteria for Blowing Agent Selection
Blowing Agent versus Application
• Environment & Sustainability
• Quantity of Process Foam (Year)
• Foam Cost
• Applied Density
• Processing
• Energy Efficiency (lambda)
• Blowing Agent Flash Point
• Investment - Machinery
• Investment - Molds
• Temperature Control/ Sensors
• Foam competiveness vs competition
• …
-Hydrocarbons are widely used with advantages of process, cost and thermal insulation
-Water blown systems are used in applications where thermal insulation is not a major requirement.
-Proper temperature control is required to avoid poor adherence in water blown systems
Discontinuous Panels – DCP
They are mainly used in cold chain, as commercial and industrial cold store
panels, and in costruction applications.
Main requirements are:
• Thermal insulation
• Fast productivity/cost
• Aesthetics
• Fire properties (both fire rated and not fire rated options are available)
HFCs, for instance HFC134a/AF, is normally used in developed countries
Main requirements are:
• Fast productivity/cost
• Thermal insulation
• Aesthetics
• Fire properties (both fire rated and not fire rated options are available)
Discontinuous Panels – DBL : Double Band Lamination
-Hydrocarbons are massively applied and represent the best option for HCFC141b elimination
-Water blown systems are used in sliding shutters and sectional doors applications where
foam k-factor is not a major requirement
HFCs are much less diffused in the market. They are used for customers sensitive to safety aspects
Main requirements :
• Thermal Insulation
• Good dimensional stability
Spray
Water blown systems fit very well to eliminate HCFC141b in spray applications
Hydrocarbons are not recommended due to risks of flammability in spray applications
HFCs, are recommended
Different fabrication processes: Pipe-in-Pipe discontinuous; continuous pouring and spray.
Main requirements :
• Mechanical resistance
• Max operating temperature
• Thermal Insulation
Pipes
-Hydrocarbons represent a viable alternative for foam production with good performance
-Water blown systems are recommended where foam insulation is not a fundamental
requirement
HFCs, are suitable alternatives for HCFC141b elimination
Main requirements:
• Thermal Insulation
• Good processing and low cost
Portable Coolers and Boilers
-Systems expanded with H2O are applicable. Temperature control is recommended for good
adhesion.
-Hydrocarbons represent a viable alternative due to foam properties and competitive cost, but
requires high investment.
HFCs, feasible for these applications
Main requirements :
• Thermal insulation
• High productivity /foam cost
Commercial Refrigeration
- Systems expanded with H2O are applicable. Low energy efficiency of water blown implies
additional costs in refrigeration systems.
- Hydrocarbons would be the best option versus volume of foam produced that could justify high
investments
HFCs, widely used in this application
• DCP Technology is used to produce panels for different segments in Cold Chain Industry,
e.g. Walk-in cold rooms, industrial cold stores, refrigerated transportation.
• Diferent injection technolgies are used: single injection point; lance withdrawal; open lid
and more sophisticated like VAI: Vacuum Assisted Injection
DCP – PUR - Hydrocarbon Technology in Cold Chain
* lower density=DCP for cold rooms, higher density=refrigerated trucks and sea containers
- Hydrocarbons blown systems have a wide range of properties, depending on the specific
application and foaming technology
- Typical Data: Lambda 21-23 mW / mK Density @ 24C and 36-60 kg/m3 *
• Besides PUR Technolgoy, Polyisocyanurates � PIR are used when superior fire
resistance performance is required
- Similarly, systems expanded with hydrocarbons have a wide range of properties
depending on the specific application and foaming technology
- Typical data of PIR : Lambda 22-24 mW/mk @24C and Density 40-45 kg/m3
DCP – PIR - Hydrocarbon Technology in Cold Chain
Hydrocarbons as alternative to HCFC 141b
• Validated technology for more than 20 years that provides high performance foams with
very competitive cost
• Requires high production foam volume to justify heavy investment for HC conversion
• Can be used in practically all applications (except spray )
H2O as alternative to HCFC 141b
• Recommended where thermal insulation is not a important requirement
• Foam cost is very competitive
• Higher applied foam density represents small incremental cost
• Requires strict range of temperature control of molds to improve foam adhesion that is
lower compared to other technologies
• Applications where foams are sealed in the structures will sustain thermal insulation with
very minor deterioration along life of equipment
General Comments
• Founded in 1987 by Herbert H. Dow in Midland, Michigan – USA
• Supplies a broad range of products and services to customers in approximately 160
countries
• More than 5.000 products manufactured at 188 sites in 35 countries
• Employs 50.000 employees globally
• Revenue of approximately US$ 60 billion in 2012
The Dow Chemical Co
• Dow has been active in manufacturing and R & D of PU foams for many years. It Is fully
committed to helping its customers and the industry to find best suitable solution to
meet their requirements in technology, processing and performance of materials
• Due to changes in the requirements of efficiency and blowing agents, Dow focused on
development of new formulations and innovative technologies capable to meeting
market needs and complying with all national and international laws and regulations
• Dow supplies a wide range of rigid polyurethane systems developed based on
hydrocarbons, water, and other innovative blowing agents
• The global reach of Dow combined with strong local presence enables a great proximity
to the base of our customers to deliver innovative solutions with quick response to the
market.
The Dow Chemical Co
Acknowledgment s
*Cecilia Girotti – Sr. R&D Chemist
*Giuseppe Vairo – Global Technology Leader
**Leo Bian- Energy Efficiency Technology Leader
**Si-Ho Lee – TS&D Leader
*Dow Italy
**Dow Asia Pacific