Zero ODS Low GWS Eliminate HCFC with alternate By A K Singh
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The document discusses alternatives to HCFC blowing agents for foam production. It summarizes mature technologies like hydrocarbons, HFCs, and CO2 that have limitations regarding cost, safety, or environmental impact. Emerging technologies are also presented, such as methyl formate, HFOs, and saturated HFCs that offer some improvements but require further development and commercialization. The overall message is an urgent need to phase out HCFCs due to environmental concerns while pursuing the most viable and sustainable alternative blowing agent options.
Zero ODS Low GWS Eliminate HCFC with alternate By A K Singh
- 1. Zero ODS Low GWS Eliminate HCFC with alternate blowing agents Processing issues and challenges for the foam sector Presented by Arun K Singh
- 2. Our Social Responsibilities Save Ozone layer Save Environment by Using ZERO ODS LOW GWS Blowing agents
- 3. 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
- 4. Ozone layer Protection Need of hour phase-out HCFC to protect Ozone layer
- 5. Montreal Protocol on ODS Turn off production tap of ODS & GWS materials & improve public health environments
- 6. Product Overview • 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
- 7. PU Industry Growth in Middle East & KSA HCFC consumption scenario in the reason
- 8. 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
- 9. 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
- 10. 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
- 11. 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
- 12. 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
- 13. 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
- 14. Blowing Agents in Rigid PU HCFC 141b ? Hydrocarbons (pentanes ) Butanes CO2 HFC HFA-L1 HBA- 2 FEA-1100 HFO Methyl Formate Water
- 15. Phase – Out HCFC
- 16. 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
- 17. 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) HFCs Boiling point HFCs a issue at high ambient conditions Hydrocarbon are highly flammables Low GWP blowing agents need to be promoted
- 18. Available Technologies Water Cell Regulation Problem Skin formation Problem High Boiling point Bonding issues CO₂ skin formation Problem Foam flowbility Problem Bonding Issues' HFC Higher operating cost ,high High GWP ,low boiling Point Pentene High Flammability issues High Investing cost Not feasible for SHEs Methyl A patented Technology by Formate Foam supplier HFO Excellent lambda value & other properties with a little extra cost
- 19. Blowing agent characteristics Easy to use Solubility with Polyol Down Trend Flammability Smooth Rising Boiling Point Foam 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 ODP Low GWS Low Toxicity Chemically & Physically Stable Lower “K” values Improve Energy efficiency Batter Thermal stability Proven & validated Technology Commercially available Economically Viable
- 20. 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
- 21. 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 B Saturated HFCs
- 22. 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 C CO₂ from Water
- 23. New Technology Molecular 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 D Methyl Formate Relative new BA options
- 24. Other Emerging Technologies Methylal HFO123 4-ze FEA- 1100 HBA-2 AFA-L1 Chemical Formula 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 19.9 None 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
- 25. 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
- 26. 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
Editor's Notes
- #18: ion