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Montreal, April 5-6, 2008
Paulo Altoe – Dow Brazil
April 2008
Challenges to Replace ODS in PU Appliance Foams in Developing Countries
Montreal, April 5-6, 2008
Blowing Agent Status - Phase Out of CFC and Growth Predictions for Blowing Agents
Source – UNEP Report 2001
Source – TEAP Report 2006
Montreal, April 5-6, 2008
HCFC – Major Volume for Replacement Developing Countries
Source – TEAP Report 2006
Montreal, April 5-6, 2008
HCFC – Major Volume for Replacement Developing Countries
Source – TEAP Report 2006
Flexible PU 29%
Phenolic 1%
Polyethelene 1%
Polystyrene 16%
Rigid PU 53%
Blowing Agent Consumption - Breakdown per Foam TypeTotal ~ 360.000 tonnes
Source: TEAP Report, 2006
Blowing Agent PU Rigid Foam
~ 200 MT
Montreal, April 5-6, 2008
HCFC – Major Volume for Replacement Developing Countries
Simulaton of HCFC Phase-Out In Developing CountriesOriginal and New Agreement of Montreal Protocol
0102030405060708090
100110120130
2010 2015 2020 2025 2030 2035 2040
Dec
reas
ing,
%
Montreal Protocol - Original Rules
Montreal Protocol - Agreement 2007
D ecrease 5% fro m 2015
48%
52%
2010 Base Line2013 Freeze Prod., consumption2015 Reduction 10%2020 Reduction 35%2025 Reduction 75%2040 Reduction 100%
2015 Base Line
2016 Freeze Prod., Consumption
2040 Reduction 100%
Blow. Agent in Appliance Foam
most importantvolume
Montreal, April 5-6, 2008
Low K Bl. AgentsVacuum PanelsCompressor EfficiencyDesign Multi-injectionsWall ThicknessEnergy Labels
Montreal ProtocolIndustrial HygieneProduct LifetimeEco-designRenewable RMRecycling Energy labels
Low DensityLow Blow. Ag. LevelLow “voids”Flow abilityFast DemoldMech. PropertiesDim. Stability
Energy Efficiency
Cost &Productivity
Environment &Regulations
Driving Forces in PU Rigid Foams for Appliances Energy Environment Cost
Montreal, April 5-6, 2008
CFC 11
CFC 11 50% red.
HCFC 141b
HFC 245fa
HFC 134a
c-pentano
Iso-/n-pentano c-pentano/LBHC
Blowing Agents History in PU Rigid Foams Technology for Appliances
HFC 365mfa/227fa
Montreal, April 5-6, 2008
Class A has become market reference
Differentiation
A15% A >75%%
Energy Eficiency and Marketing Need: Refrigerator’s energy classes 1992 – 2005 (CECED)
Montreal, April 5-6, 2008
Challenges of HCFC Replacement > Right Choice of Blowing Agents
Physical and Environmental Properties of Blowing Agents How to addressEnergy Efficiency
Environment & Regulationsand Costs ?
Montreal, April 5-6, 2008
Closed cell : Thermal conductivity contribution factors
Challenges of HCFC Replacement > Advances in Rigid Foam Technology for Appliances
λFoam = λgas + λsolid + λradiative
λgas = Gases inside foam cellsλsolid = Bulk polymer {215-245 [mW/mK]/[g/cc]}λradiative= Radiative processes (10 - 16 [mW/mK]/[mm of cell diameter]}
~ 60%~20% ~20%
Developments are focused on Bl. Agent and Radiative factor with cell size reduction
Montreal, April 5-6, 2008
Pos-Expansion, Jumbo Mold (mm) at 8 minutes1 2 3 4 5
Lam
bda,
mW
/mK
@ 10
°C
18.218.418.618.819.019.219.419.619.820.020.220.420.620.8
60.12620.12760.12900.13030.13170.13310.13450.13600.13730.13870.14010.14140.14280.1442
CP Gen4
CP Gen 3
CP Gen 1
CP Gen 2
HFC134a
CP Gen 1+CP Gen 2+
HCFC 141bCFC 11 50%
HCFC 22/142b
Iso-/N-Pentano Gen 1
Iso-/N-Pentano Gen 2
BTU.in/ft²hr°F
Molded Density Trend
CP/HFC245fa
HFC245fa
Challenges of HCFC Replacement > Advances in Rigid Foam Technology for Appliances
Low K Technology for HC & HFC 245fa
Montreal, April 5-6, 2008
Rad
iativ
eTh
erm
al C
ondu
ctiv
ity m
W/(m
K)
Cell Size (μm)
Nuc
leat
ion
Site
per
cc
of fo
amin
g m
ixtu
re
Maximum possible radius of initial bubbles (μm)
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
100 150 200 250 300 3500.0
1.0
2.0
3.0
4.0
5.0
6.015.7 23.6 31.5 39.4 47.2 55.1
Estimation of radiative conductivity
Nucleation Sites
Maximum gain of radiativecontribution, ~3 mW/m.K
We are here todaywith multi-injections
Area left forimprovement
Initial CP Foams
Challenges of HCFC Replacement > Advances in Rigid Foam Technology for Appliances
Cell Size Reduction
Montreal, April 5-6, 2008
0.080.09
0.10.110.120.130.140.150.160.170.18
k-FO
AM
_US
A A
ctua
l
.08 .09 .10 .11 .12 .13 .14 .15 .16 .17 .18k-FOAM_USA Predicted
P<.0001 RSq=0.99 RMSE=0.0014
Actual by Predicted Plot
RSquareRSquare AdjRoot Mean Square ErrorMean of ResponseObservations (or Sum Wgts)
0.9942150.9939530.0014330.125992
301
Summary of Fit
HorizVertTemperatureBulk: HFC-245faCellsizeCore Density 2
Factor24
0.91225
2
Current X
k-FOAM_USAResponse
0.13Contour
0.1301849Current Y
.Lo Limit
.Hi Limit
Contour ProfilerResponse k-FOAM_USA HFC 245fa
100
150
200
250
300
350
400
Cel
lsiz
e
k-FOAM_USA
0.15
0.1450.14
0.1350.13 0.125 0.12
0 .1 .2 .3 .4 .5 .6 .7 .8 .9 1Bulk: HFC-245fa
• General rule is: 10 micron reduction in cell size yields 0.001 btu improvement in foam k-factor• Target needs to be approaching 100 microns hoping to get a k-factor near 0.120 btu• Maybe as large as 140 micron cells size if consider 100% HFC-245fa• Issues: Density, Cost, Processing !
Low K Technology for
HFC 245fa
Challenges of HCFC Replacement > Advances in Rigid Foam Technology for Appliances
Montreal, April 5-6, 2008
Modeling Simulation
Challenges of HCFC Replacement - Advances in Rigid Foam Technology for Appliances
Montreal, April 5-6, 2008
Challenges of HCFC Replacement
Choosing the preferred Blowing Agent - Diagram
Initial Foam CharacteristicsEnvironment, Energy, Cost
Work Concluded
Choosing Blowing Agent
FlammableYesNo
StorageProcessingOperationMachinery
Pre-MixFire Brigade
Training
Plant Processing
Review Foam Characteristic
Needs Cabinet, Doors
Redesign Cabinet MoldDoor Mold
Plastic Liners Add Cost: C7
Cabinet MoldDoor MoldFixturesAdd Cost : C6
YesNo
NewCooling System
EvaporatorCompressor
Cooling SystemAdd Cost : C8
EvaporatorAdd Cost : C9
CompressorAdd Cost: C10
No
Yes
Cabinet &Foam
Cabinet &Foam
StorageBulk
DrumsDetectors
Add Cost: C1
Pre-Mixing Piping
VentilationDetectors
Add Cost: C2
ProcessingPiping
VentilationDetectors
Add Cost: C3
MachineryVentilationDetectors
Add Cost: C4
TrainingFire Brigade
People Add Cost: C5
Foam Machinery &Processing
Cabinet
Montreal, April 5-6, 2008
Challenges of HCFC Replacement - Energy Improvement - Options and Cost
0.0 4.5 0.0 10.0 20.0 35.0 0.0 3.0 8.0 5.0 2.5 18.0 3.0
0.38
0.2 0.4
1.4
0.04
0.90.8
0.6
1.9
1.7
0
10
20
30
40
Pote
ntia
l ene
rgy
savi
ng, %
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
Cos
t per
% im
prov
emen
t, Eu
ro/%
Potential Energy consumpt. reduction in %Cost per % saving, Euro/%
Cooling gas134a
Cooling gasisobutane
CompressorStandard
CompressorHigh
Efficiency
CompressorVery HighEfficiency
CompressorVariable
Speed
Blowing Agentc-pentaneand blends
Optimized PU Systemc-pentane
BlowingAgent
HFC-245fa
Cabinet foamThickness
for each 10mm
increase
Door foamThickness
for each 10mm
increase
VIP Door Design
Montreal, April 5-6, 2008
Challenges of HCFC Replacement-Simulation of Cabinet Costs
Montreal, April 5-6, 2008
Challenges of HCFC Replacement-Simulation of Foam Cost vs Blowing Agent
Protocol:
Foam = HCFC141b, 35 kg/m3 and lambda 18.5-19.5 mW/mK @ 24C
Cabinet with 35 mm thickness
Simulation - HCFC 141b Replacement - Brazil, China, IndiaAnnual Gains(+) or Losses(-) = 500M Units/Y
-800000
-600000
-400000
-200000
0
200000
400000
600000
800000
HCFC141b
Water C-pentane CP/isob C-isop HFC134a HFC245faUS
HFC245faChina
MUS$
SuccessfullyImplemented:
EuropeIndia, China
Montreal, April 5-6, 2008
Challenges of HCFC Replacement-Simulation of Cabinet Costs
Montreal, April 5-6, 2008
Challenges of HCFC Replacement-Simulation of Foam Cost vs Blowing Agent
Protocol:
Foam = HCFC141b, 34 kg/m3 and lambda 18.0-19.0 mW/mK @ 24C
Cabinet with 35 mm thickness
Simulation - HCFC 141b Replacement - Andean Countires & Mexico Annual Gains (+) and Losses in Foam = 500M units/Y
-1000000
-800000
-600000
-400000
-200000
0
200000
400000
600000
HCFC 141b Water C-pentane CP/isob C-isop HFC134a HFC245faUS
HFC245faChina
MUS$
Montreal, April 5-6, 2008
Challenges of HCFC Replacement- Simulation – Incremental Cost per Cabinet vs Options
Plant Modification to HydrocarbonsFrom 0.8 – 3.5 MM US depending
on the size
Simulations - Incremental Cost per Cabinet vs Options
0 1 2 3 4 5 6 7 8
HFC 245fa USA Price
Tooling Cabinet Redesign, 3years
Plant Modification HC, 3 years
Foam thickness, 10mm
Cooling System
Compressor, 10% + Efficient
Opt
ions
US$
Montreal, April 5-6, 2008
Conclusion* HCFCs Elimination is a Very Difficult Task Apart From all Technology Advances
* HCFC Elimination by HFC 24fa – Favorable for Energy Efficiency, Non Flammable, High Cost, High GWPAdditional costs - Predominantly in Cabinets
- Less in Machinery & Processing Cost in cabinets - Remain until the cabinet model is produced, limited paybackInvestment - Low in Machinery, High in Raw Material (High cost of Blowing Agent)
* HCFC Elimination by Hydrocarbons – Favorable to the Environment, Medium for Energy, Very Low GWPAdditional costs - Predominantly in Machinery & Plant Processing
- Less in Cabinets -Cost in cabinets – Depending on the re-design
Investment - High in Machinery & Plant Processing with Payback, - Low in Raw Material (Low cost of Blowing Agent)
* Other Options – To be evaluated case by case Blends of HC/HCFC can be an option for China where HFC245fa has lower priceHigher water blown content with other blowing agents will depend on applied molded density and Energy Efficiency requirements
•Modeling, Simulations and Formulation Science are great help for Bl. Agent comparison before final decision is taken
Montreal, April 5-6, 2008
Paulo Altoe – Dow Brazil
April 2008
Back Up - Slides
Montreal, April 5-6, 2008
Challenges of HCFC Replacement - Energy Improvement - Options and Cost
Freezer door 6%
Full foamed cabinet 24%
Compressor/condensor 20%
Accessories 18%
Packaging 4%
Fixed cost 10%
Refrigerator Door 10%
Manpower 8%
Metal 14.3%
Liner Material 9.6%
PU Foam 12.2%
Compressor 23.2%
Condensor/evaporator 11.4%
Plastic for accessories 4.3%
Seals & accessories and others 19.6%
Glass 5.4%
** excludes Manpower and fixed costs
Montreal, April 5-6, 2008
Conversion Cost to Hydrocarbons US$
Storage 100000
Ventilation 80000
Safety Control - Cabinets 35000
White Book 22000
Safety Report 15000
Pre-Mix Polyol + Hydrocarbon 150000
PU Machine + Mixing Head 300000
Civil Construction
Engineering
Man Power
Total 702000
Conversion Cost to Hydrocarbon - Estimation
Montreal, April 5-6, 2008
Paulo Altoe – Dow Brazil
April 2008
Back Up - Slides
Montreal, April 5-6, 2008
Paulo Altoe – Dow Brazil
April 2008
Back Up - Slides
Montreal, April 5-6, 2008
Paulo Altoe – Dow Brazil
April 2008
Back Up - Slides
Montreal, April 5-6, 2008
Paulo Altoe – Dow Brazil
April 2008
Challenges to Replace ODS in PU Appliance Foams in Developing Countries
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