Polyurethane Insulation for Buildingspolyacs.net/images_PSOET12/Singh.pdf · Water Heating 7% Electronics 3% ... Un-insulated stairwell Thermal Bridging ... Polyurethane Insulation

Polyurethane Insulation for Buildings Sachchida N. Singh

Huntsman Advanced Technology Center

The Woodlands, TX


Energy Consumption in Buildings

Source: Department of Energy. (n.d.). Building's data book. 2012. Retrieved from http://buildingsdatabook.eren.doe.gov/TableView.aspx?table=3.1.4;

U.S. Energy Information Administration, Annual Energy Review, October, 2011.

2011 Average Commercial Building Energy Consumption

Lighting 15%

Ventilation 7%

Refrigeration 5%

Water Heating 7%

Electronics 3%

Computers 3%

Cooking 3%

Other 15%

Space Heating 31%

Space Cooling 11%

Primary Energy Consumed Over the Past Two Decades

80

85

90

95

100

105

1990

1992

1994

1996

1998

2000

2002

2004

2006

2008

2010

En

erg

y C

on

su

med

in

qu

ad

rillio

n

BT

Us

Lately US is trying to bring down its

energy consumption to create a more

sustainable economy.

http://buildingsdatabook.eren.doe.gov/TableView.aspx?table=3.1.4


Air Infiltration

Un-insulated stairwell

Thermal Bridging

from un-insulated

metal studs +

structural members

Insulation Drivers

Building Performance Technology

New technology enables us to understand performance needs


Cost/ton of CO2 Abatement

Insulation improvements

Source: Vattenfall


Cost/ton of CO2 Abatement

Insulation improvements

Source: Vattenfall

Insulation improvements, -150 Euro/t CO2


Building Insulation: Growth Drivers

Market push and Legislative pull

Shorter payback time due to high energy

prices - current & anticipated

Financial incentives by governments

Easy comparisons due to building rating

systems like LEED®, EnergyStar

Wider acceptance of global

warming

Energy efficiency a key

priority for building codes

Higher minimum insulation

levels mandates


Insulation Drivers

Commercial Energy Codes: Changes

ASHRAE 90.1 (Energy Standard for Commercial

Buildings) – First developed in 1970’s in response to oil embargo

– ASHRAE 90.1-2010 (30% energy savings vs. 2004)

IECC (International Energy Conservation Code) – Design standards of efficient building envelopes internationally

– IECC 2012 minimum insulation requirements are

significantly higher than IECC2009 and are prescriptive

ASHRAE 189 (Standard for the Design of High

Performance Green Buildings) – A new standard first published in 2012

– Higher energy efficiency requirements than ASHRAE 90.1

International Green Construction Code – First model code to include sustainability measures

– Higher and prescriptive minimum insulation requirements

Source: Professional Contact. Codes Manager. ASHRAE. Email.; IECC Envelope Provisions. ICC. Section 502. Print.; Oregon Reach Code;

Ma

in C

od

es

http://www.google.com/imgres?imgurl=http://www.lightnowblog.com/wp-content/uploads/2010/02/Standard-189-proof.jpg&imgrefurl=http://www.lightnowblog.com/2010/03/ashrae-189-1-the-first-green-construction-standard-to-enter-national-code-stage/&usg=__nvZcE6AvrKzxRV2cEaUJwCBeZbQ=&h=260&w=200&sz=19&hl=en&start=1&zoom=1&tbnid=qGMFmKqpkgSUVM:&tbnh=112&tbnw=86&ei=gnZeTpfGAuL64QTYwYE7&prev=/search?q=aSHRAE+189&hl=en&sa=X&tbm=isch&prmd=ivns&itbs=1


Insulation Drivers

Energy Codes and other Changes

2012 IECC requires about R = 5 continuous insulation on

exterior wall for the first time

States must implement a plan to achieve 90% compliance

within 8 years of the codes published date

Source: US. Department of Energy. Comparison of 90.1-2010 and 2012 IECC. Richland: Pacific Northwest National Laboratory, Print.


Insulation Market

Source: "Residential & Commercial Insulation." (2010): 100. Principia Partners. Database. 11 Jul 2012.

Residential and commercial

by Volume in 2010

Commercial Building

$ in 2010

Fiberglass

55%

MW

2%

Cellulose

11%

XPS

3%

EPS

4% 1%

PU - Spray

6%

PU - Board

18%

Fiberglass

20%

MW

1%

Cellulose

2%

XPS

9%

EPS

9%

Other

2%

PU - Spray

12%

PU- Board

45%


Polyurethane Foam Products


Fiberglass Cellulose EPS XPS PU - Board

Thermal resistance

(R/inch) 3.7 4.0 3.8 5.0 3.6 6.2 6.0

Air Barrier/ Air

impermeable

Water vapor

retarder

Seamless

Insulation

Sound Control

Fire resistance

Structural strength

Installed costs

Ease of Installation

Types of Insulation: PU has Advantages

PU – Spray

Open Closed

http://www.google.com/imgres?imgurl=http://www.energyauditingblog.com/wp-content/uploads/2010/12/fiberglass-insulation.jpg&imgrefurl=http://www.energyauditingblog.com/why-doesnt-fiberglass-insulation-workwell/&usg=__ivYbQiq7JVPwlyci-JunXI7BR8Q=&h=400&w=600&sz=51&hl=en&start=7&zoom=1&tbnid=JN5_-Shd8d6DpM:&tbnh=90&tbnw=135&ei=RsFdTpbSOLOL4gSmmqES&prev=/search?q=fiberglass+insulation&hl=en&sa=X&tbm=isch&prmd=ivns&itbs=1

http://www.google.com/imgres?imgurl=http://www.charlesandhudson.com/green-building/photos/cellulose-insulation-green.jpg&imgrefurl=http://charlesandhudson.com/green-building/insulation/cellulose-insulation-choose-this-green-option-carefully/&usg=__3Q8A2pe3EHrJYEv8W1UjMVBOi4E=&h=260&w=480&sz=23&hl=en&start=3&zoom=1&tbnid=WrZk7f2aAzPB8M:&tbnh=70&tbnw=129&ei=a8FdTr6yGOSi4gSjtZ0G&prev=/search?q=cellulose+insulation&hl=en&sa=X&tbm=isch&prmd=ivns&itbs=1

http://www.google.com/imgres?imgurl=http://www.polyfoaminc.com/EPS/images/eps-board.jpg&imgrefurl=http://www.polyfoaminc.com/EPS/Insulation.asp&usg=__cwaXKWP6aTh-NzfdZMQweVfHrb8=&h=150&w=200&sz=12&hl=en&start=3&zoom=1&tbnid=Fa2a-PqJkZvlRM:&tbnh=78&tbnw=104&ei=jcFdTvmuEemj4gSku-A_&prev=/search?q=expanded+polystyrene+insulation&hl=en&sa=X&tbm=isch&prmd=ivns&itbs=1

http://www.google.com/imgres?imgurl=http://building.dow.com/about/images/story.jpg&imgrefurl=http://building.dow.com/about/story.htm&usg=__d32lJvjQAEoUZuqaS_YQUXec6MI=&h=271&w=402&sz=60&hl=en&start=6&zoom=1&tbnid=F-j3UxrKpkVdNM:&tbnh=84&tbnw=124&ei=DsJdTuSlBenl4QS32vEG&prev=/search?q=extruded+polystyrene+insulation&hl=en&sa=X&tbm=isch&prmd=ivns&itbs=1


Uniqueness of Polyurethane Foam

Simultaneous polymerization, foaming and shaping in ~ 1 minute

Start with relatively low MW monomer / oligomer

Mixed at relatively low pressure, ~ 400 - 2000 psi

Condensation polymerization to a cross-linked network while

expanding ~ 40 times and conforming to finished product, all in ~

15 – 90 seconds

Very versatile chemistry with wide range of components enable

enormous tailor-ability along with compatibility with various facings /

substrate

High insulation values at low density while meeting the structural and

fire requirements of building codes and the environmental mandates


catalyst

urethane urea

+

CO 2

+

surfactant

+ +

+

+

Polymer

+

gas, >97%

polyol isocyanate H2O

blowing agent

Polyurethane Insulation Foam

FOAM


Components of PU Insulation Foam:

Polymeric MDI

Polyester polyol Polyether polyol

OCN

(2,4)

OCN NCO

n

Blowing agent BP, oC

λgas,

W/m.K

CF3CH2CHF2 15.3 12.5

iso-C5 H12 24.6 14.3

cyclo-C5 H12 49.3 12.8


Components of PU Foams:

Silicone surfactant Fire retardant


Components of PU Foams: Many Choices

JEFFCAT® TD-33A catalyst

JEFFCAT® ZF-10 catalyst

JEFFCAT® ZR-40 catalyst

JEFFCAT® PMDETA catalyst

JEFFCAT® Z-110 catalyst

JEFFCAT® ZR-50 catalyst

JEFFCAT® DMEA catalyst

JEFFCAT® DPA catalyst

JEFFCAT® DMCHA catalyst

JEFFCAT® TD-20 catalyst

JEFFCAT® DMDEE catalyst

JEFFCAT® ZF-20 catalyst

Tin, Lead, & Mercury Salts

Gelation

Catalysts

Blowing

Catalysts

Trimerization Catalysts Potassium Salts

JEFFCAT® TR-90 catalyst




Typical formulation

ISOCYANATE SIDE (A) Weight %

Polymeric MDI, Mn ~ 350, fn = 2.5 – 3.0 50 - 60

POLYOL SIDE (B)

Aromatic polyester polyol, Mn ~ 500, fn = 2 - 3 5 - 30

Polyether polyols, Mn = 100 – 800, fn = 2 - 5 0 - 30

Fire retardants, one or more, fn = 0 - 2 3 - 5

Catalysts, 2 - 6 types 1 - 3

Physical blowing agent 6 - 12

Chemical blowing agent, generally water 0.1 - 1

Cell regulator, silicone surfactant 0.7 – 1.5

TOTAL POLYOL SIDE 50 - 40


Mixing

Polyol blend

(Polyol & additives)

Blowing

agent

High

pressure

pump

Static mixer

Low pressure

Dynamic mixer

Mixing

head

Isocyanate line


Reactions in PU Foam


Making Polyurethane Foam


Cellular Structure of PU Foams

Pentagonal

dodecahedron

Cells, size ~ 200 µm Window thickness

~ 0.5 µm

Strut thickness

~ 2 – 50µm


Drivers for Innovation: Blowing agent Evolutions

Blowing Agent Formula

ODP

GWP

CO2 = 1

K-factor

W/m.K

CFC 11 CCl3F 1 4600 7.9

HCFC-141b CH3CCl2F 0.11 700 10

HFC-245fa CF3CH2CHF2 0 990 12.5

Iso-pentane C5H12 0 11 14.3

HFO-1233zd (E) CF3CH=CHCl ~0 <7 ~10

Carbon Dioxide CO2 0 1 16.4


Drivers for Innovation: R-value Aging

5.0

5.5

6.0

6.5

7.0

0 1 2 3 4 5 6

Time, years

R-v

alu

e

0.0

0.3

0.6

0.9

1.2

0 2 4 6

Time, years

Cel

l Gas

Pre

ssu

re, b

ar

Air

CO2

n-P

Total


Drivers for Innovation: Renewable & Recycle Content

0% 20% 40% 60% 80% 100%

CanolaSun

SoybeanLinseed

CornPalm Lard

Palmitic C16:0 Stearic C18:0 Oleic C18:1

Linoleic C18:2 Linolenic C18:3 Natural oil polyol


Drivers for Innovation: Improve Performance Using Nano-clays

Incorporate nano-clays to reduce diffusion & improve

mechanical and fire properties

Cloisite Na+, natural, unmodified montmorillonite

Laponite JS, a synthetic smectite

Organically modified Laponite

Vermiculite, natural, unmodified

Joint program with University of Minnesota

Polymer, 2010

ACS Applied Materials & Interfaces, 2009

Green Chemistry, 2012

Patent application, WO 2009/137539


PU foam – Vermiculite Nanocomposite

X-ray scattering patterns of

vermiculite-monomer blends FTIR of vermiculite-MDI blend

Patent application WO 2009/137539


SEM Micrographs of Foam with Clay

Green Chem. 2012, 14, 766-770


XRD and TEM of PU Foam with Clay

Green Chem. 2012, 14, 766-770


Laboratory Work – Key Observations

Some improvements in initial and aged insulation values

Enhanced mechanical properties

Better fire properties

Complete exfoliation of any unmodified clay is difficult

Reproducing results of laboratory work to pilot scale is a

significant challenge

Work in progress


Summary

Benefits of insulation is well recognized

Insulation is sexy, U.S. President, Dec. 15, 2009

Uncontested recognition

Polyurethane foams will continue to play a leading role

Good insulation solutions at reasonable cost

Constant need for innovation

Better blowing agent

Renewable, recyclable content

Improved performance and/or lower cost

Developments in polymer science and technology

Polyurethane Insulation for Buildings Sachchida N. Singh


The Woodlands, TX

Thank you

Documents

Polyurethane Insulation for Buildingspolyacs.net/images_PSOET12/Singh.pdf · Water Heating 7% Electronics 3% ... Un-insulated stairwell Thermal Bridging ... Polyurethane Insulation