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