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05/07/10 Presentation to RR Meeting Caleb Management Services Limited Addressing tomorrow’s issues today Workshop on low-GWP HCFC replacement in the  foam sector Seoul, South Korea 6 th -7 th  May 2010  Latest Technology Developments and Industry Trends in the PU Sector Presented by Miguel Quintero Foams Consultant  Thursday 6 th  May 2010 Mayfield Hotel & Resort, Seoul, South Korea  CONFIDENTIAL Document Date This report is solely for the use of client personnel.  No part of it may be circulated, quoted, or reproduced for distribution outside the client organization without prior written approval from McKinsey & Company. This material was used by McKinsey & Company during an oral presentation; it is not a complete record of the discussion. Unit of measure * Footnote Source: Source
OVERVIEW ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
USE OF HCFCs IN POLYURETHANE FOAMS  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
THERMAL INSULATING FOAM  ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
POLYURETHANE (PU) RIGID FOAM  Closed cells are the key ! Blowing agents are enclosed
PU  Formulation Polyether Polyols Polyester Polyols Catalysts Surfactants Water Blowing Agents PMDI/MDI/TDI + Kinetics Control Stabilizers CO 2 C H 2 OCN NCO 4 , 4 ' - M D I n polymeric MDI CH2 CH2 NCO NCO NCO + f=2.7 Network Formation
FULLY FORMULATED POLYOL Blowing agent content around 18 % !  In total foam 9 % INGREDIENT PARTS BY WEIGHT Polyether Polyol 80 Polyester Polyol 20 Amine catalyst - gelling 1.0 Amine catalyst - blowing 0.5 Silicone surfactant  1.0 Flame Retardant 10 Water 2.0 External blowing agent (HCFC-141b) 22
ROLE OF THE BLOWING AGENT ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
REQUIRED FOAM PROPERTIES ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
REQUIRED FOAM PROPERTIES Application Processing De-mould time Insulation Mechanical strength Domestic refrigeration xxx xxx xxx xxx Other appliances xxx xxx xx xxx Continuous Panels xxx xxx xx xxx Discontinuous Panels xx xxx xx xxx Spray xx xx xx xxx
BLOWING AGENT CHARACTERISTICS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
BLOWING AGENT CHARACTERISTICS Foam requirement Relevant Blowing Agent Characteristic Ease of Processing Flammability Boiling Point Solubility in the polyols De-mould time Broadly independent Insulating Performance Gas thermal conductivity Permeability  through cell wall Mechanical Strength Boiling Point Solubility in the PU matrix
Blowing Agents in PU Rigid Foams CFC 11 CFC 11 50% red. HCFC 141b HFC 245fa HFC 134a c-pentano Iso-/n-pentano c-pentano/LBHC HFC 365mfa/227fa
MATURE TECHNOLOGIES: HYDROCARBONS ^ Measured at 0 0 C  * Precise figure varies according to local atmospheric conditions Cyclo-Pentane n-Pentane Iso-Pentane Iso-Butane n-Butane Chemical Formula (CH 2 ) 5 CH 3 (CH 2 ) 3 CH 3 CH 3 CH(CH 3 )CHCH 3 CH 3 CH(CH 3 )CH 3 CH 3 CH 2 CH 2 CH 3 Molecular Weight 70.1 72.1 72.1 58.1 58.1 Boiling Point (  0 C ) 49.3 36 28 -11.7 -0.5 Gas Conductivity  (mW/mK @ 10 0 C) 11.0 14.0 13.0 15.9 13.6 ^ Flammable Limits in Air (vol.%) 1.4-8.0 1.4-8.0 1.4-7.6 1.8-8.4 1.8-8.5 TLV or OEL (ppm) 600 610 1000 800 800 GWP (100 yr time horizon)  <25* <25* <25* <25* <25*
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],MATURE TECHNOLOGIES: HYDROCARBONS
BTU.in/ft²hr°F Hydrocarbon Technology Brett mold expansion (mm), 8 mins 1 2 3 4 5 Thermal Conductivity, mW/mK 0 °C 18.2 18.4 18.6 18.8 19.0 19.2 19.4 19.6 19.8 20.0 20.2 20.4 20.6 20.8 6 0.1262 0.1276 0.1290 0.1303 0.1317 0.1331 0.1345 0.1360 0.1373 0.1387 0.1401 0.1414 0.1428 0.1442 CP Gen4  CP Gen 3 CP Gen 1 CP Gen 2 HFC134a CP Gen 1+ CP Gen 2+ HCFC 141b CFC 11 50% HCFC 22/142b Iso-/N-Pentano Gen 1 Iso-/N-Pentano Gen 2
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],MATURE TECHNOLOGIES: HYDROCARBONS
HYDROCARBONS: Investment costs Item Description Unit Unit Cost  Sub-total  Hydrocarbon Storage/ Blending     108.000  Buffer tank 250 L 1 28.000  28.000  Premixer 1 70.000  70.000  Double pump transfer unit 1 10.000  10.000          Total Foaming Equipment     145.000  Retrofitting of the existing dosing units by replacing the polyol dosing system 1 135.000  135.000  High pressures L type mixing heads 1 10.000  10.000
HYDROCARBONS: Investment costs Total Safety Related Equipment   223.380  Moulds/ fixtures retrofit 10 8.000  80.000  Safety/ Alarms systems, base panel 1 20.000  20.000  Sensors 6 2.000  12.000  Ventilation system for dosing unit area,  8,000 m 3 /h 1 20.000  20.000  Ventilation system for cabinets/doors, 15,000 m 3 /h  1 30.000  30.000  Fire extinguishing system 1 15.000  15.000  Explosion proof motors and systems 1 10.000  10.000  Sealing of electrical control cabinets 1 10.000  10.000  Starting discharge dissipation 1 10.000  10.000  Electrical modifications (grounding, etc.)  1 10.000  10.000  Connection piping 6 230  1.380  Additional Civil Works 1 5.000  5.000
HYDROCARBONS: Investment costs Total General     110.000  System Optimization 1 30.000  30.000  Nitrogen generator 1 20.000  20.000  Training and International Technical Support 1 20.000  20.000  Trials 1 10.000  10.000  Testing 1 20.000  20.000  Safety Audits 1 10.000  10.000  SUB-TOTAL      586.380  Contingencies     58.638  TOTAL 645.018
HYDROCARBONS: Incremental Operating Costs   Chemical Average Annual Consumption, (2007/2008), kg Unit US$/unit Total cost consumption (US$) Before : HCFC - 141 b 157,242  kg 2.40 377,380   Formulated Polyol A 681,983  kg 2.60 1,773,155   Polymeric MDI 954,776  kg 2.79 2,663,824 Total 4,814,359   Cyclopentane 100,557 kg 3.00 301,670 After: Formulated Polyol B 728,961  kg 2.68 1,952,157   Polymeric MDI 1,020,545  kg 2.79 2,847,321   Nitrogen  2,915 m 3   9.50 27,690 Total 5,128,838 Incremental Operating Costs/year 314,479
MATURE TECHNOLOGIES: Saturated HFCs HFC-134a HFC-245fa HFC-365mfc HFC-227ea Chemical Formula CH 2 FCF 3 CF 3 CH 2  CHF 2 CF 3 CH 2  CF 2  CH 3 CF 3 CHF CF 3 Molecular Weight 102 134 148 170 Boiling Point (  0 C ) -27 15.3 40.2 -16.5 Gas Conductivity  (mW/mK @ 10 0 C) 12.4 12.5* 10.6* 11.6 Flammable Limits in Air (vol.%) None None 3.8-13.3 None TLV or OEL (ppm)  1000 N/A N/A 1000 GWP (100 yr time horizon) 1410 (1300) 1020 782 3140 (2900)
[object Object],[object Object],[object Object],[object Object],MATURE TECHNOLOGIES: Saturated HFCs
[object Object],[object Object],[object Object],[object Object],[object Object],MATURE TECHNOLOGIES: CO 2  from Water As Sole Binder
RELATIVELY NEW OPTION: Methyl Formate Ecomate (R) (Methyl Formate) Molecular Weight 60 Boiling Point (  C) 31.3  Gas Thermal Conductivity (Mw/Mk, 25ºC) 10.7  Flammable limits in air (vol %) 5-23 GWP (100yr  ITH) Negligible
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],RELATIVELY NEW OPTION: Methyl Formate
EMERGING OPTIONS Methylal HFO-1234ze FEA-1100 HBA-2 AFA-L1 Chemical Formula CH 3  OCH 2 OCH 3 Trans- CF 3 CH=CHF Undisclosed Undisclosed Undisclosed Molecular Weight 76.1 114 Undisclosed Undisclosed Undisclosed Boiling Point (  0 C ) 42 -19 >25.0 15.3<T<32.1 10<T<30 Gas Conductivity  (mW/mK @ 10 0 C) Not available 13.0 10.7 Not Reported 15.9 Flammable Limits in Air (vol.%) 2.2-19.9 None to 28 o C^  None None None TLV or OEL (ppm) () 1000 Unpublished Undisclosed Undisclosed Undisclosed GWP (100 yr time horizon)  <25* 6 5 <15 <15
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Emerging options
Integral Skin & Microcellular Elastomers ,[object Object],[object Object],[object Object]
MATURE TECHNOLOGIES ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
EMERGING OPTIONS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
SUMMARY ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

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Latest Developments and Trends in PU Foam Technology

  • 1. 05/07/10 Presentation to RR Meeting Caleb Management Services Limited Addressing tomorrow’s issues today Workshop on low-GWP HCFC replacement in the foam sector Seoul, South Korea 6 th -7 th May 2010 Latest Technology Developments and Industry Trends in the PU Sector Presented by Miguel Quintero Foams Consultant Thursday 6 th May 2010 Mayfield Hotel & Resort, Seoul, South Korea CONFIDENTIAL Document Date This report is solely for the use of client personnel. No part of it may be circulated, quoted, or reproduced for distribution outside the client organization without prior written approval from McKinsey & Company. This material was used by McKinsey & Company during an oral presentation; it is not a complete record of the discussion. Unit of measure * Footnote Source: Source
  • 2.
  • 3.
  • 4.
  • 5. POLYURETHANE (PU) RIGID FOAM Closed cells are the key ! Blowing agents are enclosed
  • 6. PU Formulation Polyether Polyols Polyester Polyols Catalysts Surfactants Water Blowing Agents PMDI/MDI/TDI + Kinetics Control Stabilizers CO 2 C H 2 OCN NCO 4 , 4 ' - M D I n polymeric MDI CH2 CH2 NCO NCO NCO + f=2.7 Network Formation
  • 7. FULLY FORMULATED POLYOL Blowing agent content around 18 % ! In total foam 9 % INGREDIENT PARTS BY WEIGHT Polyether Polyol 80 Polyester Polyol 20 Amine catalyst - gelling 1.0 Amine catalyst - blowing 0.5 Silicone surfactant 1.0 Flame Retardant 10 Water 2.0 External blowing agent (HCFC-141b) 22
  • 8.
  • 9.
  • 10. REQUIRED FOAM PROPERTIES Application Processing De-mould time Insulation Mechanical strength Domestic refrigeration xxx xxx xxx xxx Other appliances xxx xxx xx xxx Continuous Panels xxx xxx xx xxx Discontinuous Panels xx xxx xx xxx Spray xx xx xx xxx
  • 11.
  • 12. BLOWING AGENT CHARACTERISTICS Foam requirement Relevant Blowing Agent Characteristic Ease of Processing Flammability Boiling Point Solubility in the polyols De-mould time Broadly independent Insulating Performance Gas thermal conductivity Permeability through cell wall Mechanical Strength Boiling Point Solubility in the PU matrix
  • 13. Blowing Agents in PU Rigid Foams CFC 11 CFC 11 50% red. HCFC 141b HFC 245fa HFC 134a c-pentano Iso-/n-pentano c-pentano/LBHC HFC 365mfa/227fa
  • 14. MATURE TECHNOLOGIES: HYDROCARBONS ^ Measured at 0 0 C * Precise figure varies according to local atmospheric conditions Cyclo-Pentane n-Pentane Iso-Pentane Iso-Butane n-Butane Chemical Formula (CH 2 ) 5 CH 3 (CH 2 ) 3 CH 3 CH 3 CH(CH 3 )CHCH 3 CH 3 CH(CH 3 )CH 3 CH 3 CH 2 CH 2 CH 3 Molecular Weight 70.1 72.1 72.1 58.1 58.1 Boiling Point ( 0 C ) 49.3 36 28 -11.7 -0.5 Gas Conductivity (mW/mK @ 10 0 C) 11.0 14.0 13.0 15.9 13.6 ^ Flammable Limits in Air (vol.%) 1.4-8.0 1.4-8.0 1.4-7.6 1.8-8.4 1.8-8.5 TLV or OEL (ppm) 600 610 1000 800 800 GWP (100 yr time horizon) <25* <25* <25* <25* <25*
  • 15.
  • 16. BTU.in/ft²hr°F Hydrocarbon Technology Brett mold expansion (mm), 8 mins 1 2 3 4 5 Thermal Conductivity, mW/mK 0 °C 18.2 18.4 18.6 18.8 19.0 19.2 19.4 19.6 19.8 20.0 20.2 20.4 20.6 20.8 6 0.1262 0.1276 0.1290 0.1303 0.1317 0.1331 0.1345 0.1360 0.1373 0.1387 0.1401 0.1414 0.1428 0.1442 CP Gen4 CP Gen 3 CP Gen 1 CP Gen 2 HFC134a CP Gen 1+ CP Gen 2+ HCFC 141b CFC 11 50% HCFC 22/142b Iso-/N-Pentano Gen 1 Iso-/N-Pentano Gen 2
  • 17.
  • 18. HYDROCARBONS: Investment costs Item Description Unit Unit Cost Sub-total Hydrocarbon Storage/ Blending     108.000 Buffer tank 250 L 1 28.000 28.000 Premixer 1 70.000 70.000 Double pump transfer unit 1 10.000 10.000         Total Foaming Equipment     145.000 Retrofitting of the existing dosing units by replacing the polyol dosing system 1 135.000 135.000 High pressures L type mixing heads 1 10.000 10.000
  • 19. HYDROCARBONS: Investment costs Total Safety Related Equipment   223.380 Moulds/ fixtures retrofit 10 8.000 80.000 Safety/ Alarms systems, base panel 1 20.000 20.000 Sensors 6 2.000 12.000 Ventilation system for dosing unit area, 8,000 m 3 /h 1 20.000 20.000 Ventilation system for cabinets/doors, 15,000 m 3 /h 1 30.000 30.000 Fire extinguishing system 1 15.000 15.000 Explosion proof motors and systems 1 10.000 10.000 Sealing of electrical control cabinets 1 10.000 10.000 Starting discharge dissipation 1 10.000 10.000 Electrical modifications (grounding, etc.) 1 10.000 10.000 Connection piping 6 230 1.380 Additional Civil Works 1 5.000 5.000
  • 20. HYDROCARBONS: Investment costs Total General     110.000 System Optimization 1 30.000 30.000 Nitrogen generator 1 20.000 20.000 Training and International Technical Support 1 20.000 20.000 Trials 1 10.000 10.000 Testing 1 20.000 20.000 Safety Audits 1 10.000 10.000 SUB-TOTAL     586.380 Contingencies     58.638 TOTAL 645.018
  • 21. HYDROCARBONS: Incremental Operating Costs   Chemical Average Annual Consumption, (2007/2008), kg Unit US$/unit Total cost consumption (US$) Before : HCFC - 141 b 157,242 kg 2.40 377,380   Formulated Polyol A 681,983 kg 2.60 1,773,155   Polymeric MDI 954,776 kg 2.79 2,663,824 Total 4,814,359   Cyclopentane 100,557 kg 3.00 301,670 After: Formulated Polyol B 728,961 kg 2.68 1,952,157   Polymeric MDI 1,020,545 kg 2.79 2,847,321   Nitrogen 2,915 m 3 9.50 27,690 Total 5,128,838 Incremental Operating Costs/year 314,479
  • 22. MATURE TECHNOLOGIES: Saturated HFCs HFC-134a HFC-245fa HFC-365mfc HFC-227ea Chemical Formula CH 2 FCF 3 CF 3 CH 2 CHF 2 CF 3 CH 2 CF 2 CH 3 CF 3 CHF CF 3 Molecular Weight 102 134 148 170 Boiling Point ( 0 C ) -27 15.3 40.2 -16.5 Gas Conductivity (mW/mK @ 10 0 C) 12.4 12.5* 10.6* 11.6 Flammable Limits in Air (vol.%) None None 3.8-13.3 None TLV or OEL (ppm) 1000 N/A N/A 1000 GWP (100 yr time horizon) 1410 (1300) 1020 782 3140 (2900)
  • 23.
  • 24.
  • 25. RELATIVELY NEW OPTION: Methyl Formate Ecomate (R) (Methyl Formate) Molecular Weight 60 Boiling Point (  C) 31.3 Gas Thermal Conductivity (Mw/Mk, 25ºC) 10.7 Flammable limits in air (vol %) 5-23 GWP (100yr ITH) Negligible
  • 26.
  • 27. EMERGING OPTIONS Methylal HFO-1234ze FEA-1100 HBA-2 AFA-L1 Chemical Formula CH 3 OCH 2 OCH 3 Trans- CF 3 CH=CHF Undisclosed Undisclosed Undisclosed Molecular Weight 76.1 114 Undisclosed Undisclosed Undisclosed Boiling Point ( 0 C ) 42 -19 >25.0 15.3<T<32.1 10<T<30 Gas Conductivity (mW/mK @ 10 0 C) Not available 13.0 10.7 Not Reported 15.9 Flammable Limits in Air (vol.%) 2.2-19.9 None to 28 o C^ None None None TLV or OEL (ppm) () 1000 Unpublished Undisclosed Undisclosed Undisclosed GWP (100 yr time horizon) <25* 6 5 <15 <15
  • 28.
  • 29.
  • 30.
  • 31.
  • 32.