Alternatives to HFCs/HCFCs for the
production of foam
Miguel W. Quintero
Independent Consultant
July, 2014
Disclaimer: The views expressed are those of the author and do not
represent those of the TEAP or the FTOC
MWQ, HFC Workshop, Paris, July 11, 2014
KEY POINTS ON HFC/HCFC PHASE OUT
•
Polyurethane rigid foam for insulation is the foam sector using the largest
volume of HFC/HCFCs

•
Blowing agent is less than 12% of total foam formulation




•
XPS foam for board
Polyols, surfactants, catalysts are critical
Crucial role of System Houses…they are the “chefs”!
There is no a direct correlation between foam and substance properties
There is not a “drop-in” replacement!
Critical segment…Small and Medium Enterprises (SMEs)


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Reliant on local system houses
Low technology competence/ Poor operating discipline
Thousands of “micro” (less than 5 tonnes of HCFC-141b per year) in developing
countries
MWQ, HFC Workshop, Paris, July 11, 2014
FLAMMABLE OPTIONS
Cyclo-Pentane
n-Pentane
Iso-Pentane
Methyl
Formate
Methylal
Chemical Formula
(CH2)5
CH3(CH2)3CH3
CH3CH(CH3)CHCH3
CH3(HCOO)
CH3 OCH2OCH3
Molecular Weight
70.1
72.1
72.1
60
76.1
Boiling Point (°C )
49.3
36
28
31.5
42
Foam properties
Good
Good
Good
Acceptable
Acceptable
1.4 - 8.0
1.4 - 8.0
1.4 - 7.6
5,0 – 2.0
2.2 – 19,9
<25*
<25*
<25*
"Negligible”
”Negligible”
Flammable Limits in
air (vol.%)
GWP (100 years)
Comments
Price (USD/kg)
High incremental capital cost (ICC)
2.0 – 4.0
MWQ, HFC Workshop, Paris, July 11, 2014
2.0 – 4.0
2.0 – 4.0
Polyol blend
could be non High ICC, high
flammable solvent power
Corrosion?
2–4
1.4 -1.7
NON FLAMMABLE OPTIONS
CO2 (water)
Formacel® 1100
SolsticeTM Liquid BA
ForaneTM 1233zd
1336mzz(Z)
1233zd(E)
1233zd(E)
Common name
Chemical Formula
CO2
Cis-CF3-CH=CH-CF3
Trans-ClCH=CH-CF3
Trans-ClCH=CH-CF3
Molecular weight
44
164
130.5
130.5
In situ reaction
33
19
19
Foam properties
Acceptable
Very good
Very good
Very good
GWP (100 years
1
2
1
<7
Boiling Point (°C )
Comments
Price (US$/kg)
High IOCs
MDI price: 2 - 4
MWQ, HFC Workshop, Paris, July 11, 2014
High IOCs, New in the market, Global availability
11.0 – 17.0
11.0 – 17.0
11.0 – 17.0
STRATEGIES TO PHASE OUT HCFC/HFCs
Large enterprises
• Hydrocarbons
 Default option in many cases…exception for spray
 Large foam production over which to spread investment (high ICC)
 Economic running costs (low IOC)
• Unsaturated HFC/HCFCs (HFOs)
 High thermal performance requirements
 Low ICC/ high IOC
• Blends with other substances: methyl formate, methylal?
Medium enterprises
•
•
•
•
Extend range of hydrocarbon use by capital cost reduction (pre-blended, third stream)
Unsaturated HFC/HCFCs… saturated HFCs as precursors?
Reduce IOCs with partial replacement by CO2(water)
HCOs for some market niches: integral skin, low insulating requirements
Micro/small enterprises
•
•
•
•
Optimised 100% CO2(water) formulations
Unsaturated HFC/HCFCs… saturated HFCs as precursors?
Reduce IOCs with partial replacement by CO2(water)
HCOs for some market niches: integral skin, low insulating requirements
MWQ, HFC Workshop, Paris, July 11, 2014
SUMMARY
• For PU foams there are available options with zero ODP and low GWP (< 25)
 Their implementation requires strong efforts on formulation development
• Crucial role of global and local System Houses
 Formulation knowledge…critical for local system houses
• The low threshold value for IOC (Decision 60/44) could be an obstacle for the
introduction of non flammable options at SMEs
• Some words on XPS foam
 Great market variation through out the regions
 Rapid growth in production capacity reported in the Asian region
 Saturated HFCs…a clear alternative in many regions unless low-GWP alternatives are
proven
 CO2, CO2 blended with DME or ethanol, Hydrocarbons (butane)
 HFOs (HFO-1234ze(E)) under evaluation….high thermal insulation performance
MWQ, HFC Workshop, Paris, July 11, 2014