Energ-ICE final activities

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Summary of the final activities
May 9th 2013
Coordinating Beneficiary: Dow Italia.
Associated Beneficiaries: Afros S.p.A.; Crios S.p.A.; Federchimica;
Dow Italia Divisione Commerciale SpA.
M C, Afros SpA.
GENERAL SUMMARY OF THE PROJECT
The proposal of the Life LIFE08 ENV/IT 000411 Project ENERG-ICE is to
use the vacuum technology to improve the thermal insulation of the
polyurethane foam used in the domestic refrigerators for structural bonding
and insulation.
The final purpose is to demonstrate and achieve an important reduction of
the specific energy consumption of the refrigerators produced with the
Vacuum technology and, as consequence, reduce the equivalent emissions
of CO2 in the global environment.
The technology set up with the project, to be effective, shall be technically
valid and widely diffused.
M C, Afros SpA.
GENERAL SUMMARY OF THE PROJECT
During the project we evidenced and demonstrated what in the premises:
The thermal insulation of the solid foams is related to the small size of the
single cells of foam.
The vacuum (a pressure quite lower than the standard atmosphere),
can help a faster expansion of the foams.
As faster is the expansion, as smaller are the average dimensions of the
single cells (bubbles) forming the foam.
M C, Afros SpA.
TARGETS AND ADVANTAGES ACHIEVED
The use of the Vacuum Aided Injection (VAI), assisted also by new systems
and ways developed during the project to improve the homogeneous
distribution of the foam, achieved the results scheduled in the project:
Sensitive improvement of the insulation (insulation class improvement)
Sensitive reduction of the de-moulding time (fast reacting foam)
Safer use of pentane as blowing agent (depression in the mould)
Good ratio cost/benefits in the use of the technology (retrofitted plants).
M C, Afros SpA.
EUROPEAN AND WORLD POLICIES INVOLVED
The aim of the Energ-ICE project was and is fitting with the policies to reduce
the energy consumption in the white appliances issued in the same period by
the European Union and many other countries in the world
In particular for the domestic refrigerators, being the first appliance to be used
in the developing countries and the one continuously in use in each home for
food preserving.
As a general note please consider that, comparing the power
consumption of a normal refrigerator of year 2008 (equivalent to about
110 -120 watt), today a similar but most recent refrigerator produced with
the VAI technology has a power consumption of about 20 –23 watt with a
reduction of the equivalent CO2 emissions of five times.
M C, Afros SpA.
SUMMARY OF THE ACTIVITIES
The activity started with prliminary
samples produced with a bret mould and
with an existing fixture in the Afros Lab
M C, Afros SpA.
SUMMARY OF THE
ACTIVITIES
The preliminary Lab tests
with the vacuum evidenced
immediately
Full filling of the refrigerators
Better homogeneity
Faster filling time
Enhanced RHL
Enhanced insulation
Good (short) term stability.
M C, Afros SpA.
PREPARATION OF THE PILOT PLANT
The PILOT PLANT had been the core of the project.
We started with the detailed
definition of the components, the
design of the fixtures, the metering
units and the mixing heads.
During he project we made also
significant variations and
modifications of the prototypes to
develop and launch new solutions
as well as new ideas on a better
use of the mixing heads and of the
injection technology.
M C, Afros SpA.
FINAL COMPOSITION OF THE PILOT PLANT
The ENERG-ICE pilot demonstration plant has been composed by:
1.
2.
3.
4.
5.
6.
7.
8.
A large single stage fixture suitable for the vacuum and for hosting
wide size refrigerators
A System 200 Penta Twin metering unit to control the polyurethane
preparation and injection
Various mixing heads necessary for tests and demonstrations.
A new Roto-Jig fixture for industrial demonstration
A premix unit for the preparation of the chemicals
A single mould carrier for the refrigerators doors
Specific instrumentation to measure and record the injection phases
and to validate the mix head geometry.
Retrofitting of a the first test fixture.
M C, Afros SpA.
NEW DEVELOPMENTS AND PATENTS
During the development of the project we learn and developed new
idea, applications and technologies:
New patent to improve the distribution of the foam inside the
refrigerator shell
Design and production of two new mixing head models with specific
features to perform high injection rates with low turbulence and
different flow rates.
Modification and setting of the vacuum application and of the fixtures
sealing
Developments and applications for applications of polyurethane in
other field of thermal insulation (panels, exhibitors, pipe in pipe)
M C, Afros SpA.
ENERG-ICE PILOT PLANT: DEDICATED AREA
A specific area dedicated
to the Energ-Ice project
was located inside the
Afros buildings close
to the Lab Area
FOTO
M C, Afros SpA.
ENERG-ICE PILOT PLANT SINGLE STAGE WIDE SIZE FIXTURE
M C, Afros SpA.
ENERG-ICE PILOT PLANT ROTO-JIG STATION
New fixture type for
industrial demonstration.
M C, Afros SpA.
ENERG-ICE PILOT PLANT VACUUM SYSTEM
The vacuum has a dedicated
system to automatically control
the depression into the fixture
M C, Afros SpA.
ENERG-ICE PILOT PLANT
MULTY EASY FROTH
PREMIX STATION
Flammable blowing agents
are premixed added with a
specific station
M C, Afros SpA.
ENERG-ICE PILOT PLANT A SYSTEM 200 PENTA TWIN
The machine has
been used as a
prototype to
promote also a
new control of
the metering
M C, Afros SpA.
ENERG-ICE PILOT PLANT: MIX HEADS FOR DEMONSTRATIONS
FPL24 HP,
FPL24HP
FPL 18 HP,
JL 24 ,
FPL 24 SR
JL 18
FPL 18 SR
Jet-Less 24
JL 32
New Type
FPL24 SR
New Type
M C, Afros SpA.
. ENERG-ICE: PROCESS AND PILOT PLANT OPTIMIZATION
Instrumentation to
monitor the mixing
performances
M C, Afros SpA.
ENERG-ICE PILOT PLANT:
TESTS OF THE NEW PATENTED JET LESS
JL 24 stroke 220
during testing
M C, Afros SpA.
ENERG-ICE PILOT PLANT:
ITEMS AND DEVELOPMENTS
Design and fabrication of the
new models of mixing heads for
tests and demonstrations
FPL 24 SR (special rod)
stroke 150
during testing
M C, Afros SpA.
ENERG-ICE: SAMPLE TESTING AND VALIDATION
Hundreds of tests
have been
performed
for setting
the foam,
the vacuum,
the injection rate,
the different mix
heads
M C, Afros SpA.
ENERG-ICE: SAMPLE TESTING OPTIMIZATION AND VALIDATION
Identification of the trials
M C, Afros SpA.
ENERG-ICE:
SAMPLE TESTING
OPTIMIZATION
AND VALIDATION
Checking of the quality
M C, Afros SpA.
ENERG-ICE PILOT PLANT: DISSEMINATION
Dow and the commercial organization of Cannon promoted the
vacuum assisted technology c/o the main refrigerators producers.
These campaigns got the
immediate attention of the
main producers that hurried in
sending refrigerators samples
for tests with the specific
foam prepared by Dow
FOTO
M C, Afros SpA.
ENERG-ICE PILOT PLANT: INDUSTRIAL DEMONSTRATION
Refrigerators producers
involved in demonstration tests
Haier
“
Samsung
Bosch Siemens
“
“
Whilrpool
“
“
“
Lucky Goldstar
“
“
Electrolux
“
Archelik
Italy
China
Korea
Germany
Turkey
Italy
Brasil
Poland
China
Korea
Poland
Italy
Hungary
Turkey
M C, Afros SpA.
ENERG-ICE: INDUSTRIAL DEMONSTRATION
Demonstration and validation of the vacuum assisted technology
The demonstration and
validation campaigns are
today following a well
tested scheduling,
involving from 30 to 50
cabinets.
Long preparation works
heve been necessary to
adapt the jig, the
ancillaries, the fixture and
the mix head holder
M C, Afros SpA.
ENERG-ICE: INDUSTRIAL DEMONSTRATION
Demonstration and validation of the vacuum assisted technology
M C, Afros SpA.
ENERG-ICE: INDUSTRIAL DEMONSTRATION
Additional campaigns to set up the
VAI for one or two models of
cabinets and demonstrate the
improvements
have been performed with:
•Bosch Siemens (Turkey)
•Vestel (Turkey)
•Whirlpool (Poland, China)
•Haier (China)
•Bosch Siemens (Germany)
M C, Afros SpA.
ENERG-ICE: TECHNICAL ACHIEVEMENTS of the
INDUSTRIAL DEMONSTRATIONS
Technical achievements scheduled (and performed) on the pilot plant:
•Industrial application of the sealing of the fixtures cells.
•Reinforced structures to withstand the atmospheric pressure.
•Application of special vacuum pumps and injection ports.
•Development of a special foam formulation
with very low cell size and stability.
•Development of a specific technology of
the foam injection
•Extension of the technology to other
applications for thermal insulation
•Development of a specific injection way
•Development of specific mixing system
M C, Afros SpA.
ENERG-ICE: ENERGY SAVINGS AND APPLICATION ADVANTAGES
ACHIEVED
•Sensitive improvement of the insulation (insulation class improvement)
•Sensitive reduction of the de-moulding time (fast reacting foam)
•Safer use of pentane as blowing agent (Zero ODP & very low GWP)
•Good ratio cost/benefits of the technology for new and also retrofitted
plants.
•The Energ-ice project stimulated the Dow competitors to develop similar
enhancements and foams
It begins to be applied on other fields for energy saving, different from
domestic refrigerators (e.g. dispalys, walking coolers, pipes, automotive)
The improvement of thermal insulation and energy saving will diffuse
much sooner and reach much more refrigerators producers than the
quantity achievable by Cannon and DOW
M C, Afros SpA.
ENERG-ICE: Testing and comparison of the technologies developed by
the DOW competitors
Many campaigns of comparison have been performed c/o the Energ-ICE station
The VAI technology acted as
a strong stimulus for the
development of chemicals
other than DOW able to
improve the insulation and
reduce the cell size of the
foam.
From the point of view of
the global energy saving
this stimulus can be
considered very
important, widely
diffused and not
reversible
M C, Afros SpA.
ENERG-ICE: ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Vacuum applied to the refrigerators doors
Campaign performed with Whirlpool
Italy and China to set up the VAI
technology to the high thickness
doors
The results have been very positive
and permitted to test also a new
system for the fast demoulding
M C, Afros SpA.
ENERG-ICE: LATEST ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Testing and demonstration of the vacuum applied to the insulation
panels for cooled buildings and walking coolers
A campaign has been scheduled
in the past 4 months to
demonstrate the application of
the ENERG-ICE foam and VAI
technology to the insulation
panels with metal facing.
A specific panel press has been
designed and suppplied to the
Dow Lab (out from the Energ-ICE
budget)
M C, Afros SpA.
ENERG-ICE: LATEST ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Testing and demonstration of the vacuum applied to the insulation panels for
cooled buildings and walking coolers
The press for panels has
been installed c/o the
Dow Lab, debugged and
tested with the
application of special
sealing and specific
ports for the mix head
injection with vacuum
M C, Afros SpA.
ENERG-ICE: LATEST ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Testing and
demonstration of the
vacuum applied to the
insulation panels for
cooled buildings and
walking coolers
Vacuum sealing plugs
M C, Afros SpA.
ENERG-ICE: LATEST ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Design, testing and demonstration of new model of mix head for the VAI
application
Design of the model
FPL 14 SR for the
VAI door injection
M C, Afros SpA.
ENERG-ICE: LATEST ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Design, testing and demonstration of new model of mix head for the VAI
application
Modifications to
the SR 24 mix
head for high
rate
performances
M C, Afros SpA.
ENERG-ICE: LATEST ACTIVITY TO DEMONSTRATE ADDITIONAL INDUSTRIAL
APPLICATIONS
Design, testing and demonstration of new model of mix head for the VAI
application
The new models of mix
heads FPL 26 SR–
FPL24 SR- FPL18 SR
have been tested and
are now used for the
demonstrations with
laminar flow at high
troughput
M C, Afros SpA.
ENERG-ICE PROJEC: CONCLUSIONS
As conclusion let’s summarize the results and achievements obtained from the
point of view of the energy savings.
The Vacuum Assisted Injection and Expansion evidenced to be very valid for
improving the domestic refrigerators insulation and reduce the de-molding
time.
Most of the main refrigerators producers, world wide diffused, got the
opportunity to test and verify the technology.
The applicants of the project Dow and Cannon are leaders and world wide
diffused.
The project stimulated the competitors to enter develop alternative ways to
obtain fine foam cells and improve their thermal insulation.
M C, Afros SpA.
ENERG-ICE PROJECT: CONCLUSIONS
The aim to reduce the energy consumption of the domestic refrigerators is today
involving all the world nations.
What developed and still in evolution
and will continue.
The intense and various use
of the pilot plant gave the
possibility to extend the
application to fields different
from the domestic
refrigerators but still devoted
to increase the energy
efficiency
M C, Afros SpA.
ENERG-ICE PROJEC: CONCLUSIONS
The VAI technology is already
applied by two main refrigerator
producers and it is promoted for
existing plants.
All these results are saving and
will save a huge amount of carbon
dioxide emissions
This is the main target and result
of the project.
The pilot plant will continue to be
the main testing device for
Cannon, Dow and their customers
M C, Afros SpA.
THANK YOU FOR YOUR ATTENTION
Italia
Italia Div.
Commerciale
M C, Afros SpA.