Conversion demo in the manufacture of rigid polyurethane

Low-GWP Alternative for Small Rigid PU Foam
Enterprises
Conversion Demonstration from HCFC-141b-based to
Cyclopentane-based Pre-blended Polyol in the Manufacture of
Rigid Polyurethane Foam (CPR/FOAM/59/DEM/491)
Feng Hui
Foreign Economic Cooperation Office, China
Viraj Vithoontien
Environment and Natural Resources Global Practice
Background
 The demonstration project was approved by the
Executive Committee at its 59th Meeting;
 Project entails establishment of capacity at the foam
system house to produce polyol pre-blended with
cyclopentane, and applications of cyclopentane preblended polyol at four downstream foam enterprises;
 Project was implemented into two phases. Phase I
covered establishment of production capacity at foam
system house and conversion at one downstream foam
enterprise. Phase II expanded to four downstream foam
enterprises.
Project Implementation
Discontinuous
Sandwich Panels
Zhanjiang
Aowei
Guangdong
Vanward
Commercial Refrigerators
Foshan Ouqi
Electric Water Heaters
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Wanhua
Rongwei
Polyurethane
Development and
Production of HC
Pre-blended Polyol
Zhongshan
Minea Electric
Appliances
Wine Cabinets and Small Fridges
Development and Production of
HC Pre-blended Polyol
 Safety Assessment;
 Stability of Cyclopentane Pre-blended Polyols;
 Flammability Testing;
 Storage;
 Conversion of Cyclopentane Preblending Facility;
 Transportation Requirements;
 Conversion of Foam Workshops Using Cyclopentane Preblended Polyols
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Safety Assessment
 Assessment conducted by Nanjing Forest University;
 Stability of cyclopentane pre-blended polyols;
 Flammability;
 Transportation;
 Chinese guidelines for foam manufacturers using of
cyclopentane pre-blended polyols;
 Set up of foam producer facility converting to hydrocarbon
pre-blended polyols;
 Stability of production; and
 Quality of foam produced.
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Stability of Cyclopentane Pre-blended Polyol
 Stability of cyclopentane in the polyols is essential for
maintaining the contents of cyclopentane within the polyols
and the quality of final foam products;
 16 formulations for cyclopentane provided by 6 Chinese
polyol suppliers;
 Samples with two different contents of cyclopentane:
100:13 and 100:15 (mass ratio) stored for 48 hours and at
temperature ranging from -5oc to 25oC, tested for stability
and separation (stratification);
 Conclusion: Most samples demonstrated good stability.
Only a few samples showed stratification at low
temperature;
 Findings consistent with previous study conducted by
Huntsman.
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Flammability Testing
 Products with flash point below 45oC are classified as
flammable;
 Flash point is determined as the temperature of product
at which vapor released is instantly ignited by a flame.
(Different test methods provide different results);
 Flash point was tested by two methods (open method:
GB/T3536-2008) and closed method (GB/T5208-2008)
for formulation ranging from 100:5 to 100:15 (mass
ratios);
 Conclusion: Formulations with mass ratios of 100:13 and
higher are found flammable by the open flash point
method. Formulations with all mass ratios are found
flammable by the closed flash point method.
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Storage
 Vapor pressure determines the requirements of storage
of flammable materials;
 Vapor pressure was determined for 100:15 formulation
at temperature ranging from 30oC – 60oC;
 Vapor pressure was determined through the test
method: GB/T 21616-2008: Dangerous Goods Test
Method for Vapor Pressure of Flammable Materials;
 Conclusions:
 Highest vapor pressure was 100.18 kPa (i.e., tanks and
drums must withstand pressure of at least 200 kPa); and
 Proposed minimum thickness of steel tanks and drums of
1.22 mm.
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Conversion of Cyclopentane Preblending Facility at System House
 New Equipment Needed:
 Cyclopentane storage tank and pump;
 Tanks and pumps for dry polyols;
 Cyclopentane and polyol pre-mixing unit;
 Tank and pumps for cyclopentane pre-blended polyols;
 Filling equipment for cyclopentane pre-blended polyols;
 Safety Measures:
 Electrical installation consistent with Chinese area classifications:
Chinese Class A Workshop;
 Gas detectors and control panel;
 Standby diesel generator;
 Fire prevention and fire extinguishers;
 Ventilation;
 Safety requirements for cyclopentane storage tank and piping;
 Separate different areas of the factory.
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Conversion Costs of System
House
Equipment
Actual Cost
(US$)
Pre-mix machine and
supporting equipment
120,000
154,000
CP storage and pump
50,000
59,500
Auto packaging unit
40,000
32,077
120,000
146,493
Trial
10,000
10,000
Training
10,000
10,000
Contingency
35,000
Safety equipment
Total
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Approved
Cost (US$)
385,000
412,070
Transportation Requirements
 Formulated polyols pre-blended with
cyclopentane is classified as Grade II
flammable liquid;
 Personnel in charge must pass an
examination of transportation authorities;
 Vehicles, loading and off-loading equipment
must meet the requirements for
transportation of Dangerous Goods;
 Limitations on transporting other chemicals
with flammable liquids.
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Conversion of Foam Workshops
Using Cyclopentane Pre-blended
Polyols
 Storage of pre-blended polyols in a separate room designed
for storage of flammable liquid;
 Foaming area: Safety requirements based on the specific
situations;
 Standard safety measures:
 Electrical installations meeting Chinese requirements for Grade
II flammable liquid;
 Ventilation;
 Gas detectors and control panel;
 Back-up power supply;
 Nitrogen for blanketing;
 Piping from drums in the storage area to foaming equipment;
 Cost depending on actual situations.
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Cost Indications for Foam Manufactures
Using Cyclopentane (US$’000s)
Equipment Item
HC with
Storage
tank & Premixer
HC with
Pre-mixer
(HC
supplied in
drums)
HC supplied
in preblended
polyols
30 – 50
0
0
Pre-mixer tank including static
mixer
120 – 150
80 – 90
0
Formulated polyol storage tank
and pump, day tank
20 – 30
20 -30
25 - 30
100 –
120**
30 – 50
30 - 50
120 - 150
80 – 100
80 - 100
30
20 – 30
20 - 30
420 – 530
300 – 370
245 - 280
Cyclopentane storage tank, pumps
and piping
Retrofit of foam* dispensers (per
unit)
Safety equipment
Trials, Tech Assistance, training &
safety audit
Total
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*Cost could be lower if supplied by local engineering companies.
** Assuming two foaming units
Cost Indications for Foam Manufactures
Using Cyclopentane (US$’000s)
Equipment Item
HC with
Storage
tank & Premixer
HC with
Pre-mixer
(HC
supplied in
drums)
HC supplied
in preblended
polyols
Range
420 – 530
300 – 370
245 - 280
475
335
263
47
33.5
26.3
522
368.5
289.3
Mid point
Contingency (10%)
Total
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Incremental Operating Costs
Approved
Polyol (w/o blowing agent)
HCFC-141b
Cyclo-Pentane
MDI
Foam Usage
Foam Price ($/unit)
Actual
Polyol (w/o blowing agent)
HCFC-141b
Cyclo-Pentane
MDI
Foam Usage
Foam Price ($/unit)
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Unit Price ($/kg)
1.94
1.4
1.91
2.35
Unit Price ($/kg)
2.69
2.48
2.48
2.89
HCFC-141b
Formulation
Cyclo-Pentane
Formulation
100.00%
25.00%
100.00%
132.50%
1
2.10
13.00%
135.60%
1.04
2.25
HCFC-141b
Formulation
Cyclo-Pentane
Formulation
100.00%
25.00%
100.00%
150.00%
1
2.78
20.50%
144.60%
1.09
3.03
Conclusions
 Stability – Cyclo-pentane pre-blended polyol
demonstrates good stability;
 Flammability – Formulations (polyol:blowing agent) with
mass ratios of 100:13 and higher are found flammable
by the open flash point method;
 Storage – Minimum thickness of steel drums should be
1.22 mm;
 Conversion cost at system house - $410,000; and
 Conversion cost at foam enterprises using cyclopentane
pre-blended polyol is about $250,000 - $300,000.
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Thank you
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