XPS INDUSTRYMena Region

Alternatives currently offered to the XPS industry, compromises on physical properties, cost constraints on process development.

A.K Chotani

Information provided in this Presentation is based upon our best knowledge gained through various publications and own experience:

Producing XPS Foams Since:

1981 in Kuwait

1996 in South Africa

Operating atmospheric and HydroVac process lines

Produced and sold 400,000 m3/yearly

Information provided is without any prejudice to any manufacturer who may support different views.

Current and Future BA Approaches

Region Specific

Europe:CO2/ethanol with HC or HFC or DME as CO-BA- doesn’t meet -R5.

Japan: HC (n-butane or iso-pentane) < R5.

North America: HFC with CO2 as CO-BA plus additives

meet - R5.

MENA :HCFC and HFC meets - R5

HC doesn’t meet - R5.

Compelling Issues for Replacement

BA KEY ISSUES REMARKS

CFC s ODP Successfully Replaced

HCFCs(Blends)142B+22

ODP Under phase out

HFCs(Blends)134a 152a

GWP Under phase outZero ODP

HCS FlammabilitySafety Concerns

AcceptableLow GWP

Co2 +Co BAEthanol,DME

ProcessablityFlammability

AcceptableLow GWP

HFO s+Co BA1234ze,DME

Cost Concerns AcceptableLow GWP

Summary of CO2 TechnologyCurrent Situation:

CO2 based foam products has been in the market for around 10 yrs.

Products include 1200mm or 600mm in width, and up to 120mm in thickness.

(A few Manufacturer have succeeded to make higher thicknesses)

CO2 is always used with CO-BA, e.g. with ethanol, DME.Current Problem:

15 to 20% reduction in insulation R-value: 4 to 4.2 vs. 5

10 to 20% density penalty: 2.2 to 2.4 vs. 2 pcf.Difficult to make thick (>50mm) products – need using such as high

MI resin, BA with HCs or Moderate HFC.

Compromises on Physical Properties

Properties HCFC/HFC HC/CO2+COBA

Thermal Conductivity(EN 12 667/13164)

Annex c

.029-.032 w/mk 0.036-.041 w/mk

Water Absorption(After diffusion)

EN 12088

0.3% by volume 3 – 5 % by Volume

Dimensional StabilityEN 1604

< 2 % <5%

Compression StrengthEN 826

175 -700 KPA 150 – 700 KPA

These values doesn’t refer to any particular manufacturer.

High Performance Products Two Manufacturers have introduced their XPS products giving 20% better

thermal Performance using CO2 technology than their conventional products

produced with same technology.

They achieved this by adding special additives(Infrared blockers),whose

finely-dispersed particles reflect radiant heat thus reducing heat loss.

These are patent technologies and manufacturers are not known for offering

Licencee agreements or franchise.

The probability to acquire this Knowledge/Technology is nonexistent.

Cost Constraints on Process Development

A few manufacturer are backed by technology Partners. Big Groups have their own R&D which supports innovation &advancement.

Small Manufacturer have limited resources and their access to information and experience is very limited.

Most of the small manufacturer in MENA Region have process lines not backed by

Technology Assistance and not supplied by renowned Manufacturers.

Small Manufacturers will go for use of HCs which are Low Capital intensive.

Established companies have chosen the route of CO2 technology.

Currently use of HFOs is not pursued because of its high cost and availability

concerns.

Dilema faced by MENA REGION

There is no unified approach on the selection and use of LOW GWP BA.

The reasons are attributed to dissimilar application requirements, different

building codes and standards followed by different regions.

MENA region follows ASTM standards for the specification of XPS thermal

insulation boards since 1983 when its first Energy Conservation Code was

established in the Gulf region.

North American market follows ASTM C-578-14 which specifies requirement

of R-5.Use of HFC is currently prevalent with CO2 plus additives.

Use of the CO2 technology employed would produce a product that

doesn’t meet R-5.

Current Specification in Gulf region asks for Zero ODP and <5 GWP

Product, physical properties expected as per ASTM C-578-14.

In absence of clear building Codes and regulation in MENA region

based on Low GWP BA,manufactures are at risk to be neither

competitive nor economically feasible. They will have to bear penalty

due to higher Lamda and higher density and will be under pressure to

sustain business.

Thank You