ODS/GHG Reduction: Options in Foams

February 2011

Honeywell.com

India: February 2011 2

Forces: commercializing new molecule(s)

Environmental regulation or restriction . . . . • EU F-Gas Directive: restricts the use of materials with GWP > 150 in

emissive applications– Restricts the use of HFC-134a in specific applications– EU one component foam industry regulation: 04 July 2008– EU novelty aerosol industry regulation: 04 July 2009

• Kyoto Protocol: Developed countries reduce GHG emissions 5% (1990)– EU reduce GHG emissions by 8% (1990 levels)– Japan striving to meet Kyoto commitments

• Industry concern with further GWP regulation• Taxation of raw materials basis GWP values

– Economic impact on finished goods

• Climate Change bills in U.S. Congress• Globally: reduction in ODS and climate change

Environmental regulation is now driving commercialization

Honeywell.com

India: February 2011 3

Fluorine Products – a History of Innovation

Innovation Tied to Environmental Compliance

CFCs

HCFC Phase-out

HFOs

1900s 1990s 2000s 2010s

CFC Phase-out

F-Gas Regulation

HCFCs HFCs

MONTREAL PROTOCOL EU LEGISLATION

Ozone Depletingand Very High Global

Warming Potential

Non-Ozone Depleting but has High Global Warming Potential

Low-Global-Warming Potentials and No Ozone

Depletion Effect

Markets Served: Mobile and Stationary Air conditioning, Refrigeration, Insulation Foam for Buildings and Electrical Appliances, Cleaning Solvents, Nuclear Power,

Aerosols, Heat Pumps, Geothermal and Solar Renewables

Honeywell.com

India: February 2011 4

Montreal Protocol calls for HCFC-141b phase out

• Montreal Protocol on Substances that Deplete the Ozone LayerBaseline average of 2009 and 2010 Freeze 2013Reductions: 10%m : 2015 > 35% :2020 > 67.5% : 2025 > 2.5% per year reduction 2030 to 2040Complete phase out 2040

• HCFC-141b has been phased out in United States, Japan and Europe– HCFC transitioned the industries to environmentally improved materials

• Global pressure may accelerate the phase out date in other countries– example: India and UAE, as well as others

• HFC’s are utilised where key needs demanded are:– insulation performance, and energy efficiency of finished products (refrigerators)– non-flammability property

• Hydrocarbons, and other non-HFC materials, while flammable, may be used:– where deficiencies in insulation performance and flammability can be tolerated– spray foam industry is particularly sensitive to flammability (application / equipment)

HCFC’s successfully phased out in many countries

Honeywell.com

India: February 2011 5

Blowing Agent Attributes

• Phase out of ozone depleting substances: ODS• Global warming potential: climate change impact reduction• Ground level smog formation: limited contribution • Low order of toxicity – safety in manufacturing use and finished products• Non-flammable – safety in manufacturing use• Insulation performance / energy efficiency: low lambda or k-factor• Processing and equipment implications

– Liquids: appliance (refrigerators); commercial refrigeration; spray foam; insulating panels– Gases: extruded polystyrene (thermoplastics); special applications

• Compatible with formulations and processing equipment materials– Low conversion cost: equipment investment and reformulation

• Economic valuation in use – translates into finished product economics• Commercially available on a global basis

Attributes support governments’ and industry’s preferences

Honeywell.com

India: February 2011 6

What is HFC 245fa?

Honeywell.com

India: February 2011 7

HBA-2: Liquid Low GWP Blowing AgentFluorochemical• Liquid blowing agent• Molecular weight: less than HFC-245fa

Environmental Properties• Low global warming potential: GWP100 = 7• Non-flammable: ASTM E-681• Volatile Organic Compound: very low MIR

Toxicity Screening• Preliminary stages: Results are very promising• Assessments completed:

– Cardiac Sensitization– Genetic Testing: Ames Assay & Mouse Micronucleus– Acute Inhalation (Rat)– Inhalation: 2 & 4 week – Unscheduled DNA Synthesis

Honeywell HBA-2 Blowing Agent promising low GWP molecule

0

500

0 75Temperature ( oC)

Vap

or P

ress

ure

(kP

a)

HBA-2

c-C5

HFC-245fa

0

500

0 75Temperature ( oC)

Vap

or P

ress

ure

(kP

a)

HBA-2

c-C5

HFC-245fa

Honeywell.com

India: February 2011 8

HFC-245fa & HBA-2 Insulation Applications

• Household refrigerators (appliances)

• Commercial refrigeration – food preservation

• Building construction (residential and commercial)

– Sprayed foams– Roofing and sheathing (board stock)– Panels (faced panels, sandwich panels)

Honeywell.com

India: February 2011 9

HFO-1234ze(E) Blowing Agent Hydrofluoroolefin (HFO)

trans – 1,3,3,3 – tetrafluoropropene • CHF = CHCF3 • Molecular Weight: 114 • Gas: TBP = -19 °C (- 3 °F)

Environmental Properties• Zero ozone depletion potential (ODP)• Low global warming potential: GWP100 = 6• Non-flammable: U.S. Department of Transportation

– “Non-flammable Compressed Gas”– No flame limits by ASTM E681– “Non-flammable”: EU Test Method A11

• Volatile Organic Compound Measure – Maximum Incremental Reactivity

• MIRHFO-1234zeE < MIREthane

Non-ODS / Low GWP / Non-Flammable / Low POCP = Environmentally Sustainable Molecule =

Vapor Pressure

0

200

400

600

800

1000

1200

1400

1600

0 10 20 30 40 50 60

Temperature (oC)P

ress

ure

(K

Pa)

HFC-134a HFO-1234zeE

Honeywell.com

India: February 2011 10

HFO-1234ze(E) Insulation Applications

• Extruded thermoplastics foams– Extruded polystyrene

• One component foams– Sealing around doors and windows

– Repairing damage

– Adhesives

• Two component ‘pressurized’ foams

Honeywell.com

India: February 2011 11

Transition Strategy: Timeframe Dependent

• HFC-245fa: Commercially available today – a transition solution– Widely utilised in NA. Specific applications: EU / Japan / China– HFC/HCFC-141b blend technology: ‘reduced cost’ transition option

• HBA-2: World-scale capacity target is mid-decade– Conversion to HFC-245fa ‘directly applicable’ to HBA-2

HFC-245fa: Low capital, medium term safe route to ODS management

HCFC-141b· Appliance· Panels· Spray Foam

HFC-245fa ‘Bridge’· ODS Reduction · Environmental Compliance· HCFC-141b Blends· Low Capital Investment· Non-Flammable

HBA-2· ODS Reduction· GWP = 7· Non-Flammable · Low Capital Investment

2010 20152011 2012 2013 2014

Honeywell.com

India: February 2011 12

Blowing Agent Energy Efficiency (Lambda)

• Lambda is the measure of heat transfer through a material in a given time and temperature • Lower lambda is better: significant energy efficiency driven by insulation characteristics • When compared to HCFC-141b insulation performance:

– HFC-245fa is equal to slightly better– HBA-2 has shown improvement over HFC-245fa– HFC-245fa/HCFC-141b blends should exhibit similar insulation performance

Transitioning: HCFC-141b HFC-245fa HBA-2 maintains energy efficiency

Blowing Agent Comparative PUR Lambda

20.019.6

18.2

17.0

18.0

19.0

20.0

21.0

HCFC-141b HFC-245fa HBA-2La

mb

da

: m

W/m

- oK

at

24

oC

Honeywell.com

India: February 2011 13

Sprayed Foam Comparison: HFC-245fa & HBA-2

HFC-245fa

HBA-2

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

4 9 14 19 24 29 34 39 44

Mean Temperature, °C

Ther

mal

Con

duct

ivity

(mW

/nK

)

HFC-245fa

HBA-2

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

4 14 24 34 44

Mean Temperature, °C

Th

erm

al

Co

nd

ucti

vit

y (

mW

/n K

)

Spray Foam Properties Physical Properties Low Water Content High Water Content Blowing Agent HFC-245fa HBA-2 HFC-245fa HBA-2 Density, kg/m3 (pcf) 32.2(2.01) 29.6 (1.85) 35.7 (2.26) 42.6 (2.66) Dimensional stability, vol % Hot (90 °C) 21.6 * 21.3 21.6 Hot Humid (70°C, 95RH) 15.6 * 14.9 18.4 Cold (-29 °C) 0.4 -0.7 -0.4 -0.3 Compressive Strength, kPa (psi ) @ 10%

Parallel 138-172 (20-25)

138-172 (20-25)

138-172 (20-25)

138-172 (20-25)

Perpendicular 90-110 (13-16)

90-110 (13-16)

90-110 (13-16)

90-110 (13-16)

% Closed Cell Content >90 >90 >90 >90

Low water formulation High water formulation

Honeywell.com

India: February 2011 14

Capital Investment: HFC versus non-HFC

Why are HFC-245fa and HBA-2 blowing agents low capital investment?• They are non-flammable none to limited capital requirement

– Low risk – technology, workplace safety, environmental

• HCFC-141b PUR equipment little to no equipment modifications required• Both are liquid blowing agents with moderate vapour pressure

– May require storage vessel up-grade low capital investment

• HFC-245fa conversion from HCFC-141b in US: Cost ≈ Minor

Why are Non-HFC (hydrocarbon & methyl formate) blowing agents challenging?• Generally flammable significant investment in flammability mitigation

– Blending operations; foaming equipment; storage vessels– Consequences of miss-operations inherent risk of fire / explosions

• Factory emissions probable ground level smog formation• Non-HFC PUR foams typically exhibit deficiency in insulation performance• Non-HFC conversion in US: Cost ≈ $500 K USD to $ 5 M+ USD

HBA-2 is a LOW capital investment, near ‘drop-in’ transition from HFC-245fa

(small asset) (refrigerator factory)

Honeywell.com

India: February 2011 15

Operational Cost: Implications

• HFC = lowest total cost path to high performance for regulatory compliance• Non-HFC solutions have inherent energy efficiency penalty

– Cost to restore energy efficiency: panels – low cost; refrigerators – high cost

• Non-HFC solutions exhibit deficiencies in density, dimensional stability, LTTR*

* LTTR: Long Term Thermal Resistance

Operational Cost: Energy Efficiency Recovery w/ non-HFC PUR

0

0.5

1

1.5

2

HFC non-HFC: Panels non-HFC: RefrigeratorsCo

st R

elat

ive

to H

CF

C-1

41b

PUR Cost Cost of Energy Efficiency Restoration: Panels & Refrigerators

Non-HFC PUR requires additional costs to achieve equal performance

Honeywell.com

India: February 2011 16

HFC Solutions Summary

• ODS and GWP reduction is imperative on a global basis• HFC solutions: thru HFC-245fa ‘bridge’ route . . .

– Provides a balanced, technology neutral / low capital investment pathway– Positions the industry for future HBA-2 adoption– HFC-245fa and HBA-2 do not contribute to ground level smog formation– Non-flammable: inherently safer utilisation in applications

• HFC’s allow for orderly industrial transition:– Frees up ODS rights under an ODS Cap– Accommodates industrial and economy growth

• HCFC-141b / HFC blends possible attractive solution– ODS reduction on an interim basis– Energy efficiency neutral with respect to operational costs– Economic valuation: low capital investment & raw materials cost reduction

Honeywell.com

India: February 2011 17

Blowing Agent Commercialization Status

• HFC-245fa– Registered for use globally– Commercially available globally – Commercial manufacturing site: 2002 in U.S.

• 1234ze(E)– U.S.: SNAP listed / PMN pending EPA approval– EU: Registered under REACH (article 24): 1000+ tonnes/year– Japan: Registration complete– Commercial capacity: 2008 in U.S.– Commercialized in EU and Japan

• HBA-2– Toxicity assessment underway: completion 1Q 2011– Global notifications/registrations

• U.S.: SNAP / PMN applications are in progress• EU: REACH inquiry stage• Japan: Filed for compliance with Japan Chemical Substances Control Law

Environmental solutions have/will meet regulatory needs timing

Honeywell.com

India: February 2011 18

www.honeywell.com

DISCLAIMERAlthough all statements and information contained herein are believed to be accurate and reliable, they are presented without guarantee or warranty of any kind, expressed or implied. Information provided herein does not relieve the user from the responsibility of carrying out its own tests and experiments, and the user assumes all risks and liability for use of the information and results obtained. Statements or suggestions concerning the use of materials and processes are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe on any patents. The user should not assume that all toxicity data and safety measures are indicated herein or that other measures may not be required.

Honeywell.com

India: February 2011

Specific Innovation Requiring Regulatory Approval

– Excellent Environmental / Physical / Economic Properties• GWP of 7• ODP < 0.0005• Non-flammable• Atmospheric Life < 50 days

– Tremendous Potential as HFC / HCFC Replacement• Low GWP Material Designed for “Traditional” Applications• Foam Blowing Agent: Insulation Performance 3-5% Better vs.HFC-245fa• Solvent: Exhibits Very Attractive Solvent Performance Properties• Refrigerant for Chillers: Applications Testing by Major OEMs

– Hurdle to Overcome: Lack of Environmental / Legal Certainty• ODP Lower Than Many Non-regulated Chlorinated Solvents

– Methylene Chloride: ODP: 0.0047 Atmospheric Life: ~ 180 days– Perchloroethylene: ODP: 0.006 Atmospheric Life: ~ 110 days

• Very Low POCP

• Compatibility (Plastics and Most Elastomers)

• Similar Economics to Current HFC

No Certainty in Status Quo – Threshold Value Needed