Montreal, 06.04.2008

Experiences and potentials in replacing rigid foam manufacturingequipment in Article 5 countries

Dipl. Ing., MBA Jens Kompe Dipl. Ing. Rolf BohländerKraussMaffei Technologies GmbH Hennecke GmbHExport Manager Reaction Technology Project Manager Refrigerated Appliances

Process requirement Pentane driven PUR-systems

Pentane

Polyol

Isocyanate

25 °C

25 °C

25 °C

N2 N2

Exhausting system

open closedmould operation

Storage facilities Pre-mixing Work tanks Mixhead and operation station

Metering machine

Process requirement 245fa driven PUR-systems

Polyol

Isocyanate

12 °C

12 °C

245fa

12 °C

open closedmould operation

Pre-mixing Work tanks Metering machine Mixhead and operation station

Storage facilities

Insulated piping system

pressure work tank

Modified sealing materials

Foam distribution Pentane and 245fa driven PUR-systemCabinet production process

Pentane driven PUR-systemstandard conditions

Fluid pouring process

245fa driven PUR-systemwithout optimized temperature control

Frothed pouring process

Foam distribution Pentane and 245fa driven PUR-systemPipe insulation process

Pentane driven PUR-systemstandard conditions

pipe length up to 16.000 mm

Fluid pouring process

245fa driven PUR-systemwithout optimized temperature control

pipe length up to 16.000 mm

Frothed pouring process

Current physical blowing agents

CO2

HCFC 22

HFC134a

HCFC 141b

Preis(€/kg)

2

4

6

8

10

0,2

ODPOzoneDepletionPotential

GWPGlobal

WarmingPotential

0

0,05

0,10,2

0,05

0,1

0,30,4

0,30,4

0,5

0,6

0,70,8

0,91,0

0,50,6

0,7

0,80,9

1,0

Aceton

Methylen-chlorid

HFC365mfc

HFC245fa

HFC 152a

HCFC142b

CFC 11

C-Pentan

Important when using pentane

• Pentane will form, together with air, an explosive mixture (Between 1,7 to 7 Vol-% pentane in the air)

• Poly- Pentane mixture is a liquid categorized as an A1 hazard (similar to petrol)

• Safety measures have to be taken when processing pentane

Basic principle :Avoiding the formation of a flammable, explosive mixture of pentane and air

V o lu m e p e rc e n t P e n ta n e in a ir

M ix tu re to o c o n c e n tra te d - n o t e x p lo s iv e

O E GU E L (U p p e r E x p lo s io n L im it )

4 0 % o f L E L : p la n t s h u td o w n

M ix tu re to o le a n - n o t e x p lo s iv e

2 0 % o f L E L : a u d ib le v is u a l w a rn in g

%

7 ,0

0 ,5 6

0 ,2 8

0

Sens

or m

aesu

ring

rang

e

1 ,4

H a z a rd o u s a re a , e x p lo s io n h a z a rd

U E G 1 0 0 %L E L 1 0 0 % (L o w e r E x p lo s io n L im it)

Primary Explosion Proofing is achieved bymonitored air changinggas warning systemneutralization of daytanks and moulds with inert nitrogenequipotential bonding (earthing)

Primary Explosion Proofing is essential!

Secondary Explosion Proofing is achieved byAvoidance of ignition sourcesUse of explosion proofed parts with certification according to ATEX

Design of a pentane metering plant

A plant for processing pentane as a blowing agent for PUR-systems consists of the following components :

• Pentane storage• Polyol storage• Premixing unit for the mixing of polyol and pentane • Metering unit for the high-pressure metering and mixing of the

polyol-pentane blend and isocyanate (assuming LP machines will not be used for pentane)

• Working and foaming area

Pentane supplies via hazardous Goods Container

• Interchangeable vessels (100 - 1000 l)• Refilling from standard 200l Pentane drums•• Expansion tank with level control• Storage outside of the plant• System approved by German TÜV and used since more than 10 years

Premixing station for meteringpentane into polyol

• Enclosure incl. doors, leakage pan and ventilation duct

• Metering units, consisting of high pressure pumps for polyol and pentane

• Static mixer

Realized Projects: Technical aspects defining costs

• Part information• PU-System data• Information of the plant location• Information dry and wet side• Information foaming stations• Raw material supply• Requirements human resources, civil work• Minimum scope of supply machine manufactures

Example: New Line for District Heating Pipes in Latvia, 2005

KraussMaffei’s delivery: 260.000 €• Pentane Tapping System• Premixing Unit 40 l/min• Metering Machine 300 kg/min• Safety Equipment incl.

Nitrogen Inerting• Installation/Commissioning/

Training

Customers delivery:• Exhaust System: 20.000 €• Grounding: 3.000 €• Civil Construction: 0 € No Housing of plant necessary

Example: Retrofit of Line for District Heating Pipes in Romania, 2007KraussMaffei’s delivery: 150.000 €• Pentane Tapping System• Premixing Unit 40 l/min• Retrofit of Metering Machine 150 kg/min, consisting of:

• Stirrer for day tank with Magnetic Coupling• Magnetic Coupling for Metering Pump• Ex-Proof pressure switches

• Safety Equipment incl. Nitrogen Inertisation• Installation/Commissioning/Training

Customers delivery:• Exhaust System: 10.000 €• Grounding: 5.000 €• Civil Construction: 5.000 € No Housing of plant necessary

Example: New Foaming Line for Production of Refrigerator Cabinets and Doors in Vietnam, 2007KraussMaffei’s delivery: 650.000 €• Pentane Tapping System• Premixing Unit 40 l/min incl. 2 x 1.000 ltr. Buffer tanks• 2 Metering Machines 40 kg/min for foaming of cabinets• 1 Metering Machine 30 kg/min for foaming of doors • Safety Equipment incl. Nitrogen Inertisation• Exhaust System (excluding ducts)• Installation/Commissioning/Training

Customers delivery:• Exhaust System: 30.000 €• Grounding: 8.000 €• Civil Construction: 0 € Installation in existing building

Example: Retrofit of Refrigerator Line in Chile, 2007

KraussMaffei’s delivery: 320.000 €• Pentane Underground Storage System• Premixing Unit 40 l/min• Retrofit of Metering Machine 80 kg/min with 6 Mixing Heads• Safety Equipment incl. Nitrogen Inertisation• Installation/Commissioning/Training• Exhaust System

Customers delivery:• Civil Construction: 20.000 €

In Total more than 100 Pentane References of KraussMaffei all over the world

Example: New line for the production of household doors, Iran, dd. 2005

Hennecke’s delivery: 260.000 €• Pentane storage system (400 l)• Premixing unit Pentamat 30• Metering machine 1300 g/s• Pentane safety system• Exhausting fansCustomers delivery:• Exhausting ducts: 15.000 €• Piping works: 3.000 €• Grounding, interface

to PPT-safety system: 5.000 ۥ Nitrogen (gas cylinder)No Housing of plant necessaryNo Electricity Backup necessary

Example: New line for pipe fittings (insulation), Germany, dd. 2006

Hennecke’s delivery: 230.000 €• Premixing unit Pentamat 30• Metering machine 1300 g/s• Safety system incl. Pentane

sensors and monitoring• Exhausting fans• Inertisation systemCustomers delivery:• Storage (container): 20.000 €• Grounding, interface

to PPT-safety system: 15.000 €• Exhausting ducts: 12.000 €• Nitrogen generator: 22.000 €No Housing of plant necessaryNo Electricity Backup necessary

Example: Pentane conversion of a production line for pipe insulation, Ukraine, dd. 2007

Hennecke’s delivery: 400.000 €• Retrofitting of 2 metering

machines, each 300 kg/h,with totally 8 foaming stations

• Premixing unit Pentamat 30• Pentane safety system incl.

Pentane sensors and monitoring• Pentane supply by drumsCustomers delivery:• Exhausting system: 15.000 €• Grounding, interface

to PPT-safety system: 15.000 €• Nitrogen generator: 22.000 €No Housing of plant necessaryNo Electricity Backup necessary

In Total more than 250 Pentane References of Hennecke all over the world

• 245fa harmful to the climate (according to Swiss “Federal Office for the Environment FOEN” 800 - 1000 more harmful than CO2)

• 245fa already forbidden in countries like Sweden• Combustion of 245fa creates toxicological substances• Handling of 245fa not as easy as oftenly assumed• λ-value of 245fa almost similar with Pentane• 245fa much more expensive• Out of NAFTA region 245fa only used at customers with very small consumption• Simple Pentane Storage Equipment available and proven• Oftenly (depending on the design of the exhausting system) no housing

necessary• Pentane technology accepted and implemented worldwide since 1993• Retrofit of Low Pressure machines to Pentane not efficient • Costs for retrofit of High Pressure machines depending on local situation

Resumee

Thank you for listening.