Insulation industry news from Global Insulation

EU: The European Union (EU) is holding a consultation over possible changes to the limit on the use of hexabromocyclododecane, a brominated flame retardant (BFR) in consumer products. This includes expanded polystyrene (EPS) and extruded polystyrene (XPS) insulation. The consultation will run until 26 December 2023.

US: Israel Chemicals Limited (ICL) is preparing a new flame retardant for use in rigid polyurethane foams. Executives at ICL made the announcement at the Polyurethanes Technical Conference in New Orleans, according to ICIS. VeriQuel R100 is a non-halogenated reactive flame retardant intended to replace tris (chloroisopropyl) phosphate (TCPP) in case of any changes to existing government regulations. The new product will be targeted at building and construction applications.

Netherlands/Israel: ICL has completed ramping up its compaction capabilities and is now producing a range of its sustainable polymeric flame retardant at full capacity, to 12,000Mt/yr, at its Industrial Products (IP) plants in Israel and the Netherlands. The flame retardant, which is marketed by ICL IP under the brand name FR-122P, is an alternative for customers transitioning from hexabromocyclododecane (HBCD)-based flame retardants currently used by the building industry in extruded polystyrene (XPS) and expanded polystyrene (EPS) foam insulation products.

FR-122P is now available from both plants in three grades of products: powder material, EPS compacted grade and XPS compacted grade using ICL IP’s in-house compaction technology. FR-122P is manufactured by ICL IP using technology licensed from Dow Global Technologies LLC, a subsidiary of The Dow Chemical Company.

US: Albemarle Corporation, a flame retardant manufacturer, and ICL, a specialty chemical company, have announced that they have entered into a long-term agreement for the supply of a polymeric flame retardant. The product is manufactured at ICL's facilities in the Netherlands and in Israel using technology licensed from Dow Global Technologies LLC, a subsidiary of The Dow Chemical Company.

This next generation flame retardant, which is marketed by Albemarle under the brand name GreenCrest and by ICL under the brand name FR122P, is a sustainable alternative for customers transitioning from hexabromocyclododecane (HBCD)-based flame retardants currently used by the building industry in extruded polystyrene (XPS) and expanded polystyrene (EPS) foam insulation products. Albemarle will supply ICL with bromine for the production of GreenCrest, associated with the agreement. The agreement is subject to certain conditions precedent, including approval of Israel's Antitrust Authority.

Albemarle and ICL will continue to provide independent marketing, sales and technical service to their respective customers in Europe and around the world to ensure a transition as EPS and XPS producers continue to shift from HBCD to the polymeric flame retardants.

China: BASF has adopted a polymeric flame retardant for Neopor in China. It has replaced the flame retardant hexabromo­cyclododecane (HBCD) with PolyFR in its white expandable polystyrene insulation product.

“There is a greater need than ever for energy efficiency in the commercial and residential construction sectors, and EPS insulation materials like Neopor have the right properties to serve this need. Additionally, with the switch to PolyFR, we are now ensuring that the thermal insulation products are suitable for a wide range of sustainable building projects in the future. These high-quality materials can help developers address the increasing market requirements for energy efficient living and working spaces while ensuring regulatory compliance,” said Giorgio Greening, Senior Vice President of BASF’s global styrene foams business unit.

PolyFR is already used as an effective flame retardant in BASF’s portfolio of polystyrene-based insulation materials worldwide, including the Neopor range used in Europe, North America and China. As the first manufacturer in Europe and the first in Korea to switch entirely to PolyFR, BASF is now the first to do so in China.

US: Following earlier action by the EU, the US Environmental Protection Agency (EPA) is planning to publish guidelines on safer alternatives to the flame retardants that are currently used in consumer and commercial products, including building insulation and products with flexible polyurethane foam.

Flame retardant chemicals such as hexabromocyclododecane (HBCD) and pentabromodiphenyl ether (pentaBDE) raise concerns for human health and the environment, including potential reproductive, developmental and neurological effects that can be persistent, bioaccumulative and toxic to aquatic organisms.

The EPA has identified butadiene styrene brominated copolymer as a safer alternative to HBCD used in polystyrene building insulation. The substitute is currently in commercial production in the US. Additionally, oligomeric phosphonate polyol has been proposed as a safer alternative to pentaBDE.

The European Chemicals Agency (ECHA) is due to decide on 9 July 2014 whether exemptions can be granted to manufacturers of expanded polystyrene (EPS) to continue using HBCD as a flame retardant beyond the August 2015 phase-out deadline. Most international players are switching to the new non-halogen flame polymeric retardant PolyFR.

Japan: Sekisui Chemical's High Performance Plastics Company has acquired the Ministry of Land, Infrastructure, Transport and Tourism approval for a new type of flame retardant for polyurethane. Clearance was granted in September 2013 and now Sekisui Chemical has formally made the announcement as it launches the product.

Under internal testing the new product has passed the 5V-A standard, the most stringent of UL94(3) flame-retardant standards and it meets US flammability standards. When subjected to heat the fire retardant in the new material reacts with oxygen to create layers of charcoal, preventing fires from spreading. Similar to conventional urethane in weight and light stability, it can be shaped into any form.

The new product has a maximum density of 65kh/m³, a minimum compressive strength of 30N/cm², a maximum heat conductivity of 0.031W/m•k and a maximum water absorption of 1.1g/100cm². The company aims for annual domestic sales of US$98m by 2020.

US: Californian governor Jerry Brown has signed into law bill AB 127 that directs the California State Fire Marshal to consider fire safety without the use of toxic flame retardant chemicals, now commonly used in building insulation. The bill does not ban the use of chemicals such as a Hexabromocyclododecane (HBCD) but it does encourage a reduction in their use.

The Californian State Fire Marshal, in consultation with the Bureau of Electronic and Appliance Repair, Home Furnishings and Thermal Insulation will review the flammability standards for building insulation materials. The State Fire Marshal may propose, by 1 July 2015, for consideration by the State Energy Resources Conservation and Development Commission, updated insulation flammability standards whose objectives include maintaining overall building fire safety.

US: A proposed Californian state legal bill threatens to phase out potentially toxic flame-retardants in foam insulation. The chemical industry has opposed the bill arguing that the move jeopardises energy-efficiency measures and doesn't take into account forthcoming legislation.

The sponsor of the bill, the US Green Building Council of California, said in a supporting letter that the bill is necessary because the adverse effects on health by halogenated organic compounds in flame-retardants are well documented.

However, the American Chemistry Council (ACC) has stated that the bill will unnecessarily circumvent the Department of Toxic Substances Control's forthcoming green chemistry regulations, which will identify potentially problematic chemicals in consumer products. The ACC added that, "Since buildings account for an estimated 36% of total energy use and 30% of greenhouse gas emissions in the United States, California should be encouraging, not discouraging, the use of energy-saving building materials."

The bill is scheduled to be heard by the Assembly Natural Resources Committee on 29 April 2013.

US: With the housing market bottoming out and showing signs of recovery, demand for flame retardants will also begin to improve, according to a report from Global Information Inc.

It says that demand for flame retardants in the US is expected to grow by 4.6%/yr year to reach around US$1.5bn in 2016, a significant rebound as the industry benefits from an improving economy and a turnaround in key markets.

Global Information says that construction-related applications of flame-retardants will provide the biggest impetus to growth and continue to account for the greatest share of sales in the market for flame retardants. Boron and phosphorus-based flame retardants will expand at the fastest rates. Brominated compounds will benefit from use in polystyrene and polyurethane insulation.