Insulation industry news from Global Insulation

Germany: BASF is developing a pilot project to make insulation panels from plastics waste as part of its ChemCycling project. The company is making ethylene and propylene from the waste to use as raw material for further chemical manufacturing. Other projects the company is testing using waste plastics with include mozzarella packaging and refrigerator components.

“With our ChemCycling project, we are using plastic waste as a resource. In this way, we create value for the environment, society and the economy. We have joined forces with partners throughout the value chain to establish a working circular model,” said Martin Brudermüller, chairman of the board of executive directors and chief technology officer of BASF.

BASF feeds oil derived from plastic waste by an oiling process into the Production Verbund process. BASF gets this feedstock for the pilot products from Recenso in Germany. As an alternative, syngas made from plastic waste can also be used. The first batch of this oil was fed into the steam cracker at BASF’s site in Ludwigshafen in October 2018. The steam cracker is the starting point for Verbund production. It breaks down or ‘cracks’ this raw material at temperatures of around 850°C. The primary outputs of the process are ethylene and propylene. Under the mass balance approach, the share of recycled raw material can be mathematically allocated to the final certified product. Each customer can select the allocated percentage of recycled material.

BASF is working with its customers and partners, which range from waste management companies to technology providers and packaging producers, to build a circular value chain. Its next step is to make the first products from the ChemCycling project commercially available. However, technological and regulatory conditions need to be met on a regional basis before the project is market-ready.

UK: SIG has forecast in a trading update that its sales revenue will fall by 2.3% year-on-year in 2018. It described the UK trading environment as increasingly ‘challenging’ in the second half of 2018 with commercial demand reduced by economic uncertainty, slower house price inflation and falling secondary housing market transactions. Conditions in France and Germany were also reported as slowing down in the second half.

Germany: Evonik’s Calostat insulation product has received an environmental product declaration (EPD) from the Institut für Bauen und Umwelt (IBU). The EPD takes into account the entire production process, from manufacture of precursors, their transport, production of Calostat and the option of recycling the material.

Calostat is a non-combustible thermal insulation material based on silicon dioxide.

It is a class A (non-combustible) building material with a thermal conductivity λ of 0.019 W/(mK). It does not absorb liquid water but is permeable to water vapour. Other distinguishing features are its compressive strength of ≥ 90 kPa and gross density of 165kg/m³. It contains no fungicides, algicides, pesticides, binding agents, or flame-retardants. Notably, the manufacturer also says that the product can be recycled.

UK: SIG’s revenue has fallen in the three months to October 2018 due to a weakening construction market in the UK. Its revenue in the UK and Ireland fell by 8.7% year-on-year. It said that commercial construction demand had remained dampened by macro-economic uncertainty, house price inflation was slowing and secondary housing market transactions had continued to fall. Its sales in Europe were mixed with quarterly declines in France and Germany but strong gains in Poland, the Benelux region and in its Air Handling business.

US: Germany’s Covestro plans to spend Euro1.5bn on building a new methylene diphenyl diisocyanate (MDI) plant at Baytown in Texas. The new plant will have a production capacity of 0.5Mt/yr and production is expected to start in 2024. The investment at the existing site in Baytown is the largest single investment in the history of the company. It will replace the 90,000t/yr MDI unit at the site.

“Demand for innovative MDI materials will continue to grow for the foreseeable future and likewise promises attractive capacity utilisation rates. We have already announced a significant increase in capital expenditures, now it’s time to put it into action”, said Markus Steilemann, chief executive officer (CEO) of Covestro. He added that the investment would strengthen the company’s ‘leading position’ in polyurethanes.

Covestro is also running a global investment programme in MDI production capacity, including plans to double its MDI production at Brunsbuettel, Germany to 0.4Mt/yr from 0.2Mt/yr by the second half of 2019. Other parts of this initiative include the continuation and expansion of plants in Tarragona in Spain, Caojing in China and Antwerp in Belgium.

Germany: Dennert Poraver has developed an insulating render formulation by using Poraver expanded glass aerogel granules from Cabot in 0.01 - 4mm sizes. The expanded glass granules producer says that aerogel thermal insulation renders are ultra-light, water-repellent, open to diffusion and achieve high thermal insulation even with small layer thicknesses.

The new product is targeted for the interior and exterior renovation of historic buildings. Due to the thin application layer, the producer says that the characteristics of the building remain largely unchanged. The building material can also be used for rendering masonry in new buildings. The insulating renders are also classified as ‘non-combustible, smoke-development free, non dripping.’ This means that they can also be used for facades, where previously only mineral wool-based insulating materials could be used due to increased fire protection requirements.

Poraver and Aerogel were combined for the development of a mineral thermal insulation render in order to combine the advantages of both lightweight aggregates. Cabot Aerogel supplied aerogel in the form of 0.01 - 4mm granules for the insulation render. Poraver was added to the render as a mineral aggregate with a grain size of 1 - 2mm. Various proportions of aerogel and Poraver were tested. After the tests, it could be determined that the compressive strength and processing properties had improved ‘significantly’ with the addition of Poraver. The most economical and practicable formulation has a thermal conductivity of 0.037W/mK with a dry bulk density of 199 kg/m³.

Germany: Saint-Gobain has acquired HKO, a manufacturer of very high temperature thermal insulation and fire protection solutions made from various types of glass fibres to cover temperature resistances between 600 and 1000°C. The French building materials company said that the purchase was in line with its strategy of developing technological niches. It will join the ADFORS business within the High-Performance Materials Activity.

Founded in the 1970s, HKO employs 225 people and has two plants in Germany with sales affiliates in France, USA and China. It reported sales of Euro39m in 2017. With mostly customised solutions. It serves the construction, industrial and automotive markets.

Germany: BASF’s Performance Products division’s sales fell by 5% year-on-year to Euro7.94bn in the first half of 2018 from Euro8.4bn in the same period in 2017. Its earnings before interest and taxation (EBIT) fell by 41% to Euro879m from Euro920m. The company blamed the falling sales and earnings on negative currency effects as well as reduced sales volumes from its Nutrition & Health division. The chemical producer manufactures polyurethane-based insulation foams as part of its Performance Products division. Overall, BASF’s sales and its EBIT grew in the reporting period.

Germany: Va-Q-Tec has nearly completed the expansion of its Kölleda plant in Thuringia. A new second plant at its Kölleda site has increased the production area by 3000m2 and created additional space for storage, laboratories and offices. Production capacity at the site will be tripled following the upgrade. Va-Q-Tec manufactures vacuum isolation panels at Kölleda for use in pharmalogistics, cooling units and in the construction industry for thermal isolation or cold chain logistics. The expansion is expected to be completed in June 2018.

India: Wacker Metroark Chemicals has officially opened a 6000t/day hydrosilylation plant for manufacturing functional silicone fluids at Amtala near Kolkata. The plant cost Euro6m. The expansion is Wacker’s response to growing regional demand for specialty silicones for use in the textile, personal care, rigid and flexible polyurethane foam and agrochemical sectors. Polyurethane foams produce at the unit will be used to make insulation materials and other products.

“Our new hydrosilylation plant enables us to address promising new markets where we haven’t been represented in India and Southeast Asia until now – for example the market for silicone functional fluids with its many sales opportunities,” said Soumitra Mukherjee, Managing Director of Wacker Metroark Chemicals.

Wacker Metroark Chemicals is a joint venture between Germany’s Wacker and Metroark. The company is responsible for all marketing and sales activities in the India relating to Wacker silicones. Wacker owns a 51% share in the joint venture, which was set up in 1998.