Insulation industry news from Global Insulation

Russia: Knauf Insulation expects its mineral wool insulation factory in Tyumen Oblast, Russia to reach its design capacity of 45,000t/yr in late 2014. More than Euro64.3m was invested in the project. The plant sells its products in the Ural district, Siberia, the Far East and Kazakhstan.

UK: A Salford housing association has begun a pilot project to trial a new type of party cavity wall insulation. The project will see the new mineral wool insulation fitted to separating walls between terraced and semi-detached houses in City West Housing Trust's properties in Greater Manchester, UK.

The housing association, which owns and manages 14,600 homes in Salford, is undertaking the project with Knauf Insulation using the company's ECOSE Technology, which creates insulation using formaldehyde-free binder technology and naturally occurring and recycled raw materials.

If the pilot is successful, customers could save Euro73 - 109/yr on their energy bills. Additionally, household carbon emissions will be reduced by between 0.33 - 0.50t/yr per home. The performance of the insulation will be monitored by Leeds Metropolitan University, the Mineral Wool Insulation Manufacturers Association and Knauf Insulation.

"Through our commitment to the green agenda we are ensuring our properties can be as energy efficient as possible and offer value for money for our customers," said City West head of supply chain and sustainability Garry Vaughan.

Canada: Johns Manville (JM) has added commercial and residential mineral wool to its full spectrum of insulation products in Canada.

JM mineral wool insulation offers a variety of performance benefits in both commercial and residential construction. With a melting point in excess of 1093˚C, mineral wool can help delay fire spread, create quieter buildings and homes, increase privacy between rooms and reduce heating and cooling costs by keeping structures warm in winter and cool in summer.

"Mineral wool has long been a favourite product of Canadian building professionals, but there's no longer just one game in town," said Fred Stephan, senior vice president of Insulation Systems at Johns Manville. "With JM mineral wool, building occupants benefit from acoustically superior environments, moisture protection and increased fire performance, while contractors benefit from JM's full range of product offerings, providing more options and resources across all insulation categories."

Malaysia: PGF Insulation Sdn Bhd plans to build a second mineral wool plant next to its existing plant in Penang and start production in early 2016. PGF has awarded the first phase of the project to a local contractor and work is expected to commence in May 2014. This phase of the project, when completed, will have a capacity of 20,000MT/yr with a focus on batts and boards production.

PGF has started its plant expansion plan due to growing demand for its glasswool products in the Asia Pacific region. The five-acre site was acquired in 2008 for future expansion purposes. PGF's current facility has a production capacity of 20,000Mt/yr. The first phase project will add 20,000Mt/yr and it will be operational in 2016. A second phase will add a further 20,000Mt/yr bringing the total production capacity to 60,000Mt/yr. PGF intends to be become the largest mineral wool manufacturer in the Association of Southeast Asian Nations (ASEAN) region when the upgrades are completed.

This news article was updated on 3 April 2014

Saudi Arabia: Saudi International Insulation Manufacturing Company (SIIMCO), a joint venture equally owned by Alghanim Industries and Saint-Gobain, has signed an agreement with the Yanbu Royal Commission to lease a 65,000m² site at Yanbu Al-Sinaiyah, Saudi Arabia for 30 years. Construction of plant is expected to begin in August 2013 and it is planned to be operational by early 2014.

"Our joint venture investment at Yanbu will supply local and regional industrial and building areas with a reliable source of high quality insulation, which is both environmentally-friendly and will assist in improving the fire safety of buildings," said Omar Alghanim, chief executive of Alghanim Industries. The agreement follows a comprehensive review of the environmental impact and approval for plant layouts, building structure and utilities from the Yanbu local authorities.

SIIMCO has invested about Euro45m in the project. When completed it will have a production capacity of 60,000Mt/yr, building minderal wool, thermal and acoustical insulation materials. The plant is intended to serve markets in Saudi Arabia and other regional markets in the Gulf Cooperation Council region such as Egypt and Iraq.

Turkey: Austrian insulation producer Austrotherm has said that its second insulation plant in Turkey will go into operation at the beginning of April 2013. Austrotherm has invested Euro4m in the project.

The new plant is located in Turgutlu, near Izmir and will be focused on the production of grey thermally insulated curtail panels from expanded polystyrene and rigid foams. The new plant will employ 40 workers.

Austrotherm saw its sales rise by 8% to Euro245m in 2012. Austrotherm's foreign sales grew stronger than those on the domestic Austrian market in 2012, according to its CEO Peter Schmid.

Egypt: GlassRock Insulation Company, part of regional mining platform Ascom, has reported the successful completion of the commissioning phase of its new production line for glass wool. The new production line will produce 20,000t/yr of glass wool increasing the plant's total production to 50,000t/yr, of which 30,000t/yr is mineral wool.

"We are exceptionally proud to be manufacturing these strategic insulation materials, which can be used as both residential thermal insulation and as acoustic insulation. Our products can help to significantly reduce the impact of the energy crisis that Egypt is currently facing," said chief executive officer Bechir Dardour. According to Dardour the glass wool insulation that will be produced in GlassRock's Sadat City Free Zone plant is being manufactured principally with local materials.

In September 2012 GlassRock announced the launch of its first mineral wool production line. The company is now targeting exports to key markets in Europe, North Africa, the Gulf Cooperation Countries and Turkey.

Egypt: GlassRock Insulation Co. has started targeting exports of mineral wool to key markets in Europe, North Africa, the Gulf Cooperation Council countries and Turkey following the start of production at its US$70m Egyptian greenfield facility in May 2012. The company, part of a portfolio owned by Citadel Capital's regional mining platform ASCOM, will also begin production of glass wool insulation in September 2012.

"Our goal is to become a world-class provider of heat and noise insulation solutions," said GlassRock Insulation chief executive officer Bechir Dardour. "Energy-efficient building materials are the only option going forward in Egypt and around the world and we are delighted to be part of the solution to the creation of a greener, more environmentally-friendly future."

Construction of the US$70m greenfield GlassRock plant, located eqhalf-way between Cairo and Alexandria in the Sadat City Free Zone, began in 2010. The facility has created 260 direct jobs and operates with technology licensed from Italy's Tenova. When fully operational GlassRock's production capacity will be 30,000Mt/yr of mineral wool and 20,000Mt/yr of glass wool.

Spain: Renewable energy advisory firm Renovetec has conducted research into fires at a number of concentrating solar power (CSP) plants in Spain. According to the company, mineral wool used to line the piping containing the heat transfer fluid (HTF) in these plants' solar fields is to blame.

"On occasions the causes of the fires have been unclear," explains Santiago García Garrido, Technical Director of Renovetec. "The HTF has behaved differently to the specifications on its safety sheet".

Renovetec has published an article on its work which examines the relationship between the thermal insulation used to line heat transfer piping and the fires, after the company managed to reproduce the conditions leading to certain fires under laboratory conditions. The tests performed by Renovetec show that the thermal insulation can ignite at below 200°C, whereby there is a risk of spontaneous combustion even if there is no ignition spark or other ignition source.

"This explains some of the incidents at a number of CSP plants," says the company especially given that the ignition point of the HTF generally used in CSP plants (biphenyl and diphenyl oxide) is 615°C – a temperature which is highly unlikely to be reached anywhere on site.

Witnesses of some of the fires recall that the incidents arose when some of the HTF escaped from the piping installed in the solar field soaking the thermal insulation (which is normally mineral wool) covered by an aluminium jacket. On removing the aluminium jacket, the mineral wool occasionally ignited spontaneously. These fires started despite the technical specifications of the HTF manufactured by Dow Chemical and Solutia indicating that the fluid would not ignite.

The outcome of Renovetec's experiment to reproduce the conditions leading to the fires is conclusive: on certain occasions the point of spontaneous combustion is not as reflected in the safety sheets of these HTF, with the liquid igniting at temperatures below 203°C.

Kazakhstan: A new Vodokanalstroy Company mineral wool plant has started operation in the city of Karaganda in Karaganda region as part of the Business Roadmap-2020 programme.

The executive director of the company, Mikhail Lashkov, said, "The project cost USD11.2m. The sources of financing were our own funds, accounting for USD7.6m and a loan of USD3.7m borrowed at an interest rate of 7%/yr."

According to Lashkov, the production capacity of the plant is 85,000m3/yr of thermal insulation material. "The main product of the plant are mineral wool slabs with Misot synthetic binding agent," he added. The raw materials for the products are sourced from ArcelorMittal Temirtau.

"There is a huge demand for heat insulation materials in Kazakhstan and 85% of such products are imported. Now the imports can be reduced," said Lashkov.