Insulation industry news from Global Insulation

Germany: Chemicals producer BASF has partnered with RAMPF Eco Solutions, Poland-based Remondis Electrorecycling and engineering company KraussMaffei to develop depolymerisation techniques to produce polyol from waste polyurethane (PU) fridge insulation, as an alternative to natural hydrocarbons. The recovered polyol could then be used as a raw material in PU insulation production.

BASF said "This innovative process is particularly challenging because it has to be very robust in order to reliably convert post-consumer waste with high levels of foreign substances into a high-quality recycled polyol.”

Waste fridge insulation's only current use is as an alternative fuel by the energy sector.

India: Germany-based chemicals producer BASF has broken ground on its construction of a polyurethane (PU) application development laboratory in Mumbai, Maharashtra. From its inauguration in 2024, the laboratory will offer customer support services including customised formulations, line trials and training sessions PU industry partners, including insulation producers. In this, it will support the work of BASF’s existing Creation Center at its Mumbai Innovation Campus.

BASF’s senior vice president, performance materials Asia Pacific, Andy Postlethwaite said “As a part of the global innovation network, the lab will enable global and regional BASF teams to work closely with local customers in testing and formulation optimisation. BASF has been providing technical services to customers, enabling the co-creation of innovative product solutions with its high-performance materials. With our strength in innovation and comprehensive range of high-quality solutions, we help our customers meet increasingly stringent regulatory standards and optimise product properties for their specific needs at an early stage.”

UK: AMA Research has recorded a 16% year-on-year decline in UK insulation demand to Euro1.62bn in 2020 from Euro1.93bn in 2019. The researcher forecast a 3% year-on-year decline in 2021 to Euro1.57m. It said the demand would not recover 2019 levels before 2025. In the three years after 2021, the predicted annual growth rate is 4 - 6%.

China/Japan: Researchers from Kyoto University, the University of Tokyo in Japan and Jiangsu Normal University in China have developed a new material that can selectively capture carbon dioxide (CO₂) molecules and convert them into ‘useful’ organic materials, including a precursor for polyurethane. The research project has been described in the journal Nature Communications.

The material is a porous coordination polymer (PCP, also known as a metal-organic framework), a framework consisting of zinc metal ions. The researchers tested their material using X-ray structural analysis and found that it can selectively capture only CO₂ molecules with ten times more efficiency than other PCPs. The material has an organic component with a propeller-like molecular structure, and as CO₂ molecules approach the structure, they rotate and rearrange to permit CO₂ trapping, resulting in slight changes to the molecular channels within the PCP. This allows it to act as molecular sieve that can recognise molecules by size and shape. The PCP is also recyclable; the efficiency of the catalyst did not decrease even after 10 reaction cycles.

After capturing the carbon, the converted material can be used to make polyurethane, a material with a wide variety of applications including insulation materials.

China: A study by researchers from Australia's Commonwealth Scientific and Industrial Research Organisation and Britain's University of Bristol says that the provinces of Shandong and Hebei are the source of a rise in trichlorofluoromethane (CFC-11) emissions. It attributed about 40% to 60%of in the rise in CFC-11 since 2013 to this region, according to Reuters. After studying atmospheric data from South Korea and Japan they estimated that CFC-11 emissions from eastern China during the 2014 - 2017 period were around 7000t/hr higher than 2008 - 2012.

Previously in mid-2018 an investigation by the Environmental Investigation Agency (EIA) speculated that the widespread use of CFC-11 by Chinese rigid polyurethane (PU) foam producers might be the source of the reported rise of emissions.

China launched an inspection campaign into 3000 foam manufacturers in 2018 and promised to punish any violations of the Montreal Protocol treaty. The Ministry of Ecology and Environment said in March 2019 that it had shut down two manufacturing areas that produced CFC-11. It added that its investigation into PU foam makers had not found any large-scale usage so far but that producers may be getting better at hiding their operations. It also noted that there was ‘uncertainty’ in published research and called for better detection mechanisms.

US: Researchers at Washington State University (WSU) have developed an alternative to extruded polystyrene foam that uses nanocrystals of cellulose instead of petroleum based products. The team, led by Amir Ameli, assistant professor in the School of Mechanical and Materials Engineering, and Xiao Zhang, associate professor in the Gene and Linda School of Chemical Engineering and Bioengineering, have also developed a manufacturing process to make the foam using water as a solvent.

The project is working on developing an environmentally friendly replacement for extruded polystyrene foam. The WSU team created a material that is made of about 75% cellulose nanocrystals from wood pulp. They added polyvinyl alcohol, another polymer that bonds with the nanocellulose crystals and makes the resultant foams more elastic.

“We have used an easy method to make high-performance, composite foams based on nanocrystalline cellulose with an excellent combination of thermal insulation capability and mechanical properties,” said Ameli.

The researchers are now developing formulations for stronger and more durable materials for practical applications. They are interested in incorporating low‑cost feedstocks to make a commercially viable product and considering how to move from laboratory to a real-world manufacturing scale.

UK/France: A project between the University of Bath, University of Brighton, UniLaSalle in Rouen and five other academic and non-academic partners, and funded under the Interreg VA France (Channel) England programme, is investigating the performance of a range of waste materials and bio-based co-products as alternative building insulation materials. Three different materials are being evaluated: wheat straw bales, rapeseed stalks (processed into bio-composite) and recycled duvets.

A research team at the University of Bath is testing and comparing the thermal performance of each of the insulation materials by constructing three identical prototype wall panels, each containing one of the materials. Their performances will be compared and contrasted with each other as well as against industry standard insulation used currently in most buildings. The panels are 150mm thick by 1.1m2 and fitted with 9mm plywood either side, similar to how insulation is commonly installed within buildings. Each panel contains a number of probes to measure relative humidity, interior and exterior temperature, and heat flux. The panels will undergo six weeks of consecutive testing in an environmental chamber at the University’s Building Research Park. There will be two tests – a steady state and a non-steady state temperature test.

“This is the first time these materials will have been tested in such a robust scientific way, allowing us to accurately assess their thermal performance against each other as well as against industry standard insulation,” said Shawn Platt, Research Associate in the University of Bath’s Department of Architecture & Civil Engineering.

Japan: Research by the Japan Sustainable Building Consortium suggests that under floor insulation could reduce negative health effects such as high blood pressure. The study found that when the temperatures near the floor of a person's home were lower, the proportion of people seeing a doctor regularly for conditions such as high blood pressure and diabetes increased, according to the Ministry of Land, Infrastructure, Transport and Tourism and the Mainichi newspaper.

The study looked at 4131 people in 2307 homes identified for insulation retrofitting. The average age of the participants was about 57 years with an even gender split. Comparisons were drawn between residents' health before and after insulation upgrades were completed. The researchers found that in homes where the temperature near the floor was below 15°C, the people were on average 1.51 times more likely to have high blood pressure and 1.64 times more likely to have diabetes. The study also noted adverse health effects when bedrooms and living rooms were unevenly heated.

Belgium: Recticel is coordinating the four-year PUReSmart project that was launched on 1 January 2019. The project will look at ways of recycling polyurethane (PU) and turning it into a circular material. It is supported by Euro6m in funding from the European Union Horizon 2020 Research and Innovation Programme.

PUReSmart plans to recover over 90% of end-of-life PU with the goal of converting it into inputs for new and known products. The project consortium will develop sorting technologies to separate a diverse range of PU materials into dedicated feedstocks. These feedstocks will be broken down into their basic components as inputs for existing PU products, and as raw materials for a newly designed polymer that merges the durability of thermosets with the circularity of thermoplastics.

The PUReSmart consortium is an end-to-end collaboration spanning the entire polyurethane reprocessing value chain, and comprises both industrial players and dedicated research partners. As well as Recticel the other partners on the project include Covestro Deutschland, BT-Wolfgang Binder, WeylChem InnoTec, Ecoinnovazione, Ghent University, KU Leuven, Universidad De Castilla – La Mancha and Ayming.

Denmark: Rockwool is working with engineering company FLSmidth and the Technical University of Denmark (DTU) on a research project to develop sustainable process technologies that will increase the use of renewable fuels and raw materials and reduce CO₂ emissions. The project has received a Euro2.7m grant from Innovation Fund Denmark.

The project plans to investigate and optimise high-temperature processes throughout the entire production chain in both companies. The DTU holds experience in this field from the CHEC research centre at DTU Chemical Engineering, which has focused on combustion research and emission abatement in recent years. Rockwool intends to lower CO₂ emissions and reduce its fuel consumption to make its production become more sustainable. FLSmidth plans to explore using alternative cement formulas and production methods to enable the company to launch more efficient technologies for using renewable fuels and reducing emissions.