Insulation industry news from Global Insulation

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.

Russia: Teplex, a Russian producer of insulation materials, has ordered new equipment to increase its output of extruded polystyrene (XPS) to 500,000m³/yr. The increase in production will give the company a 15% share of the Russian market and meet the demand in the Central, North-Western and Volga Federal Districts of the country. The new equipment will begin production by early 2013.

The company is also in talks to move part of its operations to Novosibirsk in Siberia to meet the needs of the local regional market. The new plant is expected to produce 200,000m³/yr of XPS and will begin operation by early 2014.

US: Knauf Insulation has been granted a building permit to construct an US$8.7m warehouse and logistics facility in Shelbyville in the US state of Indiana. At a tax abatement hearing, local attorney Lee McNeely, who represented Knauf, told the Shelbyville Common Council that the building is part of an expansion that will bring back a major line producing light fibreglass to the insulation producing plant, known as the 602 line.

"The warehouse will replace an old manufacturing building," said Joey Viselli, vice president of marketing for Knauf. "It just gives us a lot more flexibility to have a warehouse on site," he said.

The building was the subject of a tax abatement request in November 2011, which was granted by the council. According to the tax abatement documentation, Knauf plans to tear down an existing building and then build the new 285,000ft², pre-fabricated metal warehouse and office space. Knauf's main US office is located in the same town.

The abatement documentation further added that, "Knauf intends to demolish an existing structure and build a new warehousing and office facility in order to support additional production for a growing customer base."

Knauf reported the total cost of the project to be US$10.9m. The City of Shelbyville permit is for US$8.7m in construction. The project is expected to add about eight jobs, creating an additional payroll of US$319,000.

In June 2011 Knauf closed its plant in Lanett, Alabama with the loss of 146 jobs. At the time, a company spokesman had said that Knauf was affected by an ongoing slump in housing construction. Viselli said that the closure of the Alabama plant is one element that changes the demands placed on the Shelbyville location.

Russia: Denmark's Rockwool has opened a US$150m plant producing insulating materials in the Alabuga Special Economic Zone in Tatarstan. A second production line may be added to double capacity. The economic zone now has six plants from a variety of companies.

Eelco van Heel, Rockwool president and CEO, said at the opening ceremony that this was the group's biggest plant in the world with a capacity of 110,000t/yr, and its biggest investment in a new plant. Its products will supply the Volga region, Urals, Siberia and Kazakhstan. Russian Economic Development Minister Elvira Nabiullina said at the ceremony, "We aim to reduce the energy-output ratio of GDP to 40% by 2020 and that means using energy-saving technologies." Heat consumption is currently high in Russia - it takes roughly three times more energy per cubic meter to heat buildings in Russia than in Scandinavia, which has a comparable climate.

US: Dow Chemical Company, the world's second-largest chemical producer, plans to close four plants producing Styrofoam. Dow Chemical will close plants that make the insulation material in Portugal, Hungary and the US state of Illinois and it will idle a Styrofoam facility in the Netherlands.

The decision comes as part of a cost saving exercise, including a cut of 900 jobs and a US$350m restructuring charge, to counter weakness in the European construction market and exit a loss-making business in Brazil. The moves are aimed at saving US$250m/yr.

Dow Chemical had cut production during the final quarter of 2011 to levels not seen since early 2009. It cited concerns about ebbing demand in Europe and the outlook in China during a recovery that Chief Executive Andrew Liveris described as 'jagged'. The job cuts represent around 1.7% of Dow's global work force. The effort is part of a broader streamlining program unveiled by the chemical giant in 2011.