# 2010 Report of the Rigid and Flexible Foams Technical Options Committee (FTOC)

Montreal Protocol on Sub s tance s

that De p lete the O zone L ayer

Celebrating 25 years of success in 2012 

# 2010 Assessment

## MONTREAL PROTOCOL

ON SUBSTANCES THAT DEPLETE

THE OZONE LAYER



# UNEP

2010 REPORT OF THE RIGID AND FLEXIBLE FOAMS TECHNICAL OPTIONS COMMITTEE

2010 ASSESSMENT REPORTiii 

### UNEP R EPORT OF THE 

### R IGID AND 

### F LEXIBLE 

### F OAMS 

### T ECHNICAL 

### O PTIONS 

### C OMMITTEE



### 2010 A SSESSMENT 

### R EPORTiii 

### UNEP R EPORT OF THE 

### R IGID AND 

### F LEXIBLE 

### F OAMS 

### T ECHNICAL 

### O PTIONS 

### C OMMITTEE



### 2010 A SSESSMENT 

### R EPORTiv Montreal Protocol On Substances that De plete the Ozone Layer


### Report of the UNEP Rigid and Flexible Foam s Technical Options Committee

2010 Assessment

A SSESSMENT R EPORT

The text of this report is composed in Times New Roman.

Co-ordination: Rigid and Flexible Foams Technical Options Committee

Reproduction: Ozone Secretariat, UNEP Date: May 2011

Under certain conditions, printed copies of this report are available from:

UNITED NATIONS ENVIRONMENT PROGRAMME Ozone Secretariat, P.O. Box 30552, Nairobi, Kenya

This document is also available in portable document format from the UNEP Ozone Secretariat's website:
http://ozone.unep.org/Assessmen t_Panels/TEAP/Reports/FTOC/

No copyright involved. This publication may be freely copie d, abstracted and cited, with acknowledgement of the s ource of the material.

ISBN: 978-9966-20-003-7

v DISCLAIMER

The United Nations Environment Program me (UNEP), the Technology and Economic Assessment Panel (TEAP) co-chairs and me mbers, the Technical Options Committee, chairs, co-chairs and members, the TEAP Task Forces co-chairs and members and the companies and organisations that employ them do not endorse the performance, worker safety, or environmenta l acceptability of any of the technical options discussed. Every industrial operation require s consideration of worker safety and proper disposal of contaminants and waste products. Mo reover, as work continues - including additional toxicity evaluation - more inform ation on health, environmental and safety effects of alternatives and replacements will become available for use in selecting among the options discusse d in this document.

UNEP, the TEAP co-chairs and members, the Technical Options Committee, chairs, co-chairs and members a nd the Technology and Economic Assessment Panel Task Forces co-chairs and members, in furnishi ng or distributing this information, do not make any warranty or represen tation, either express or implied, with respect to the accuracy, completeness, or utility; nor do they assume any liability of any kind whatsoever resulting from the use or re liance upon any information, material, or procedure contained herein, including but notlimited to any claims regarding health, safety, environmental effect or fate, effi cacy, or performance, made by the source of information.

Mention of any company, association, or pr oduct in this document is for information purposes only and does not constitute a recommendation of any such company, association, or product, e ither express or implied by UNEP, the Technology and Economic Assessment Panel co-chairs or members, the Technical Options Committee chairs, co-chairs or members, the TEAP Task Forces co-chairs or members or the companies or organisations that employ them.iv Montreal Protocol On Substances that De plete the Ozone Layer


### Report of the UNEP Rigid and Flexible Foam s Technical Options Committee

2010 Assessment

A SSESSMENT R EPORT

The text of this report is composed in Times New Roman.

Co-ordination: Rigid and Flexible Foams Technical Options Committee

Reproduction: Ozone Secretariat, UNEP Date: May 2011

Under certain conditions, printed copies of this report are available from:

UNITED NATIONS ENVIRONMENT PROGRAMME Ozone Secretariat, P.O. Box 30552, Nairobi, Kenya

This document is also available in portable document format from the UNEP Ozone Secretariat's website:
http://ozone.unep.org/Assessmen t_Panels/TEAP/Reports/FTOC/

No copyright involved. This publication may be freely copie d, abstracted and cited, with acknowledgement of the s ource of the material.

ISBN: 978-9966-20-003-7

v DISCLAIMER

The United Nations Environment Program me (UNEP), the Technology and Economic Assessment Panel (TEAP) co-chairs and me mbers, the Technical Options Committee, chairs, co-chairs and members, the TEAP Task Forces co-chairs and members and the companies and organisations that employ them do not endorse the performance, worker safety, or environmenta l acceptability of any of the technical options discussed. Every industrial operation require s consideration of worker safety and proper disposal of contaminants and waste products. Mo reover, as work continues - including additional toxicity evaluation - more inform ation on health, environmental and safety effects of alternatives and replacements will become available for use in selecting among the options discusse d in this document.

UNEP, the TEAP co-chairs and members, the Technical Options Committee, chairs, co-chairs and members a nd the Technology and Economic Assessment Panel Task Forces co-chairs and members, in furnishi ng or distributing this information, do not make any warranty or represen tation, either express or implied, with respect to the accuracy, completeness, or utility; nor do they assume any liability of any kind whatsoever resulting from the use or re liance upon any information, material, or procedure contained herein, including but notlimited to any claims regarding health, safety, environmental effect or fate, effi cacy, or performance, made by the source of information.

Mention of any company, association, or pr oduct in this document is for information purposes only and does not constitute a recommendation of any such company, association, or product, e ither express or implied by UNEP, the Technology and Economic Assessment Panel co-chairs or members, the Technical Options Committee chairs, co-chairs or members, the TEAP Task Forces co-chairs or members or the companies or organisations that employ them.vii 

### 2010 RIGID AND FLEXIBLE FOAMS REPORT

TABLE OF CONTENTS

Page

1) EXECUTIVE SUMMARY ES – 1

2) FOREWORD 1

3) CHAPTER 1 – TRANSITIONAL STATUS 3

4) CHAPTER 2 – TECHNICAL OPTIONS 40

5) CHAPTER 3 – BANKS AND RECOVERY OPTIONS 56

Appendices

APPENDIX 1 – REVIEW OF ALTERNATIVE BLOWING AGENTS A1 – 1

APPENDIX 2 – ALLOCATION OF COUNTRIES TO REGIONS A2 – 1

APPENDIX 3 – UNEP FOAMS TECHNI CAL OPTIONS COMMITTEE A3 – 1vii 

### 2010 RIGID AND FLEXIBLE FOAMS REPORT

TABLE OF CONTENTS

Page

1) EXECUTIVE SUMMARY ES – 1

2) FOREWORD 1

3) CHAPTER 1 – TRANSITIONAL STATUS 3

4) CHAPTER 2 – TECHNICAL OPTIONS 40

5) CHAPTER 3 – BANKS AND RECOVERY OPTIONS 56

Appendices

APPENDIX 1 – REVIEW OF ALTERNATIVE BLOWING AGENTS A1 – 1

APPENDIX 2 – ALLOCATION OF COUNTRIES TO REGIONS A2 – 1

APPENDIX 3 – UNEP FOAMS TECHNI CAL OPTIONS COMMITTEE A3 – 1ES - 1 

### 2010 RIGID AND FLEXIBLE FOAMS REPORT

EXECUTIVE SUMMARY

Executive Summary

E.1 Introduction

Not since the initial decision to phase-out CFCs in the ea rly 1990s has the foam sector faced a period of such uncerta inty. Although a large proportion of the industry has previously settled on hydrocarbons or CO 2 (water) as their blowing agent of choice, there are increasing pressures to improve the thermal performance of foams – primarily in the appliance sector, but also in some construction and tr ansport applications. Coupled with this, there are pressures to limit future use of saturated hydrofluorocarbons (s -HFCs) because of their high global warming potential, and to phase these dow n where possible. Finally, there is the time-certain schedule for phasing out HCFC use in Article 5 countries, but substantial uncertainties remain about the optimal choice of alternatives. These three trends are placing unparalleled stresses on the sector and there is a significant divergence of opinion at this time about the most appropriate way forward, particularly as there are a growing num ber of emerging alternatives to consider. The following sections provide further background on the issues being faced.

E. 2 Foam Market Dynamics

Growth in thermal insulation foams con tinues to be driven by increasing energy efficiency requirements in appliances, trans port and buildings. Space constraints in the built environment (e.g. cavity dimensions) have driven dr amatic shifts from fibrous products to foam products in some localised markets to meet th e required thermal performance. However, fibre has largely maintained its shar e through growth in the resident ial refurbishment sector where cost is a prime issue. An addi tional downward trend on foam use in non-Article 5 countries has been the on-going shift of app liance and refrigerated equipment manufacture to other regions where costs of manufacture are lo wer. The latest extension of a graph for Western Europe shown in previous reports (see overleaf) indicates that this combination of factors has led to only a small net shift to the overall foam/fibre balance de spite the turbulence of individual sectors.

Nonetheless, the same region saw overall growth in thermal insulation sales to the domestic and commercial building sector of over 20% in the period between 2001 and 2008 despite the impact of the global downturn in 2008, thereby driving demand for appropriate blowing agents. This is likely to be representa tive of other non-Article 5 regions responding to the parallel drivers of climate ch ange policy and energy security.

In Article 5 countries, the growth in demand for thermal insulation has been even starker than for non-Article 5 countries in view of the increasing manufac turing base for global appliances and the recognition that energy efficien t buildings have a major contribution to make in combating climate change for Article 5 countries. As an example, the use of PU Spray Foam

ES - 2 in China is understood to have grown to 70,000-80,000 tonnes, making it already the second largest market in the world for PU Spray Foam, with onl y the United States market larger.

66.5% 62.0% 59.5% 59.2% 32.0% 36.6% 39.2% 39.7%

1.5% 1.4% 1.3% 1.1%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

1990 1995 2001 2008Market Share

Year Variation of Insulation by Product Type (1990-2008) in Western Europe

Other Cellular polymer

Fibrous

Source; IAL

E.3 Transitional Status

As of 2010, HCFC phase-out is virtually complete in all non-Article 5 countries, with XPS in North America being the last major sector to make the transition. In this instance, the technology choice has been saturated HFCs, refl ecting the demanding product range and process requirements that the XPS industry has in the re gion. Experience from this transition has made the industry wary about committing to any further transitions in the medium term, since proving emerging alternatives in these applications will involve substantial furthe r effort. As shown in the graph below, the main growth in blowing agent use between 2005 and 2008 had occurred with hydrocarbons, although there was also some additional use of HFCs. By contrast, only a very marginal further decline in HCFC use had taken place, highlighting the fact that the XPS sector in North America was not able to addr ess its usage of HCFCs in the period to 2008, but was able to do so prior to the phase-out deadline in 2010.ES - 1 

### 2010 RIGID AND FLEXIBLE FOAMS REPORT

EXECUTIVE SUMMARY

Executive Summary

E.1 Introduction

Not since the initial decision to phase-out CFCs in the ea rly 1990s has the foam sector faced a period of such uncerta inty. Although a large proportion of the industry has previously settled on hydrocarbons or CO 2 (water) as their blowing agent of choice, there are increasing pressures to improve the thermal performance of foams – primarily in the appliance sector, but also in some construction and tr ansport applications. Coupled with this, there are pressures to limit future use of saturated hydrofluorocarbons (s -HFCs) because of their high global warming potential, and to phase these dow n where possible. Finally, there is the time-certain schedule for phasing out HCFC use in Article 5 countries, but substantial uncertainties remain about the optimal choice of alternatives. These three trends are placing unparalleled stresses on the sector and there is a significant divergence of opinion at this time about the most appropriate way forward, particularly as there are a growing num ber of emerging alternatives to consider. The following sections provide further background on the issues being faced.

E. 2 Foam Market Dynamics

Growth in thermal insulation foams con tinues to be driven by increasing energy efficiency requirements in appliances, trans port and buildings. Space constraints in the built environment (e.g. cavity dimensions) have driven dr amatic shifts from fibrous products to foam products in some localised markets to meet th e required thermal performance. However, fibre has largely maintained its shar e through growth in the resident ial refurbishment sector where cost is a prime issue. An addi tional downward trend on foam use in non-Article 5 countries has been the on-going shift of app liance and refrigerated equipment manufacture to other regions where costs of manufacture are lo wer. The latest extension of a graph for Western Europe shown in previous reports (see overleaf) indicates that this combination of factors has led to only a small net shift to the overall foam/fibre balance de spite the turbulence of individual sectors.

Nonetheless, the same region saw overall growth in thermal insulation sales to the domestic and commercial building sector of over 20% in the period between 2001 and 2008 despite the impact of the global downturn in 2008, thereby driving demand for appropriate blowing agents. This is likely to be representa tive of other non-Article 5 regions responding to the parallel drivers of climate ch ange policy and energy security.

In Article 5 countries, the growth in demand for thermal insulation has been even starker than for non-Article 5 countries in view of the increasing manufac turing base for global appliances and the recognition that energy efficien t buildings have a major contribution to make in combating climate change for Article 5 countries. As an example, the use of PU Spray Foam

ES - 2 in China is understood to have grown to 70,000-80,000 tonnes, making it already the second largest market in the world for PU Spray Foam, with onl y the United States market larger.

66.5% 62.0% 59.5% 59.2% 32.0% 36.6% 39.2% 39.7%

1.5% 1.4% 1.3% 1.1%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

1990 1995 2001 2008Market Share

Year Variation of Insulation by Product Type (1990-2008) in Western Europe

Other Cellular polymer

Fibrous

Source; IAL

E.3 Transitional Status

As of 2010, HCFC phase-out is virtually complete in all non-Article 5 countries, with XPS in North America being the last major sector to make the transition. In this instance, the technology choice has been saturated HFCs, refl ecting the demanding product range and process requirements that the XPS industry has in the re gion. Experience from this transition has made the industry wary about committing to any further transitions in the medium term, since proving emerging alternatives in these applications will involve substantial furthe r effort. As shown in the graph below, the main growth in blowing agent use between 2005 and 2008 had occurred with hydrocarbons, although there was also some additional use of HFCs. By contrast, only a very marginal further decline in HCFC use had taken place, highlighting the fact that the XPS sector in North America was not able to addr ess its usage of HCFCs in the period to 2008, but was able to do so prior to the phase-out deadline in 2010.ES - 3 ‐ 120000 ‐ 100000 ‐ 80000 ‐ 60000 ‐ 40000 ‐ 20000 0 20000 40000 60000 80000 100000

CFC HCFC HFC HC CFC HCFC HFC HC

Developed DevelopingChangesinBlowingAgentConsumption(toones)

Changes in Blowing Agent Use by Type/Region Changes in Blowing Agent Use 2001

‐ 2005 compared with 2001

‐ 2008

2001

‐ 2005

2001

‐ 2008

In Article 5 countries, the phase-out of rema ining CFC use has been completed with the main replacement for these residua l applications being HCFCs. Growth has also continued in hydrocarbon use, largely driven by a further increase in the a ppliance manufacturing base in these regions.

Overall, the comparison between 2001-2005 and 2001-2008 time periods illustrates that the changes in the last four years have been re latively moderate compared with those of the previous four years.

Although hydrocarbons continue to be the prim ary solution in non-Article 5 countries, there is pressure in some sectors to further optimise these solutions by blending. While cyclopentane continues to play an important role in optimising blend performance, other components such as unsaturated HFCs (u-HFCs or HFOs) and methyl formate are also being assessed at this time. Early work on unsaturated HFCs suggests th at they deliver better thermal performance than their satura ted counterparts, although toxico logical work remains to be completed for those substances yet to be commercialised. In the interim, there is evidence that some enterprises manufacturing appliances in developing countries are already blending saturated HFCs with hydrocarbons to meet energy requirements.

Decisions need to be made at short noti ce within HCFC Phase-out Management Plans (HPMPs) on the choice of alternative to HCFCs in Article 5 countries. The prioritisation of ‘worst first’ embodied within Decision XIX/6 puts a strong focus on dealing with HCFC-141b

ES - 4 applications in the early phase s of implementation. Nevertheless, some countries are finding it easier to manage their compliance issues by phasi ng the foam sector transitions according to the ease with which projects can be implemented and the magnitude of their impact. Shortfalls are then being made up from other sectors.

E.4 Likely Future Scenarios

In general terms, the future technology sele ctions in both Artic le 5 and non-Article 5 countries continue to be uncertain. This makes it particularly difficult to forecast the precise blowing agent mix in the period to 2020 and the im pact that this may have on bank composition at that time. As noted above, HCFC phase-out in Article 5 countries continues to be a serious source of unease. In several sectors, particularly in rigid PU foams, previously identified low-GWP alternatives to HCFCs have yet to be fully proven in the field or require high investments. This is particularly important since many of the enterpri ses expected to take up these technologies are small medium enterprises (SMEs) and have li ttle, if any, internal capacity to optimise formulations. There is evidence that measures to manage flammability for methyl formate may require system houses to reformulate with more compatible polyols in order to reduce the risk. However, in a limited number of cases it may be more productive to blend methyl formate in the isocyanate component to obtain the required foam properties wh ilst avoiding flammable blends.

There continues to be a need to characteris e the performance of foams made from lowGWP alternatives in the range of applications envisaged. This is an on -going exercise, but is particularly important for technologi es that do not have a significan t history of use in non-Article 5 countries. The role of the P ilot Projects sponsored under the Multilateral Fund are especially relevant here and the work of UNDP on methyl formate, for example, has already cleared the way for wider use in the flexible moulded and inte gral skin sectors with potential for others to follow.

In non-Article 5 countries, the primary future interest is in fu rther improving energy efficiency. However, an additi onal pressure may arise from pr oposals to see the phase-down in use of saturated HFCs. Apart from initiatives si gnalled under the Montreal Protocol itself, there is growing interest in seeing such a measure as part of the re-cast F-Ga s Regulation in Europe. This may serve to strengthen research effort s in non-Article 5 countries towards low-GWP solutions and, in particular, towards the intellig ent use of blends. There may be added spin-offs for Article 5 countries from this work, but these are unlikely to emerge in time for incorporation within relevant HPMPs.

For the immediate challenge of phasing out HCFC-reliance in Article 5 countries, there are a number of obstacles. The time pressure to resolve these only serves to add to the complexity of the situation and it may be that a nu mber of not fully proven solutions need to be adopted in the short-term, with the potential downs ide risk to enterprises and investors alike. Another consequence could be th at enterprises choose to minimise their risks by choosing proven, but sub-optimal, technology solutions (e. g. high GWP or less energy efficient solutions) with the intent of making a second conversion wh en more appropriate solutions have become established.ES - 3 ‐ 120000 ‐ 100000 ‐ 80000 ‐ 60000 ‐ 40000 ‐ 20000 0 20000 40000 60000 80000 100000

CFC HCFC HFC HC CFC HCFC HFC HC

Developed DevelopingChangesinBlowingAgentConsumption(toones)

Changes in Blowing Agent Use by Type/Region Changes in Blowing Agent Use 2001

‐ 2005 compared with 2001

‐ 2008

2001

‐ 2005

2001

‐ 2008

In Article 5 countries, the phase-out of rema ining CFC use has been completed with the main replacement for these residua l applications being HCFCs. Growth has also continued in hydrocarbon use, largely driven by a further increase in the a ppliance manufacturing base in these regions.

Overall, the comparison between 2001-2005 and 2001-2008 time periods illustrates that the changes in the last four years have been re latively moderate compared with those of the previous four years.

Although hydrocarbons continue to be the prim ary solution in non-Article 5 countries, there is pressure in some sectors to further optimise these solutions by blending. While cyclopentane continues to play an important role in optimising blend performance, other components such as unsaturated HFCs (u-HFCs or HFOs) and methyl formate are also being assessed at this time. Early work on unsaturated HFCs suggests th at they deliver better thermal performance than their satura ted counterparts, although toxico logical work remains to be completed for those substances yet to be commercialised. In the interim, there is evidence that some enterprises manufacturing appliances in developing countries are already blending saturated HFCs with hydrocarbons to meet energy requirements.

Decisions need to be made at short noti ce within HCFC Phase-out Management Plans (HPMPs) on the choice of alternative to HCFCs in Article 5 countries. The prioritisation of ‘worst first’ embodied within Decision XIX/6 puts a strong focus on dealing with HCFC-141b

ES - 4 applications in the early phase s of implementation. Nevertheless, some countries are finding it easier to manage their compliance issues by phasi ng the foam sector transitions according to the ease with which projects can be implemented and the magnitude of their impact. Shortfalls are then being made up from other sectors.

E.4 Likely Future Scenarios

In general terms, the future technology sele ctions in both Artic le 5 and non-Article 5 countries continue to be uncertain. This makes it particularly difficult to forecast the precise blowing agent mix in the period to 2020 and the im pact that this may have on bank composition at that time. As noted above, HCFC phase-out in Article 5 countries continues to be a serious source of unease. In several sectors, particularly in rigid PU foams, previously identified low-GWP alternatives to HCFCs have yet to be fully proven in the field or require high investments. This is particularly important since many of the enterpri ses expected to take up these technologies are small medium enterprises (SMEs) and have li ttle, if any, internal capacity to optimise formulations. There is evidence that measures to manage flammability for methyl formate may require system houses to reformulate with more compatible polyols in order to reduce the risk. However, in a limited number of cases it may be more productive to blend methyl formate in the isocyanate component to obtain the required foam properties wh ilst avoiding flammable blends.

There continues to be a need to characteris e the performance of foams made from lowGWP alternatives in the range of applications envisaged. This is an on -going exercise, but is particularly important for technologi es that do not have a significan t history of use in non-Article 5 countries. The role of the P ilot Projects sponsored under the Multilateral Fund are especially relevant here and the work of UNDP on methyl formate, for example, has already cleared the way for wider use in the flexible moulded and inte gral skin sectors with potential for others to follow.

In non-Article 5 countries, the primary future interest is in fu rther improving energy efficiency. However, an additi onal pressure may arise from pr oposals to see the phase-down in use of saturated HFCs. Apart from initiatives si gnalled under the Montreal Protocol itself, there is growing interest in seeing such a measure as part of the re-cast F-Ga s Regulation in Europe. This may serve to strengthen research effort s in non-Article 5 countries towards low-GWP solutions and, in particular, towards the intellig ent use of blends. There may be added spin-offs for Article 5 countries from this work, but these are unlikely to emerge in time for incorporation within relevant HPMPs.

For the immediate challenge of phasing out HCFC-reliance in Article 5 countries, there are a number of obstacles. The time pressure to resolve these only serves to add to the complexity of the situation and it may be that a nu mber of not fully proven solutions need to be adopted in the short-term, with the potential downs ide risk to enterprises and investors alike. Another consequence could be th at enterprises choose to minimise their risks by choosing proven, but sub-optimal, technology solutions (e. g. high GWP or less energy efficient solutions) with the intent of making a second conversion wh en more appropriate solutions have become established.ES - 5 E.5 Banks, Emissions and Destruction

The management of ODS banks in appliance foams is currently being addressed by a variety of regulatory and volunt ary frameworks and using a range of fully automated, semiautomated and manual technologies. Although there is evidence to suggest that fully automated approaches provide the most co mprehensive recovery potential, the relevant cost-abatement curves would suggest that some semi-automat ed processes will have a place in the on-going management of ODS banks, particularly in areas where population densities are low or investment is restricted.

Efforts have been made to further characteri se foam inventories in a number of regions. The flow of ODS-containing foams into the demolit ion waste stream from buildings is currently low and is likely to remain so for at least the next decade for most product types. Although the economics of recovery vary by region and are influenced by wider demolition waste management frameworks, even the most favourab le circumstances lead to costs of above $100 per tonne CO 2 saved on average. There wi ll be a need for further innovation in the longer-term if recovery from this source is going to become economically feasible.

Considerations will continue into the most appropriate strategies for ODS bank management in foams, with particular focu s on ensuring that CFC capture from existing appliance-based banks is optimised before thos e opportunities are lost. This may involve the need to look at efficient ways of transferring existing technologies from non-Article 5 to Article 5 environments. The most appropriate funding mechanisms for such action are still under discussion, but a conclusion needs to be reached soon if opportunities are going to be grasped.

Although less emissive than the refrigeration an d air conditioning sector, the foam sector continues to represent a substantial bank of long-lived ODS which provide opportunities for future management. Time pressures for manageme nt initiatives vary by sector, but ultimate policy decisions will depend on the emerging cost abatement curves on a wide range of other ozone layer protection and climate m easures. It remains to be seen whether or not th e recovery of ODS from buildings will become a viable opti on given the scattered nature of the sources involved and the efforts required for recovery.

E.6 Specific Regional Messages

Developed Countries

**3⁄4** The growth of appliance foams and blowing ag ent use will continue broadly with general economic drivers, since markets are largely sa turated. However, there may continue to be shifts in manufacturing location which will in fluence regional blowing agent consumption trends.

**3⁄4** Hydrocarbons are now almost fully optimised for appliances, but the relentless drive for energy efficiency is encouraging more focus on cyclo-pentane as a com ponent of blends and, beyond that, interest in unsaturated HFCs (H FOs), which themselves are showing better

ES - 6 potential thermal performance than current liqui d HFCs. It may be that there is some switch from hydrocarbons to HC/u-HFC blends in fu ture as well as a possible switch in North America from liquid HFCs directly to unsat urated HFCs over time depending on the future HFC policy in the United States.

**3⁄4** The growth in blowing agent demand for cons truction applications is driven by energy efficiency in new and existing buildings; there has been a slow-down in the construction of new buildings because of global recession but retrofitting continues with spray foam and other foam products (boards, et c). Nevertheless, growth in th e demand for insulation foams has been dramatic over the last ten years with changes in market share between foam and fibrous insulation over that period, driven by th e requirement for increased thicknesses and a relatively buoyant construction market.

**3⁄4** Hydrocarbons are the dominant blowing agent in the construction sector, with the exception of spray foam where s-HFCs continue to domin ate due to safety issu es, although there is likely to be a further prolifera tion of blends – perhaps with u-HFCs (HFOs) and/or methyl formate – particularly where the thickness requir ements for insulation are perceived to be becoming unmanageable.

**3⁄4** In extruded polystyrene, the long-term future for blowing agent selection is still unclear, with a significant range of technologies in current use. The emergence of u-HFCs (HFOs) may prove of interest as a replacement for gaseous HFCs, particularly as a component of blends. Pressure for transition is like ly to be greater in Europe where the F-Gas Regulation is currently under review. However, in North America there are no further plans to make transitions in the next 10 years since the tran sfer to gaseous s-HFCs has only just been implemented as of 2010.

Developing Countries

**3⁄4** Economic growth rates in several key devel oping countries are likely to drive demand for appliances and other consumergoods over the coming years wh ich will be reflected in the expected growth in demand for blowing agents.

**3⁄4** Since the appliance market is becoming largely a globalised market, future blowing agent selection is largely expected to follow the same patterns as in developed countries.

**3⁄4** Some appliance manufacturers have been or are considering moving from cyclopentane to blends of cyclopentane and HFCs to meet emer ging energy efficiency standards and to better meet existing energy standards for products exported to developed countries.

**3⁄4** Focus on insulation materials for the constructi on market and, in par ticular, foam products varies substantially by developing country regi on, influenced primarily by climatic aspects and the ability to invest in infra-structure.

**3⁄4** There is evidence of considerable effort to insulate both new and existing buildings in China and this has driven demand for PU spray foam as one of the most energy efficient options.ES - 5 E.5 Banks, Emissions and Destruction

The management of ODS banks in appliance foams is currently being addressed by a variety of regulatory and volunt ary frameworks and using a range of fully automated, semiautomated and manual technologies. Although there is evidence to suggest that fully automated approaches provide the most co mprehensive recovery potential, the relevant cost-abatement curves would suggest that some semi-automat ed processes will have a place in the on-going management of ODS banks, particularly in areas where population densities are low or investment is restricted.

Efforts have been made to further characteri se foam inventories in a number of regions. The flow of ODS-containing foams into the demolit ion waste stream from buildings is currently low and is likely to remain so for at least the next decade for most product types. Although the economics of recovery vary by region and are influenced by wider demolition waste management frameworks, even the most favourab le circumstances lead to costs of above $100 per tonne CO 2 saved on average. There wi ll be a need for further innovation in the longer-term if recovery from this source is going to become economically feasible.

Considerations will continue into the most appropriate strategies for ODS bank management in foams, with particular focu s on ensuring that CFC capture from existing appliance-based banks is optimised before thos e opportunities are lost. This may involve the need to look at efficient ways of transferring existing technologies from non-Article 5 to Article 5 environments. The most appropriate funding mechanisms for such action are still under discussion, but a conclusion needs to be reached soon if opportunities are going to be grasped.

Although less emissive than the refrigeration an d air conditioning sector, the foam sector continues to represent a substantial bank of long-lived ODS which provide opportunities for future management. Time pressures for manageme nt initiatives vary by sector, but ultimate policy decisions will depend on the emerging cost abatement curves on a wide range of other ozone layer protection and climate m easures. It remains to be seen whether or not th e recovery of ODS from buildings will become a viable opti on given the scattered nature of the sources involved and the efforts required for recovery.

E.6 Specific Regional Messages

Developed Countries

**3⁄4** The growth of appliance foams and blowing ag ent use will continue broadly with general economic drivers, since markets are largely sa turated. However, there may continue to be shifts in manufacturing location which will in fluence regional blowing agent consumption trends.

**3⁄4** Hydrocarbons are now almost fully optimised for appliances, but the relentless drive for energy efficiency is encouraging more focus on cyclo-pentane as a com ponent of blends and, beyond that, interest in unsaturated HFCs (H FOs), which themselves are showing better

ES - 6 potential thermal performance than current liqui d HFCs. It may be that there is some switch from hydrocarbons to HC/u-HFC blends in fu ture as well as a possible switch in North America from liquid HFCs directly to unsat urated HFCs over time depending on the future HFC policy in the United States.

**3⁄4** The growth in blowing agent demand for cons truction applications is driven by energy efficiency in new and existing buildings; there has been a slow-down in the construction of new buildings because of global recession but retrofitting continues with spray foam and other foam products (boards, et c). Nevertheless, growth in th e demand for insulation foams has been dramatic over the last ten years with changes in market share between foam and fibrous insulation over that period, driven by th e requirement for increased thicknesses and a relatively buoyant construction market.

**3⁄4** Hydrocarbons are the dominant blowing agent in the construction sector, with the exception of spray foam where s-HFCs continue to domin ate due to safety issu es, although there is likely to be a further prolifera tion of blends – perhaps with u-HFCs (HFOs) and/or methyl formate – particularly where the thickness requir ements for insulation are perceived to be becoming unmanageable.

**3⁄4** In extruded polystyrene, the long-term future for blowing agent selection is still unclear, with a significant range of technologies in current use. The emergence of u-HFCs (HFOs) may prove of interest as a replacement for gaseous HFCs, particularly as a component of blends. Pressure for transition is like ly to be greater in Europe where the F-Gas Regulation is currently under review. However, in North America there are no further plans to make transitions in the next 10 years since the tran sfer to gaseous s-HFCs has only just been implemented as of 2010.

Developing Countries

**3⁄4** Economic growth rates in several key devel oping countries are likely to drive demand for appliances and other consumer goods over the coming years wh ich will be reflected in the expected growth in demand for blowing agents.

**3⁄4** Since the appliance market is becoming largely a globalised market, future blowing agent selection is largely expected to follow the same patterns as in developed countries.

**3⁄4** Some appliance manufacturers have been or are considering moving from cyclopentane to blends of cyclopentane and HFCs to meet emer ging energy efficiency standards and to better meet existing energy standards for products exported to developed countries.

**3⁄4** Focus on insulation materials for the constructi on market and, in par ticular, foam products varies substantially by developing country regi on, influenced primarily by climatic aspects and the ability to invest in infra-structure.

**3⁄4** There is evidence of considerable effort to insulate both new and existing buildings in China and this has driven demand for PU spray foam as one of the most energy efficient options.ES - 7 Substantial growth in EPS/XPS has also been observed. However, in recent years, a few high profile fires in cities such as Beijing and Sha nghai have resulted in stricter regulations that may limit the future use of organic insulati on materials for residential buildings.

**3⁄4** There is much less clarity about the choice of blowing agent for the small/medium size enterprises in the construction sector and a variety of technology options (including preblended hydrocarbons, methyl formate, CO 2 (water), liquid s-HFCs and u-HFCs) could all be used to some degree.

**3⁄4** Although methyl formate has SNAP approval by the US EPA for PU spray foam applications, it is still not clear whether the market will view the flammability issues as sufficiently differentiated from hydrocarbons to dr ive uptake. There is likely to be some use of methyl formate in those integral skin applications where CO 2 (water) is not already established.

**3⁄4** Although commercialisation of the various u-HFCs (HFOs) under co nsideration is likely to occur slightly earlier than previously expect ed (perhaps 2013-2015), th ese technologies are still likely to be too late for the bulk of HCFC-141b transitions. Therefore two-step transitions may be necessary to take advantage of their properties. Since the investment costs are likely to be minimal for su ch technologies, a two-step st rategy might be appropriate where the economics support it.

**3⁄4** Work on ‘three-stream’ technologies fo r spray foam (e.g. super-critical CO 2 and gaseous uHFCs) may allow an earlier transition in some instances, although the investment implications are still being assessed.

1 

### FOREWORD

DATA AVAILABILITY

There is no single reference source for the consump tion of blowing agents on a global basis. This is because most bottom-up quantitative assessments are carried out at count ry or regional level. However, supply-side information is available fo r some blowing agent type s at the global level. For example, the fluorocarbon industry has pub lished this data on relevant fluorocarbons at hemispherical level through the AFEAS project . However, this activity was recently discontinued. There has been an understandable reluctance by blowing agent manufacturers to provide supply-side information at greater leve ls of disaggregation because of disclosing valuable confidential information and ultimatel y the risk of contravening competition law.

Without a reliable, comprehensive source of data, the Foams Technical Options Committee (FTOC) has developed its own set of data base d on information gained from a variety of the above sources over a period of years. From this a model has been assembled to characterise consumption – past, present and future. Duri ng each Assessment period, FTOC members are encouraged to research information at regional level. However, this is never expected to result in a comprehensive picture of usag e patterns at any one juncture , but the information gained provides a cross-check on the proj ections contained in the exis ting FTOC model. Adjustments can then be made based on the robus tness of the information obtained.

In this Assessment, the outputs of this process are reported for 2008, which is the latest year for which data could be accessed by the Committee. However, anecdotal qualitative information is conveyed for the subsequent peri od to 2010 where this is known.

The data is reported by blowing agent type and by region, with developed countries being divided into four regions and developing countries into the se ven. The country allocation is provided in Appendix 3. It should be noted that ‘Russia and the Fo rmer Soviet countries’ is a new designation, which replaces ‘Countries with Economies in Transition (CEIT)’. Although not all of these countries would now be classified as ‘d eveloping’ the allocatio n is maintained in order to provide continuity w ith previous Assessments.

LEVELS OF CONSENSUS

The Assessment has proved the most challenging to date in which to reach consensus for the FTOC. This is partly because th ere is a high level of uncertainty in the likely success of competing alternative blowing agents. This, in tu rn, arises from the fact that there is little previous experience with many of these alternatives in developed countries. With the future of some blowing agent options resti ng in the balance and pressures to make choices in a number of developing countries, there has b een and understandable culture of claim and counter-claim. The FTOC has not been immune from these claims and counter-claims and, in the absence of sound scientific evidence or practical e xperience, it has been impossible to resolve some differences of opinion. However, in most instances a strong majo rity view has emerged. One of the focal pointsES - 7 Substantial growth in EPS/XPS has also been observed. However, in recent years, a few high profile fires in cities such as Beijing and Sha nghai have resulted in stricter regulations that may limit the future use of organic insulati on materials for residential buildings.

**3⁄4** There is much less clarity about the choice of blowing agent for the small/medium size enterprises in the construction sector and a variety of technology options (including preblended hydrocarbons, methyl formate, CO 2 (water), liquid s-HFCs and u-HFCs) could all be used to some degree.

**3⁄4** Although methyl formate has SNAP approval by the US EPA for PU spray foam applications, it is still not clear whether the market will view the flammability issues as sufficiently differentiated from hydrocarbons to dr ive uptake. There is likely to be some use of methyl formate in those integral skin applications where CO 2 (water) is not already established.

**3⁄4** Although commercialisation of the various u-HFCs (HFOs) under co nsideration is likely to occur slightly earlier than previously expect ed (perhaps 2013-2015), th ese technologies are still likely to be too late for the bulk of HCFC-141b transitions. Therefore two-step transitions may be necessary to take advantage of their properties. Since the investment costs are likely to be minimal for su ch technologies, a two-step st rategy might be appropriate where the economics support it.

**3⁄4** Work on ‘three-stream’ technologies fo r spray foam (e.g. super-critical CO 2 and gaseous uHFCs) may allow an earlier transition in some instances, although the investment implications are still being assessed.

1 

### FOREWORD

DATA AVAILABILITY

There is no single reference source for the consump tion of blowing agents on a global basis. This is because most bottom-up quantitative assessments are carried out at count ry or regional level. However, supply-side information is available fo r some blowing agent type s at the global level. For example, the fluorocarbon industry has pub lished this data on relevant fluorocarbons at hemispherical level through the AFEAS project . However, this activity was recently discontinued. There has been an understandable reluctance by blowing agent manufacturers to provide supply-side information at greater leve ls of disaggregation because of disclosing valuable confidential information and ultimatel y the risk of contravening competition law.

Without a reliable, comprehensive source of data, the Foams Technical Options Committee (FTOC) has developed its own set of data base d on information gained from a variety of the above sources over a period of years. From this a model has been assembled to characterise consumption – past, present and future. Duri ng each Assessment period, FTOC members are encouraged to research information at regional level. However, this is never expected to result in a comprehensive picture of usag e patterns at any one juncture , but the information gained provides a cross-check on the proj ections contained in the exis ting FTOC model. Adjustments can then be made based on the robus tness of the information obtained.

In this Assessment, the outputs of this process are reported for 2008, which is the latest year for which data could be accessed by the Committee. However, anecdotal qualitative information is conveyed for the subsequent peri od to 2010 where this is known.

The data is reported by blowing agent type and by region, with developed countries being divided into four regions and developing countries into the se ven. The country allocation is provided in Appendix 3. It should be noted that ‘Russia and the Fo rmer Soviet countries’ is a new designation, which replaces ‘Countries with Economies in Transition (CEIT)’. Although not all of these countries would now be classified as ‘d eveloping’ the allocatio n is maintained in order to provide continuity w ith previous Assessments.

LEVELS OF CONSENSUS

The Assessment has proved the most challenging to date in which to reach consensus for the FTOC. This is partly because th ere is a high level of uncertainty in the likely success of competing alternative blowing agents. This, in tu rn, arises from the fact that there is little previous experience with many of these alternatives in developed countries. With the future of some blowing agent options resti ng in the balance and pressures to make choices in a number of developing countries, there has b een and understandable culture of claim and counter-claim. The FTOC has not been immune from these claims and counter-claims and, in the absence of sound scientific evidence or practical e xperience, it has been impossible to resolve some differences of opinion. However, in most instances a strong majo rity view has emerged. One of the focal points2 of these differences has been methyl format e technology, which has become something of a ‘cause célèbre’ , since its promotion in some quarters has influenced the funding basis for many MLF projects. The FTOC remains sceptical abou t some of the claims made for the technology, but a minority believe that these claims either have been, or can be, substan tiated. In dealing with this situation, the following statement has been agr eed as an appropriate e xpression of the status:

Although the majority view of the Committee is that the use of methyl formate
in rigid foam is unproven, a minority of members ‐ particularly the protagonists of the technology ‐ contest this view, arguing that usage is already occurring or has been sanctioned. A further aspect on which there is a discrepancy of view is

over the significance of the flammability issue, with the majority aligning with the text of this report. Key areas of dispute are annotated by footnotes.

The co-chairs of the FTOC advocate that readers approach the relevant se ctions of this report with this caveat in mind.

3 

### CHAPTER 1: TRANSITIONAL STATUS

POLYURETHANE FOAMS

RIGID POLYURETHANE FOAM

NON-CONSTRUCTION APPLICATIONS

This sector includes domestic refrigerators and freezers, commercial refrigeration units, water heaters and refrigerated transport applications . It does not include mi scellaneous non-insulating applications.

REFRIGERATION EQUIPMENT AND APPLIANCES

Developed Countries

Domestic Refrigerators and Freezers

- Current market trends

The manufacture of domestic refrigerators and freezers continues across most of the developed world, although there is an increasing shift of production from developed to developing countries. Current estimates suggest that the split is now 45%:55%.

Polyurethane foam continues to dominate the mark et for refrigerator and freezer insulation, with more sophisticated technologies such as vacuum panels still being limited to very specialist applications. However, it is noted that one manuf acturer [Panasonic] has re cently re-introduced a model containing such panels in to Europe and there is also some continuing use of vacuum panels (based on open-celled foams) in Japan fo r the walls of some models. One of the shortcomings observed with vacuum panels is that th ey have low thermal inertia when compared to foam, which leads to more rapid warm-up in the event of a power outage.

Further increases in the thermal performance of do mestic refrigerators in Europe are expected to continue, but it is not yet clear whether this will lead to increased foam use, bearing in mind that space is usually at a premium. However, conti nued trends towards North American styles of cabinet refrigerator will permit increased foam usag e per unit. In Japan the market is relatively static, although showing li ttle sign of decline, partly because the country continues to be a net importer of white goods (1.9 million produced versus 4.5 million sold). As in Europe, North America will see further increases in energy efficiency requirements over the next five years. In the United States of America, the Department of Energy had already set a new rule for domestic appliances being manufactured in 2014 and onwar ds. These requirements are likely to be met by a combination of compressor efficiencies, incr eased foam use and pote ntial changes to the blowing agent selection.2 of these differences has been methyl format e technology, which has become something of a ‘cause célèbre’ , since its promotion in some quarters has influenced the funding basis for many MLF projects. The FTOC remains sceptical abou t some of the claims made for the technology, but a minority believe that these claims either have been, or can be, substan tiated. In dealing with this situation, the following statement has been agr eed as an appropriate e xpression of the status:

Although the majority view of the Committee is that the use of methyl formate
in rigid foam is unproven, a minority of members ‐ particularly the protagonists of the technology ‐ contest this view, arguing that usage is already occurring or has been sanctioned. A further aspect on which there is a discrepancy of view is

over the significance of the flammability issue, with the majority aligning with the text of this report. Key areas of dispute are annotated by footnotes.

The co-chairs of the FTOC advocate that readers approach the relevant se ctions of this report with this caveat in mind.

3 

### CHAPTER 1: TRANSITIONAL STATUS

POLYURETHANE FOAMS

RIGID POLYURETHANE FOAM

NON-CONSTRUCTION APPLICATIONS

This sector includes domestic refrigerators and freezers, commercial refrigeration units, water heaters and refrigerated transport applications . It does not include mi scellaneous non-insulating applications.

REFRIGERATION EQUIPMENT AND APPLIANCES

Developed Countries

Domestic Refrigerators and Freezers

- Current market trends

The manufacture of domestic refrigerators and freezers continues across most of the developed world, although there is an increasing shift of production from developed to developing countries. Current estimates suggest that the split is now 45%:55%.

Polyurethane foam continues to dominate the mark et for refrigerator and freezer insulation, with more sophisticated technologies such as vacuum panels still being limited to very specialist applications. However, it is noted that one manuf acturer [Panasonic] has re cently re-introduced a model containing such panels in to Europe and there is also some continuing use of vacuum panels (based on open-celled foams) in Japan fo r the walls of some models. One of the shortcomings observed with vacuum panels is that th ey have low thermal inertia when compared to foam, which leads to more rapid warm-up in the event of a power outage.

Further increases in the thermal performance of do mestic refrigerators in Europe are expected to continue, but it is not yet clear whether this will lead to increased foam use, bearing in mind that space is usually at a premium. However, conti nued trends towards North American styles of cabinet refrigerator will permit increased foam usag e per unit. In Japan the market is relatively static, although showing li ttle sign of decline, partly because the country continues to be a net importer of white goods (1.9 million produced versus 4.5 million sold). As in Europe, North America will see further increases in energy efficiency requirements over the next five years. In the United States of America, the Department of Energy had already set a new rule for domestic appliances being manufactured in 2014 and onwar ds. These requirements are likely to be met by a combination of compressor efficiencies, incr eased foam use and pote ntial changes to the blowing agent selection.4 - Current blowing agent selection

The choice of blowing agent in developed countries as a whole is illustrated in the graph below.

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Dom. Appliances 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

The divide between the North American market a nd the rest of the developed world continues as the domestic appliance industry continues its use of HFC-245fa and, to a lesser extent HFC-134a in refrigerators and freezers. With the US Department of Energy continuing to demand increasing minimum energy standards across the i ndustry it seems unlikely that the bulk of the industry will consider a move out of saturated HFCs until unsat urated HFCs (HFOs) such as 1234ze(Z) and 1336mzz and other still undisclos ed molecules are commercially available. However, there are some US manufacturers who ha ve gained experience of manufacturing with hydrocarbon in Mexico and may still consider a switch to HCs in the United States as their ultimate solution. Indeed, one is already reported to have switched one plant to hydrocarbons.

Meanwhile, in Europe and elsewhere, the experi ence with hydrocarbons is well established and increasing energy efficiency demands continue to be met, partly as a result of on-going improvements in hydrocarbon technol ogies. It is therefore likely that European manufacturers will stay with their choice for the foreseeable future, even though there is some interest in evaluating unsaturated HFCs – particularly where these are exhibiting superior thermal performance. In Japan, the market is fully settled on hydrocarbons with cyclo-pentane and cyclo/iso blends being amongst the blow ing agents of choice.

5 Other Appliances

- Current Market Trends

This sector covers a number of product types including water heaters, vending machines, display cabinets and commercial freezers. The widespr ead use of vending mach ines across the hotel industry in the United States and their relative size, makes the North American market for foams more significant than other regions.

Despite the drive for improved ener gy efficiency, the market is seen as relatively static from a technology perspective with size being a less significan t constraining factor than it is in the domestic sector. This has allowed the use of less efficient insulation types and has made the choice of blowing agent less significant.

The situation is rather different for supermarket display cabinets, wh ere occupied floor area is an important factor. Nonetheless, the energy effici ency of such supermarket systems is often dictated by the choice of refrigeran t delivery system (distributed vers us stand-alone). It is only in the stand-alone cases, where the foam technology choices are likely to be critical.

- Current blowing agent selection

The graph below illustrates the spread of blowing agent choice as at 2008:

0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Other Appliances 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs4 - Current blowing agent selection

The choice of blowing agent in developed countries as a whole is illustrated in the graph below.

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Dom. Appliances 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

The divide between the North American market a nd the rest of the developed world continues as the domestic appliance industry continues its use of HFC-245fa and, to a lesser extent HFC-134a in refrigerators and freezers. With the US Department of Energy continuing to demand increasing minimum energy standards across the i ndustry it seems unlikely that the bulk of the industry will consider a move out of saturated HFCs until unsat urated HFCs (HFOs) such as 1234ze(Z) and 1336mzz and other still undisclos ed molecules are commercially available. However, there are some US manufacturers who ha ve gained experience of manufacturing with hydrocarbon in Mexico and may still consider a switch to HCs in the United States as their ultimate solution. Indeed, one is already reported to have switched one plant to hydrocarbons.

Meanwhile, in Europe and elsewhere, the experi ence with hydrocarbons is well established and increasing energy efficiency demands continue to be met, partly as a result of on-going improvements in hydrocarbon technol ogies. It is therefore likely that European manufacturers will stay with their choice for the foreseeable future, even though there is some interest in evaluating unsaturated HFCs – particularly where these are exhibiting superior thermal performance. In Japan, the market is fully settled on hydrocarbons with cyclo-pentane and cyclo/iso blends being amongst the blow ing agents of choice.

5 Other Appliances

- Current Market Trends

This sector covers a number of product types including water heaters, vending machines, display cabinets and commercial freezers. The widespr ead use of vending mach ines across the hotel industry in the United States and their relative size, makes the North American market for foams more significant than other regions.

Despite the drive for improved ener gy efficiency, the market is seen as relatively static from a technology perspective with size being a less significan t constraining factor than it is in the domestic sector. This has allowed the use of less efficient insulation types and has made the choice of blowing agent less significant.

The situation is rather different for supermarket display cabinets, wh ere occupied floor area is an important factor. Nonetheless, the energy effici ency of such supermarket systems is often dictated by the choice of refrigeran t delivery system (distributed vers us stand-alone). It is only in the stand-alone cases, where the foam technology choices are likely to be critical.

- Current blowing agent selection

The graph below illustrates the spread of blowing agent choice as at 2008:

0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Other Appliances 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs6 At this point in time, there was some residual use of HCFCs in this sector in North America. This was partly as a result of the fact that regulator y requirements were only just taking effect in the US. However, there was also some continue d use in Canada, since the phase-down there continues to progress on a tr adable allowance system.

In the North American vending machine sect or, there has also been some use of CO 2 (water) systems as well as some emerging acceptance of me thyl formate in the application. In 2008, the use of methyl formate was nominal (perhaps 125 tonnes [3-4%]), but ther e is an u nderstanding that it may have grown further sinc e then to perhaps about 5%.

Reefers and Refrigerated Transport

- Current Market Trends

This sector covers both the ma nufacture of reefers (refrigerate d containers) and the manufacture of other refrigerated transpor t bodies (e.g. insulated tanks a nd truck bodies). The sector is distinguished from others by the f act that the polyurethane foam system is injected into a cavity rather than constructed from pre-fabricated pa rts (e.g. discontinuous steel-faced panels). Over 50% of all foam in this sector is manufactured in developing countries indicating the dominant position that China holds in the gl obal manufacture of reefers.

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Reefers & Refr. Transport 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

7 The graph of consumption in developed countries shows the substantial variations in blowing agent choice across the regions, with the European region fo cusing on the use of hydrocarbons, whilst Japan and North America are largely relian t on HFCs. As with other appliances, there was some residual reliance on HCFCs in 2008 in No rth America – primarily in Canada.

Developing Countries
Domestic Refrigerators and Freezers

- Current Market Trends
The manufacture of domestic refrigerators and freezers in developing count ries is dominated by production by North East Asia (inc luding China and South Korea) and Latin America. In China alone it is estimated that mo re than 300,000 tonnes of PU foam was consumed in 2008 in the domestic refrigerator and freezer market alone. Growth rates are running at around 8% per annum based on both domestic growth and the shift of production capacity from other countries.
In Latin America, the market has been growing at 5-7% per year, but has been influenced in the post-2008 period by some Government intervention to increase refrigerator ownership and to catalyse the replacement of old, inefficient un its. The market, particularly in Mexico and surrounding countries, also continues to be infl uenced by the relocation of production from the United States and the export demand that this provides.
- Current Blowing Agent Selection
The choice of blowing agent in developed countries as a whole is illustrated in the graph below.

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Dom. Appliances 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs6 At this point in time, there was some residual use of HCFCs in this sector in North America. This was partly as a result of the fact that regulator y requirements were only just taking effect in the US. However, there was also some continue d use in Canada, since the phase-down there continues to progress on a tr adable allowance system.

In the North American vending machine sect or, there has also been some use of CO 2 (water) systems as well as some emerging acceptance of me thyl formate in the application. In 2008, the use of methyl formate was nominal (perhaps 125 tonnes [3-4%]), but ther e is an u nderstanding that it may have grown further sinc e then to perhaps about 5%.

Reefers and Refrigerated Transport

- Current Market Trends

This sector covers both the ma nufacture of reefers (refrigerate d containers) and the manufacture of other refrigerated transpor t bodies (e.g. insulated tanks a nd truck bodies). The sector is distinguished from others by the f act that the polyurethane foam system is injected into a cavity rather than constructed from pre-fabricated pa rts (e.g. discontinuous steel-faced panels). Over 50% of all foam in this sector is manufactured in developing countries indicating the dominant position that China holds in the gl obal manufacture of reefers.

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Reefers & Refr. Transport 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

7 The graph of consumption in developed countries shows the substantial variations in blowing agent choice across the regions, with the European region fo cusing on the use of hydrocarbons, whilst Japan and North America are largely relian t on HFCs. As with other appliances, there was some residual reliance on HCFCs in 2008 in No rth America – primarily in Canada.

Developing Countries
Domestic Refrigerators and Freezers

- Current Market Trends
The manufacture of domestic refrigerators and freezers in developing count ries is dominated by production by North East Asia (inc luding China and South Korea) and Latin America. In China alone it is estimated that mo re than 300,000 tonnes of PU foam was consumed in 2008 in the domestic refrigerator and freezer market alone. Growth rates are running at around 8% per annum based on both domestic growth and the shift of production capacity from other countries.
In Latin America, the market has been growing at 5-7% per year, but has been influenced in the post-2008 period by some Government intervention to increase refrigerator ownership and to catalyse the replacement of old, inefficient un its. The market, particularly in Mexico and surrounding countries, also continues to be infl uenced by the relocation of production from the United States and the export demand that this provides.
- Current Blowing Agent Selection
The choice of blowing agent in developed countries as a whole is illustrated in the graph below.

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Dom. Appliances 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs8 The market in developing countries is split be tween the use of hydrocarbons and HCFCs. There is also a small amount of HFC use for the export market to North America in the Latin American region.

The original decision to invest in hydrocar bon technology was driven, in part, by the likely demand arising from large populations, which in tu rn led to perceived economies of scale. An additional factor in the direct transition from CFCs to hydrocar bons in the previous phase was the active promotion and encouragement provi ded under the Multilateral Fund, which offered additional support to leap-frog HCFCs in this sector.

Other Appliances

- Current Market Trends
In contrast with domestic appliances, only just over 25% of ‘other ap pliances’ manufactured globally are made in developing co untries, with the bulk of these being in China. As noted for developed countries, the range of product types is very diverse. However, there is typically greater demand for small-scale di splay cabinets in developing count ries driven by the size of retail outlets.

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region

Blowing Agent Consumption by Type ‐ Other Appliances 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

9 As can be seen in the graph above, virtually th e total blowing agent demand in this sector in 2008 was for HCFCs. There is now interest in h ydrocarbons and methyl formate. Accordingly, this sector is reliant on the delivery of HCFC alternatives under Deci sion XIX/6 initiatives. Options are discussed further in Chapter 2.

Reefers and Refrigerated Transport

- Current Market Trends

Although refrigerated transport un its (e.g. insulated tankers and refrigerated truck bodies) are manufactured throughout the developed world for local use, the bulk of global refrigerated container manufacture has shifted to China ba sed on unit pricing – partially derived from economies of scale. This market has grown rela tively rapidly and, as an in-situ process has needed to be based on proven tec hnologies for the most part.

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Reefers & Refr. Transport 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

As can be seen from the graph above, main blowi ng agents currently in use are HCFCs, and this is almost exclusively HCFC-141b. There is al so some reported use of HFC-134a in Latin America, although the precise appl ication is not known. It is expected that a froth foaming process would be practised in this instance.8 The market in developing countries is split be tween the use of hydrocarbons and HCFCs. There is also a small amount of HFC use for the export market to North America in the Latin American region.

The original decision to invest in hydrocar bon technology was driven, in part, by the likely demand arising from large populations, which in tu rn led to perceived economies of scale. An additional factor in the direct transition from CFCs to hydrocar bons in the previous phase was the active promotion and encouragement provi ded under the Multilateral Fund, which offered additional support to leap-frog HCFCs in this sector.

Other Appliances

- Current Market Trends
In contrast with domestic appliances, only just over 25% of ‘other ap pliances’ manufactured globally are made in developing co untries, with the bulk of these being in China. As noted for developed countries, the range of product types is very diverse. However, there is typically greater demand for small-scale di splay cabinets in developing count ries driven by the size of retail outlets.

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region

Blowing Agent Consumption by Type ‐ Other Appliances 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

9 As can be seen in the graph above, virtually th e total blowing agent demand in this sector in 2008 was for HCFCs. There is now interest in h ydrocarbons and methyl formate. Accordingly, this sector is reliant on the delivery of HCFC alternatives under Deci sion XIX/6 initiatives. Options are discussed further in Chapter 2.

Reefers and Refrigerated Transport

- Current Market Trends

Although refrigerated transport un its (e.g. insulated tankers and refrigerated truck bodies) are manufactured throughout the developed world for local use, the bulk of global refrigerated container manufacture has shifted to China ba sed on unit pricing – partially derived from economies of scale. This market has grown rela tively rapidly and, as an in-situ process has needed to be based on proven tec hnologies for the most part.

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ Reefers & Refr. Transport 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

As can be seen from the graph above, main blowi ng agents currently in use are HCFCs, and this is almost exclusively HCFC-141b. There is al so some reported use of HFC-134a in Latin America, although the precise appl ication is not known. It is expected that a froth foaming process would be practised in this instance.10 CONSTRUCTION APPLICATIONS

This sector covers all applications of rigid polyurethane foams in building and construction, including the use of foamed panels in large-scale walk-in cold storage facilities, which are typically consider ed as temporary buildings.

Developed Countries

PU Boardstock

- Current Market Trends
The growth in use of PU (incl. PIR) boardstoc k products has been dramatic in some markets, particularly where cavity wall constructions are common and the minimum energy efficiency requirements cannot be met with less efficient insu lation types such as mine ral fibre. There is a trend toward incorporating boardstock products in external thermal insulation construction systems (ETICS) for the refurbis hment of solid walls. Although these typical ly have a payback within their lifetimes (i.e. net negative whole life cost), they are amongst the more expensive renovation options. Accordingly, fi bre insulation has made ground in on-going residential loft insulation upgrades as a more cost-effective renovation strategy, where it can be applied.

- Current blowing agent selection

0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Boardstock 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

11 The bulk of the polyurethane boardstock market has transferred to hydr ocarbon (initially cyclo pentane but now more typically n- or iso-pentane), with only very minor use of HFCs in North America. As can be seen, consumption levels in Japan are relatively low based on the fact that PU Spray systems are a more prevalent way of in sulating than PU boardst ock in that region. No further transitions are expected in devel oped regions in the near future.

PU Continuous Panels

- Current Market Trends

The growth of the polyurethane composite (sandwich) panel mark et has continued apace in the period since the last Assessment. These panels can typically be faced with steel, aluminium or other metallic surfaces and are increasingly being marketed as architectural panels. In some instances, they are now being designed to incorpor ate PV solar panels and offer the potential of contributing strongly towards zero-carbon building solutions now being demanded in some countries.

- Current blowing agent selection

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Continuous Panel 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

There has been retention of HFCs in some countri es in Europe based on th e requirements to meet certain regulatory and insurance criteria with respect to fire. However, increasingly, hydrocarbon is seen as the long term solution in this sector, since the thickness of foam requirements is driven10 CONSTRUCTION APPLICATIONS

This sector covers all applications of rigid polyurethane foams in building and construction, including the use of foamed panels in large-scale walk-in cold storage facilities, which are typically consider ed as temporary buildings.

Developed Countries

PU Boardstock

- Current Market Trends
The growth in use of PU (incl. PIR) boardstoc k products has been dramatic in some markets, particularly where cavity wall constructions are common and the minimum energy efficiency requirements cannot be met with less efficient insu lation types such as mine ral fibre. There is a trend toward incorporating boardstock products in external thermal insulation construction systems (ETICS) for the refurbis hment of solid walls. Although these typical ly have a payback within their lifetimes (i.e. net negative whole life cost), they are amongst the more expensive renovation options. Accordingly, fi bre insulation has made ground in on-going residential loft insulation upgrades as a more cost-effective renovation strategy, where it can be applied.

- Current blowing agent selection

0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Boardstock 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

11 The bulk of the polyurethane boardstock market has transferred to hydr ocarbon (initially cyclo pentane but now more typically n- or iso-pentane), with only very minor use of HFCs in North America. As can be seen, consumption levels in Japan are relatively low based on the fact that PU Spray systems are a more prevalent way of in sulating than PU boardst ock in that region. No further transitions are expected in devel oped regions in the near future.

PU Continuous Panels

- Current Market Trends

The growth of the polyurethane composite (sandwich) panel mark et has continued apace in the period since the last Assessment. These panels can typically be faced with steel, aluminium or other metallic surfaces and are increasingly being marketed as architectural panels. In some instances, they are now being designed to incorpor ate PV solar panels and offer the potential of contributing strongly towards zero-carbon building solutions now being demanded in some countries.

- Current blowing agent selection

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Continuous Panel 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

There has been retention of HFCs in some countri es in Europe based on th e requirements to meet certain regulatory and insurance criteria with respect to fire. However, increasingly, hydrocarbon is seen as the long term solution in this sector, since the thickness of foam requirements is driven12 more by panel strength requirements than it is by thermal performance per se. Typical panel thicknesses for new buildings can be in the 80 -100mm range. As can also be seen from the relevant graph, this technology is far more esta blished in Europe than elsewhere. However, growth rates are rapid in part s of North America and in the Rest of the Developed World (RODW). There was, in 2008, some residual use of HCFC technology in Canada.

PU Discontinuous Panels

- Current Market Trends

There has been a level of conj ecture about the relativ e size of the discontinuous panel market sector as a proportion of the total metal-faced pa nel industry. Some projections have the absolute size of the discontinuous panel ma rket staying relatively static – arguing that increased demand will be met exclusively by the continuous sector as investments respond to economies of scale. Others, including this Assessmen t, argue that, where market penetration is spreading geographically, fledgling pr oduction facilities will always star t in a discontinuous fashion. In the end, it is the transport costs of fi nished products that probably dict ates the final outcome and this will be further reviewed in subsequent Assessments.

- Current blowing agent selection

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Discontinuous Panel 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

13 Again Europe has the bulk of this market w ith the blowing agent choice being split between HFCs and hydrocarbons depending on the prev ailing response to the risk of handling hydrocarbons in discontinuous processes. As for th e continuous panel scenario, there was some residual use of HCFCs in No rth America as at 2008.

PU Spray Foam

- Current Market Trends

As noted under the PU boardstock section, this technology is a major com ponent of the Japanese insulation sector and spray foam remains the mostsignificant market on a per-capita basis. In North America, there are two distinct product type s: - a low density infill product for gap-filling between timber studs (primarily to avoid air infiltra tion) and a higher density thermal insulation material for more technically demanding appli cations such as commercial flat-roofing. In Europe, the product is typically us ed on flat-roofed residential build ings in Southern Europe (e.g. Spain and Italy). The technology is s een to have a particular role in cost-effective renovations in these regions.

- Current blowing agent selection

0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Spray 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

The primary blowing agent choices for this technology in developed countri es are HFCs. This can be either HFC-245fa (primarily in the Un ited States) or HFC-365mfc/227ea blends (more12 more by panel strength requirements than it is by thermal performance per se. Typical panel thicknesses for new buildings can be in the 80 -100mm range. As can also be seen from the relevant graph, this technology is far more esta blished in Europe than elsewhere. However, growth rates are rapid in part s of North America and in the Rest of the Developed World (RODW). There was, in 2008, some residual use of HCFC technology in Canada.

PU Discontinuous Panels

- Current Market Trends

There has been a level of conj ecture about the relativ e size of the discontinuous panel market sector as a proportion of the total metal-faced pa nel industry. Some projections have the absolute size of the discontinuous panel ma rket staying relatively static – arguing that increased demand will be met exclusively by the continuous sector as investments respond to economies of scale. Others, including this Assessmen t, argue that, where market penetration is spreading geographically, fledgling pr oduction facilities will always star t in a discontinuous fashion. In the end, it is the transport costs of fi nished products that probably dict ates the final outcome and this will be further reviewed in subsequent Assessments.

- Current blowing agent selection

0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Discontinuous Panel 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

13 Again Europe has the bulk of this market w ith the blowing agent choice being split between HFCs and hydrocarbons depending on the prev ailing response to the risk of handling hydrocarbons in discontinuous processes. As for th e continuous panel scenario, there was some residual use of HCFCs in No rth America as at 2008.

PU Spray Foam

- Current Market Trends

As noted under the PU boardstock section, this technology is a major com ponent of the Japanese insulation sector and spray foam remains the most significant market on a per-capita basis. In North America, there are two distinct product type s: - a low density infill product for gap-filling between timber studs (primarily to avoid air infiltra tion) and a higher density thermal insulation material for more technically demanding appli cations such as commercial flat-roofing. In Europe, the product is typically us ed on flat-roofed residential build ings in Southern Europe (e.g. Spain and Italy). The technology is s een to have a particular role in cost-effective renovations in these regions.

- Current blowing agent selection

0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Spray 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

The primary blowing agent choices for this technology in developed countri es are HFCs. This can be either HFC-245fa (primarily in the Un ited States) or HFC-365mfc/227ea blends (more14 prevalent in Europe). The low density in-fi ll foams used in North America are typically CO 2 (water) blown. There is also sign ificant use of super-critical CO 2 in Japan, although this has not been graphed separately at this stage, since CO 2 consumption data has been harder to verify. Nonetheless, it is estimated that CO 2 -based technologies as a whol e represent the majority of consumption in the Japanese market.

PU One Component Foam

- Current Market Trends

This is a predominantly European market arisin g from the construction methods used with brick and block constructions. The product is based on a moisture-cured system (hence the term ‘onecomponent’) and is used primarily on site. The mark et is highly sensitive to construction activity, particularly in the residential se ctor, but is likely to benefit from renovation activities also.

- Current blowing agent selection

0 1,000 2,000 3,000 4,000 5,000 6,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU One Component 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Although hydrocarbons are no ted as the primary blowing agent in Europe, this analysis needs to be enhanced further in future Assessments si nce, although many formulations are based on blends, one of the principle components is beli eved to be dimethyl either (DME) and other similar products. Ethers would typically qua lify as oxygenated hydrocarbons (HCOs) and would be accounted accordingly in future analyses.

15 PU Pipe-in-Pipe (including moulding of pipe sections)

- Current Market Trends

This market has historically been strong in centralised economies where the pr ovision of heat to large residential complexes is delivered from a cen tral heat source. These district heating systems have become more significant now in other regi ons where the advent of combined heat and power (CHP) systems has encouraged simila r underground pipe solutions. Some of these systems can now be on quite a small-scale (so-called micro-CHP ).

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Pipe

‐ in

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

The major market for this approach is in Europe where hydrocarbon technologies have proved fully operable for the pre-insulated pipes requir ed. There is also some minor use of HFCs.

PU Block – Pipe Section

- Current Market Trends

Compared with other polyurethane markets, this sector remains fairly mature and tends to fluctuate mostly with process-ba sed investments. Polyur ethane pipe sections (particularly PIR)14 prevalent in Europe). The low density in-fi ll foams used in North America are typically CO 2 (water) blown. There is also sign ificant use of super-critical CO 2 in Japan, although this has not been graphed separately at this stage, since CO 2 consumption data has been harder to verify. Nonetheless, it is estimated that CO 2 -based technologies as a whol e represent the majority of consumption in the Japanese market.

PU One Component Foam

- Current Market Trends

This is a predominantly European market arisin g from the construction methods used with brick and block constructions. The product is based on a moisture-cured system (hence the term ‘onecomponent’) and is used primarily on site. The mark et is highly sensitive to construction activity, particularly in the residential se ctor, but is likely to benefit from renovation activities also.

- Current blowing agent selection

0 1,000 2,000 3,000 4,000 5,000 6,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU One Component 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Although hydrocarbons are no ted as the primary blowing agent in Europe, this analysis needs to be enhanced further in future Assessments si nce, although many formulations are based on blends, one of the principle components is beli eved to be dimethyl either (DME) and other similar products. Ethers would typically qua lify as oxygenated hydrocarbons (HCOs) and would be accounted accordingly in future analyses.

15 PU Pipe-in-Pipe (including moulding of pipe sections)

- Current Market Trends

This market has historically been strong in centralised economies where the pr ovision of heat to large residential complexes is delivered from a cen tral heat source. These district heating systems have become more significant now in other regi ons where the advent of combined heat and power (CHP) systems has encouraged simila r underground pipe solutions. Some of these systems can now be on quite a small-scale (so-called micro-CHP ).

- Current blowing agent selection

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Pipe

‐ in

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

The major market for this approach is in Europe where hydrocarbon technologies have proved fully operable for the pre-insulated pipes requir ed. There is also some minor use of HFCs.

PU Block – Pipe Section

- Current Market Trends

Compared with other polyurethane markets, this sector remains fairly mature and tends to fluctuate mostly with process-ba sed investments. Polyur ethane pipe sections (particularly PIR)16 have a niche in cryogenic applications, where thei r resilience at these temperatures is important. In other parts of the market they are under more pr essure from other products offering better fire performance (e.g. phenolic foam or mineral fibre).

- Current blowing agent selection

PU block can be made both continuously and discontinuous. Where market demand supports it, continuous block offers less waste. However, cutt ing pipe sections from blocks is always an inefficient process and the choice of blowing ag ent needs to reflect this, both economically and environmentally. Accordingly, there has been in creasing pressure on the use of hydrocarbons in this sector despite the initial concerns over process safety. For th e larger producers, the management of hydrocarbon technology has proved both possible and cost-effective – once the initial investment was made. For smaller manufacturers , HFCs have been a more obvious choice.

0 200 400 600 800 1,000 1,200 1,400

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Block - Slabstock

- Current Market Trends

Again, this product type is relatively mature and is typically used for non-r outine applications for polyurethane foams where a degree of fabrica tion is necessary. The market for slabstock products is typically higher than for pipe section – partly due to the lower losses resulting from the fabrication step. This can be passed on in more competitive pricing.

17 - Current blowing agent selection

The processing is precisely as desc ribed for PU Block-Pipe and the blowing choice is identical as a result. There are few applications for slabstock where the choice of a hydr ocarbon blowing agent does not suffice. Therefore, the final bl owing selection is broadly driven by process considerations.

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Slab 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Developing Countries

PU Boardstock

- Current Market Trends

PU Boardstock has not been an historic part of the product mix in deve loping countries and the only known production facility has been in Turk ey (accounted for under MENA). This facility has broadly been supplying the European market and does not really reflect indigenous demand. That said, there is an increasing interest in all thermal insulation options for new buildings, particularly in colder climates as the de mand for energy efficienc y, driven both by energy security and climate change considerations, in creases. It has been observed by the FTOC that technology transfer from devel oped to developing countries relating to energy efficiency16 have a niche in cryogenic applications, where thei r resilience at these temperatures is important. In other parts of the market they are under more pr essure from other products offering better fire performance (e.g. phenolic foam or mineral fibre).

- Current blowing agent selection

PU block can be made both continuously and discontinuous. Where market demand supports it, continuous block offers less waste. However, cutt ing pipe sections from blocks is always an inefficient process and the choice of blowing ag ent needs to reflect this, both economically and environmentally. Accordingly, there has been in creasing pressure on the use of hydrocarbons in this sector despite the initial concerns over process safety. For th e larger producers, the management of hydrocarbon technology has proved both possible and cost-effective – once the initial investment was made. For smaller manufacturers , HFCs have been a more obvious choice.

0 200 400 600 800 1,000 1,200 1,400

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Block - Slabstock

- Current Market Trends

Again, this product type is relatively mature and is typically used for non-r outine applications for polyurethane foams where a degree of fabrica tion is necessary. The market for slabstock products is typically higher than for pipe section – partly due to the lower losses resulting from the fabrication step. This can be passed on in more competitive pricing.

17 - Current blowing agent selection

The processing is precisely as desc ribed for PU Block-Pipe and the blowing choice is identical as a result. There are few applications for slabstock where the choice of a hydr ocarbon blowing agent does not suffice. Therefore, the final bl owing selection is broadly driven by process considerations.

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Slab 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Developing Countries

PU Boardstock

- Current Market Trends

PU Boardstock has not been an historic part of the product mix in deve loping countries and the only known production facility has been in Turk ey (accounted for under MENA). This facility has broadly been supplying the European market and does not really reflect indigenous demand. That said, there is an increasing interest in all thermal insulation options for new buildings, particularly in colder climates as the de mand for energy efficienc y, driven both by energy security and climate change considerations, in creases. It has been observed by the FTOC that technology transfer from devel oped to developing countries relating to energy efficiency18 solutions and standards has been on the increas e during this Assessment period and may lead to the adaptation of more developed country insulation strategies fo r both timber-framed and brick/ block constructions.

- Current blowing agent selection

In the one known facility, the choice of blowing agent has been consistent with the market served (Europe) and no particular technol ogical challenges have been observed.

0 20 40 60 80 100 120 140 160 180

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Boardstock 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Continuous Panels

- Current Market Trends

In view of the pre-fabricated natu re of these products and the repr oducibility that th is brings, this technology has been more transfer able than others and multi-nat ional interests have not been afraid to invest dir ectly in continuous plants where the overall population size and potential economic growth are seen to justif y it. One of the advantages of th is type of construction is the speed at which the erection of new buildings can take place around a steel frame. The technology also has the advantage of having the thermal insu lation characteristics in- built, thereby avoiding the risk of under-insulation which can be asso ciated with systems built up on site.

19 - Current blowing agent selection

The choice of blowing agent has largely been a measure of the timing of the investment. Once the developed countries became co mfortable with the use of hydrocarbons, it was inevitable that this would be adopted for new investments in de veloping countries. However, earlier plants were based on HCFCs (typically HCFC-141b) and will requi re conversion as part of the enactment of Decision XIX/6. The choice of alternative will is quite widespread wi th both hydrocarbons and HFCs being options.

0 200 400 600 800 1,000 1,200 1,400 1,600

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Continuous Panel 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Discontinuous Panels

- Current Market Trends

A similar argument exists to that in develope d countries about the prop ortion of the PU panel sector that will remain discontinuo us as the market grows. Howeve r, an additional factor is in play in the developing country scen ario. This is simply that the investment cost for continuous processing equipment is likely to be beyond many indigenous manufacturers. As is shown in the following graph, the manufacture of steel-faced discont inuous panels is quite widespread within the developing world and is likely to remain so for a significant period to come. Again, the value of prefabrication in a factory environment has a dditional value in a developing country scenario.18 solutions and standards has been on the increas e during this Assessment period and may lead to the adaptation of more developed country insulation strategies fo r both timber-framed and brick/ block constructions.

- Current blowing agent selection

In the one known facility, the choice of blowing agent has been consistent with the market served (Europe) and no particular technol ogical challenges have been observed.

0 20 40 60 80 100 120 140 160 180

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Boardstock 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Continuous Panels

- Current Market Trends

In view of the pre-fabricated natu re of these products and the repr oducibility that th is brings, this technology has been more transfer able than others and multi-nat ional interests have not been afraid to invest dir ectly in continuous plants where the overall population size and potential economic growth are seen to justif y it. One of the advantages of th is type of construction is the speed at which the erection of new buildings can take place around a steel frame. The technology also has the advantage of having the thermal insu lation characteristics in- built, thereby avoiding the risk of under-insulation which can be asso ciated with systems built up on site.

19 - Current blowing agent selection

The choice of blowing agent has largely been a measure of the timing of the investment. Once the developed countries became co mfortable with the use of hydrocarbons, it was inevitable that this would be adopted for new investments in de veloping countries. However, earlier plants were based on HCFCs (typically HCFC-141b) and will requi re conversion as part of the enactment of Decision XIX/6. The choice of alternative will is quite widespread wi th both hydrocarbons and HFCs being options.

0 200 400 600 800 1,000 1,200 1,400 1,600

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Continuous Panel 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Discontinuous Panels

- Current Market Trends

A similar argument exists to that in develope d countries about the prop ortion of the PU panel sector that will remain discontinuo us as the market grows. Howeve r, an additional factor is in play in the developing country scen ario. This is simply that the investment cost for continuous processing equipment is likely to be beyond many indigenous manufacturers. As is shown in the following graph, the manufacture of steel-faced discont inuous panels is quite widespread within the developing world and is likely to remain so for a significant period to come. Again, the value of prefabrication in a factory environment has a dditional value in a developing country scenario.20 - Current blowing agent selection

As with continuous panels, the primary blow ing agents were HCFCs in 2008. However, the proportion of the market based on this technology was higher, based on the lack of multi-national influence on the chosen investment strategies.

0 500 1,000 1,500 2,000 2,500 3,000 3,500

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Discontinuous Panel 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

There have been reports from Latin America (notab ly Brazil) that this is an area where methyl formate may have a role based on its basic pe rformance. Some commercialisation has taken place since 2008, although the longer-term prospects still need to be evaluated. Hydrocarbons and saturated HFCs will be the other choices likely to be considered in the short-term, with unsaturated HFCs (HFOs) unlikely to make in roads until commercialisation takes place and the cost implications have been fully assessed.

PU Spray Foam

- Current Market Trends

The requirement for the refurbishment of residential properties in China has led to the unprecedented growth of the PU Spray Foam market there. The centralised nature of parts of the economy in that region means that this trend might not be replicated to the same extent in other parts of the developing world. Nonetheless, the obvious value of PU Spray Foam in cost-

21 effectively improving the thermal performance of existing buildings will certainly ensure that it has a major role in thermal insulati on strategies around the world.

- Current blowing agent selection

The current estimate for the Chinese market alone is 70,000-80,000 tonnes per year currently. However, in 2008, this was considerably lo wer (probably around 25,000 t onnes) leading to a demand for blowing agent of between 2,500 tonnes and 3,000 tonnes for that year.

The sector is currently completely dependent on HCFCs (most typically HCFC-141b) and is seeking to resist the transition to saturated HFCs with their climate dis-benefits. However, the challenge for developing countries is to identif y technologies that are largely unproven (at least on a large scale) within devel oped countries. Methyl formate, methylal and super-critical CO 2 have all been mentioned in this context and pilo t projects have been targeted at evaluating each in the spray foam environment. In Mexico, for example, the PU spray foam market represents 30% of all HCFC consumption in that country and the HPMP is currently proposing methyl formate as the replacement of choice. However, th e FTOC has concern that the evidence base is currently too low to demonstrate that methyl form ate can be used safely and effectively in PU Spray applications 1

.
PU One Component Foam

- Current Market Trends

The PU One Component Foam mark et is prevalent in two developing country regions. The first of these is ‘Russia and the former Soviet States ’ primarily reflecting the extension of European building practices into these regions. The secon d, and most significant, market is China where approximately 150 million cans are produced annually. This accounts for approximately 100 ktonnes of PU chemical and up to 6,000 tonnes of blowing agent – making it a similar size to the European market.

- Current blowing agent selection

Although HFCs are understood to be the primary choi ce in the former Soviet States, the Chinese market has followed the Europ ean technology move into hydr ocarbons. The following graph demonstrates this trend.

1 The ‘minority view’ challenges this statement and cite s the number of project submissions made to the MLF Secretariat in support of this position. However, the FTOC is conscious that the decision to submit or approve such products cannot be used as a ‘proxy’ for technology endorsement.20 - Current blowing agent selection

As with continuous panels, the primary blow ing agents were HCFCs in 2008. However, the proportion of the market based on this technology was higher, based on the lack of multi-national influence on the chosen investment strategies.

0 500 1,000 1,500 2,000 2,500 3,000 3,500

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Discontinuous Panel 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

There have been reports from Latin America (notab ly Brazil) that this is an area where methyl formate may have a role based on its basic pe rformance. Some commercialisation has taken place since 2008, although the longer-term prospects still need to be evaluated. Hydrocarbons and saturated HFCs will be the other choices likely to be considered in the short-term, with unsaturated HFCs (HFOs) unlikely to make in roads until commercialisation takes place and the cost implications have been fully assessed.

PU Spray Foam

- Current Market Trends

The requirement for the refurbishment of residential properties in China has led to the unprecedented growth of the PU Spray Foam market there. The centralised nature of parts of the economy in that region means that this trend might not be replicated to the same extent in other parts of the developing world. Nonetheless, the obvious value of PU Spray Foam in cost-

21 effectively improving the thermal performance of existing buildings will certainly ensure that it has a major role in thermal insulati on strategies around the world.

- Current blowing agent selection

The current estimate for the Chinese market alone is 70,000-80,000 tonnes per year currently. However, in 2008, this was considerably lo wer (probably around 25,000 t onnes) leading to a demand for blowing agent of between 2,500 tonnes and 3,000 tonnes for that year.

The sector is currently completely dependent on HCFCs (most typically HCFC-141b) and is seeking to resist the transition to saturated HFCs with their climate dis-benefits. However, the challenge for developing countries is to identif y technologies that are largely unproven (at least on a large scale) within devel oped countries. Methyl formate, methylal and super-critical CO 2 have all been mentioned in this context and pilo t projects have been targeted at evaluating each in the spray foam environment. In Mexico, for example, the PU spray foam market represents 30% of all HCFC consumption in that country and the HPMP is currently proposing methyl formate as the replacement of choice. However, th e FTOC has concern that the evidence base is currently too low to demonstrate that methyl form ate can be used safely and effectively in PU Spray applications 1

.
PU One Component Foam

- Current Market Trends

The PU One Component Foam mark et is prevalent in two developing country regions. The first of these is ‘Russia and the former Soviet States ’ primarily reflecting the extension of European building practices into these regions. The secon d, and most significant, market is China where approximately 150 million cans are produced annually. This accounts for approximately 100 ktonnes of PU chemical and up to 6,000 tonnes of blowing agent – making it a similar size to the European market.

- Current blowing agent selection

Although HFCs are understood to be the primary choi ce in the former Soviet States, the Chinese market has followed the Europ ean technology move into hydr ocarbons. The following graph demonstrates this trend.

1 The ‘minority view’ challenges this statement and cite s the number of project submissions made to the MLF Secretariat in support of this position. However, the FTOC is conscious that the decision to submit or approve such products cannot be used as a ‘proxy’ for technology endorsement.22 0 1,000 2,000 3,000 4,000 5,000 6,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU One Component 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Pipe-in-Pipe (including moulding of pipe sections)

- Current Market Trends

As noted in the developed country section for this application, the mo re centralised economies have tended to adopted district heating systems as a means of distribution and, with it, have made good use of pre-insulated polyuretha ne pipes. As with PU One Co mponent Foams, China is the dominant market for these, alt hough there is considerable use in Russia and Former Soviet States as well.

- Current blowing agent selection

The current foam systems are based on HCFC tec hnology, but there is a clear option to switch to hydrocarbon, based on the substantial experience gained in Europe usin g this technology. This will be particularly the case in China, where the economies of scale should make investment a rational proposition. The situation will be less cl ear in Russia and the former Soviet States, where some use of HFC-based technologies is also possible – particularly in smaller manufacturers.

23 0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region

Blowing Agent Consumption by Type ‐ PU Pipe

‐ in

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Block – Pipe Section

- Current Market Trends

These markets (both for pipe sectio n and slabstock) are relatively ma ture in nature. In developing countries, the PU Block processes are almost ex clusively discontinuous. This reflects the fact that investment costs are lower and small operati ons can be scattered across regions where larger scale investments would not be cost-effective. Ho wever, for the same reasons, it is particularly difficult to track the split be tween pipe section demand and slabstock demand, since the only distinction occurs at the block fabrication stage.

For the purposes of this report, it is assumed that the split betw een the two sectors is 50/50. This is largely an arbitrary split at this point and further bottom-up research would certainly help in validating this assumption. The ma in significance of the separation of the two produc t types is in the waste levels from each, with pipe section fabrication resulting in up to 50% waste in some instances.22 0 1,000 2,000 3,000 4,000 5,000 6,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU One Component 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Pipe-in-Pipe (including moulding of pipe sections)

- Current Market Trends

As noted in the developed country section for this application, the mo re centralised economies have tended to adopted district heating systems as a means of distribution and, with it, have made good use of pre-insulated polyuretha ne pipes. As with PU One Co mponent Foams, China is the dominant market for these, alt hough there is considerable use in Russia and Former Soviet States as well.

- Current blowing agent selection

The current foam systems are based on HCFC tec hnology, but there is a clear option to switch to hydrocarbon, based on the substantial experience gained in Europe usin g this technology. This will be particularly the case in China, where the economies of scale should make investment a rational proposition. The situation will be less cl ear in Russia and the former Soviet States, where some use of HFC-based technologies is also possible – particularly in smaller manufacturers.

23 0 500 1,000 1,500 2,000 2,500 3,000 3,500 4,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region

Blowing Agent Consumption by Type ‐ PU Pipe

‐ in

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Block – Pipe Section

- Current Market Trends

These markets (both for pipe sectio n and slabstock) are relatively ma ture in nature. In developing countries, the PU Block processes are almost ex clusively discontinuous. This reflects the fact that investment costs are lower and small operati ons can be scattered across regions where larger scale investments would not be cost-effective. Ho wever, for the same reasons, it is particularly difficult to track the split be tween pipe section demand and slabstock demand, since the only distinction occurs at the block fabrication stage.

For the purposes of this report, it is assumed that the split betw een the two sectors is 50/50. This is largely an arbitrary split at this point and further bottom-up research would certainly help in validating this assumption. The ma in significance of the separation of the two produc t types is in the waste levels from each, with pipe section fabrication resulting in up to 50% waste in some instances.24 - Current blowing agent selection

The dominant blowing agent choice at present is HC FCs. This sector theref ore represents one of those requiring to be addressed under Decision XIX/6. It is also one that acc ounts for a large number of the really small consuming enterprises. The t echnology choices are therefore s-HFCs, or those potentially flammable bl owing agents that can be shown to be managed at this scale. This may include pre-blended hydrocarbons, methyl formate and others, but pilot projects are yet to deliver conclusive messages for these technologies.

0 100 200 300 400 500 600 700 800 900 1,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Block - Slabstock

- Current Market Trends

Comments for this sector are the same as those for PU Block – Pipe.

- Current blowing agent selection

Comments for this sector are the same as those for PU Block – Pipe.

25 0 100 200 300 400 500 600 700 800 900 1,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Slab 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

FLEXIBLE POLYURETHANE FOAM

PU - Flexible Slabstock

The use of CFCs in flexible slabstock has been completely phased out over this Assessment period, if not before. There was lit tle, if any, substituti on with HCFCs as an auxiliary blowing agent and therefore the issues with respect to ozone depleting substances (ODS) are virtually fully resolved.

However, the Montreal Protocol through its Technical Options Committees has a duty of care to maintain an overview of the replacement technologies - particular ly where there may be on-going health, safety or envir onmental concerns. These remaini ng paragraphs therefore briefly review the current status.

The main technologies now in use are met hylene chloride and carbon dioxide (CO 2 (LCD)). Other, more minor technologies also ex ist and, between them all, they cover all applications. However, processing is sometim es more challenging and in some cases more expensive. This is specifical ly the case for low density/ ‘high hardness’ foams where the high process temperature (“exotherm”) limits the effectiveness of some current replacement technologies.24 - Current blowing agent selection

The dominant blowing agent choice at present is HC FCs. This sector theref ore represents one of those requiring to be addressed under Decision XIX/6. It is also one that acc ounts for a large number of the really small consuming enterprises. The t echnology choices are therefore s-HFCs, or those potentially flammable bl owing agents that can be shown to be managed at this scale. This may include pre-blended hydrocarbons, methyl formate and others, but pilot projects are yet to deliver conclusive messages for these technologies.

0 100 200 300 400 500 600 700 800 900 1,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PU Block - Slabstock

- Current Market Trends

Comments for this sector are the same as those for PU Block – Pipe.

- Current blowing agent selection

Comments for this sector are the same as those for PU Block – Pipe.

25 0 100 200 300 400 500 600 700 800 900 1,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PU Block

‐ Slab 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

FLEXIBLE POLYURETHANE FOAM

PU - Flexible Slabstock

The use of CFCs in flexible slabstock has been completely phased out over this Assessment period, if not before. There was lit tle, if any, substituti on with HCFCs as an auxiliary blowing agent and therefore the issues with respect to ozone depleting substances (ODS) are virtually fully resolved.

However, the Montreal Protocol through its Technical Options Committees has a duty of care to maintain an overview of the replacement technologies - particular ly where there may be on-going health, safety or envir onmental concerns. These remaini ng paragraphs therefore briefly review the current status.

The main technologies now in use are met hylene chloride and carbon dioxide (CO 2 (LCD)). Other, more minor technologies also ex ist and, between them all, they cover all applications. However, processing is sometim es more challenging and in some cases more expensive. This is specifical ly the case for low density/ ‘high hardness’ foams where the high process temperature (“exotherm”) limits the effectiveness of some current replacement technologies.26 Methylene chloride continues to be under scru tiny from a health and safety perspective. However, the pressure for replacement has not grown substantially since 2001.

Liquid carbon dioxide, while suc cessful in developed countries , specifically when the use of methylene chloride is restrict ed or forbidden, proved to be a se rious challenge in most Article 5(1) countries. The combination of a complicated technology with virtua lly unchallenged use of easy-to-process methylene chloride proved a major burden for an initially enthusiastic embrace of the environmentally preferable LDC option. In the USA there is also considerable use of acetone and in Europe some use of variable pressure technology. On a smaller scale, special additives are used—frequently as co-technolo gy to limit the amount of methylene chloride required. There is also very limited use of n- pentane, formic acid and MDI based foams—the latter generally for speciality products. Forced cooling, a previously po pular technology in the USA has virtually disappeared because of percei ved increased emissions of TDI and fire risk. The further uptake of Exotherm Management T echnologies (EMT) continue s to be monitored, although little has been published recently on th e subject. There is also some recent, but unsubstantiated, information that methyl format e may be acting as a replacement for pentane, acetone and methylene chloride.

PU – Flexible Moulded

All-water-based technology is predominant in cold cured foams. In hot-cure applications there is also use of methylene chloride. In ve ry low density/soft foams (e.g pillows) there is some use of LCD or GCD but generally, this t echnology did not get the same attention as in slabstock applications—most likely because th ere is no exotherm problem and water-based technology performs well in most cases. HCFC-141b is used in exceptional circumstances such as highly filled acoustical foams but is not essentia l as a replacement in th is industry. The use of HCFCs in this industry is not allowed in most developed countries. Methyl formate has emerged as a legitimate replacement for HCFC-141b wh ere it is still used and may also provide advantages over CO 2 (water) where this technology ha s already been adopted.

PU – Integral Skin and Miscellaneous

This sector includes both rigid and flexible integral skin applications and also noninsulating rigid foam applications for packaging, leisur e (e.g. surf boards), floatation and floral foams.

A variety of blowing agents has been identified as alternatives to HCFCs in this sector. These include CO 2 (water), various s-HFCs, n-pentan e and methyl formate. With some drawbacks associated with skin formation using CO 2 (water) technologies, methyl formate may offer a particularly attractive alternative and ther e has already been considerable uptake in Latin America (most notably Brazil) already.

27 

### POLYOLEFIN FOAMS

There are three prime product types in the uncross-linked polyethylene foam sector:sheet, plank and tubular. All of these have used CFCs in the past. This is in contrast to crosslinked polyethylene foams which are produced for sp ecialist applications a nd have typically been blown with inert gases such as nitrogen. The transition issues facing sheet, plank and tubular products are broadly similar and these are theref ore considered together in this review.

Developed Countries

- Current Market Trends
The market for polyethylene pipe section continues to be buoyant based on the demand for lowcost, easy-to-install pipe insulation in the residential sector, where fire performance is less regulated in many regions. The pro duct is particularly suited to do-it-yourself activities, since it is easy handled and manipulated. However, the actual thermal performance can be variable depending on the quality of installation.

- Current blowing agent selection
Hydrocarbons (typically iso-butane) are the domin ant blowing agents in Europe and predominate in other regions too (see graph below)

0 50 100 150 200 250 300 350 400 450 500

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs26 Methylene chloride continues to be under scru tiny from a health and safety perspective. However, the pressure for replacement has not grown substantially since 2001.

Liquid carbon dioxide, while suc cessful in developed countries , specifically when the use of methylene chloride is restrict ed or forbidden, proved to be a se rious challenge in most Article 5(1) countries. The combination of a complicated technology with virtua lly unchallenged use of easy-to-process methylene chloride proved a major burden for an initially enthusiastic embrace of the environmentally preferable LDC option. In the USA there is also considerable use of acetone and in Europe some use of variable pressure technology. On a smaller scale, special additives are used—frequently as co-technolo gy to limit the amount of methylene chloride required. There is also very limited use of n- pentane, formic acid and MDI based foams—the latter generally for speciality products. Forced cooling, a previously po pular technology in the USA has virtually disappeared because of percei ved increased emissions of TDI and fire risk. The further uptake of Exotherm Management T echnologies (EMT) continue s to be monitored, although little has been published recently on th e subject. There is also some recent, but unsubstantiated, information that methyl format e may be acting as a replacement for pentane, acetone and methylene chloride.

PU – Flexible Moulded

All-water-based technology is predominant in cold cured foams. In hot-cure applications there is also use of methylene chloride. In ve ry low density/soft foams (e.g pillows) there is some use of LCD or GCD but generally, this t echnology did not get the same attention as in slabstock applications—most likely because th ere is no exotherm problem and water-based technology performs well in most cases. HCFC-141b is used in exceptional circumstances such as highly filled acoustical foams but is not essentia l as a replacement in th is industry. The use of HCFCs in this industry is not allowed in most developed countries. Methyl formate has emerged as a legitimate replacement for HCFC-141b wh ere it is still used and may also provide advantages over CO 2 (water) where this technology ha s already been adopted.

PU – Integral Skin and Miscellaneous

This sector includes both rigid and flexible integral skin applications and also noninsulating rigid foam applications for packaging, leisur e (e.g. surf boards), floatation and floral foams.

A variety of blowing agents has been identified as alternatives to HCFCs in this sector. These include CO 2 (water), various s-HFCs, n-pentan e and methyl formate. With some drawbacks associated with skin formation using CO 2 (water) technologies, methyl formate may offer a particularly attractive alternative and ther e has already been considerable uptake in Latin America (most notably Brazil) already.

27 

### POLYOLEFIN FOAMS

There are three prime product types in the uncross-linked polyethylene foam sector:sheet, plank and tubular. All of these have used CFCs in the past. This is in contrast to crosslinked polyethylene foams which are produced for sp ecialist applications a nd have typically been blown with inert gases such as nitrogen. The transition issues facing sheet, plank and tubular products are broadly similar and these are theref ore considered together in this review.

Developed Countries

- Current Market Trends
The market for polyethylene pipe section continues to be buoyant based on the demand for lowcost, easy-to-install pipe insulation in the residential sector, where fire performance is less regulated in many regions. The pro duct is particularly suited to do-it-yourself activities, since it is easy handled and manipulated. However, the actual thermal performance can be variable depending on the quality of installation.

- Current blowing agent selection
Hydrocarbons (typically iso-butane) are the domin ant blowing agents in Europe and predominate in other regions too (see graph below)

0 50 100 150 200 250 300 350 400 450 500

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs28 0 100 200 300 400 500 600 700 800 900

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Slab 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

For PE Block-Slab, the market is split between c onstruction, leisure and packaging applications, with packaging dominating on so me regions (e.g. Japan).

Developing Countries

- Current Market Trends

Although the markets are similarly characterised in developing count ries as those in developed countries, the geographic distributio n is limited rather more in this case by historic technology transfer, with Latin America embracing PE pipe section more significantly than other regions.

Latin America also has significan t involvement with PE slab pr oduction, again with a similar application portfolio to that in developed countr ies. However, the larger market for slab in developing countries is found in South East Asia. As with Ja pan, this is understood to be underpinned by a larger use in the packaging sector.

- Current blowing agent selection

In all developing country re gions, the dominant blowi ng agent is now hydrocarbon.

29 0 100 200 300 400 500 600 700 800 900

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

0 50 100 150 200 250 300 350 400 450

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Slab 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs28 0 100 200 300 400 500 600 700 800 900

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Slab 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

For PE Block-Slab, the market is split between c onstruction, leisure and packaging applications, with packaging dominating on so me regions (e.g. Japan).

Developing Countries

- Current Market Trends

Although the markets are similarly characterised in developing count ries as those in developed countries, the geographic distributio n is limited rather more in this case by historic technology transfer, with Latin America embracing PE pipe section more significantly than other regions.

Latin America also has significan t involvement with PE slab pr oduction, again with a similar application portfolio to that in developed countr ies. However, the larger market for slab in developing countries is found in South East Asia. As with Ja pan, this is understood to be underpinned by a larger use in the packaging sector.

- Current blowing agent selection

In all developing country re gions, the dominant blowi ng agent is now hydrocarbon.

29 0 100 200 300 400 500 600 700 800 900

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

0 50 100 150 200 250 300 350 400 450

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PE Block

‐ Slab 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs30 

### EXTRUDED POLYSTYRENE FOAMS

Developed Countries

Sheet

- Current Market Trends

The XPS sheet market has a number of similaritie s with the PE Slab market in that a large proportion is used for leisure and packaging. In some instances, the packing requires some thermal performance (e.g. fast foods and hot drinks ), but the thermal properties are no required to be persistent in the same way as thermal insulation applications in construction, transport or appliances. The market has been less studied quantitatively by th e FTOC since the phase-out of CFCs and almost universal switch to hydrocarbons.

- Current blowing agent selection

As noted above, hydrocarbons (butane, isobut ane, pentane, isopentane), HFCs (HFC134a, HFC-152a); and hydrocarbon / CO 2 (LCD) blends, have found a range of commercial use with hydrocarbons being the dominant selection in most regions. HFC-152a also been used significantly in the United States to ov ercome local VOC emission regulations.
Few future developments are expected. Howe ver, capital investment required for the handling of flammability issues and on-going c oncerns over VOC emissions will be limiting factors in further expansion of hydrocarbon containing systems.

Board

- Current Market Trends

Extruded polystyrene board has effectively emul ated the growth of PU /PIR products in the thermal insulation sector as markets have been stimulated by increased energy efficiency in buildings. The product’s competitive position is underpinned by its particularly good moisture resistance, which has been responsible for wide spread use as a floor insulation material in Europe. In North America, the pr oduct is typically competing w ith PIR (“polyiso”) products in the residential sheathing market, as well as in a number of commercia l and industrial building applications.

- Current blowing agent selection

The following graph illustrates the rather bizarre s ituation in terms of blowing agent selection by region as it was in 2008.

31 0 5,000 10,000 15,000 20,000 25,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ XPS Board 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

In Europe, the primary replacement techno logies have been HFC-134a, HFC-152a and CO 2 (or CO 2 /alcohol), while in Japan th ere has also been signif icant use of hydrocarbons (notably isobutene). In North America, the tran sition away from HCFCs has been more difficult because of particular product requirements, esp ecially in the resident ial sector. HCFC-142b, therefore, remained the dominant blowing agent as at 2008. However, since then, transition to sHFCs has occurred, as companies have master ed the adoption of HFC technology for sheathing products and also achieved the relevant building code requirements.

Investment criteria continue to be a barrier to further use of CO 2 -based technologies in Europe, although pressures are likel y to increase concerning the on- going use of HFCs. A review of the F-Gas regulation is on-going in the EU and will be completed before the end of 2011. There may be some future interest in the use of HFOs for this application, but cost considerations may necessitate the use of these substances as blends with HCs and possibly HCOs (e.g. dimethyl ether).

Developing Countries

Sheet

- Current Market Trends

The market drivers are very similar to t hose described for developed countries.30 

### EXTRUDED POLYSTYRENE FOAMS

Developed Countries

Sheet

- Current Market Trends

The XPS sheet market has a number of similaritie s with the PE Slab market in that a large proportion is used for leisure and packaging. In some instances, the packing requires some thermal performance (e.g. fast foods and hot drinks ), but the thermal properties are no required to be persistent in the same way as thermal insulation applications in construction, transport or appliances. The market has been less studied quantitatively by th e FTOC since the phase-out of CFCs and almost universal switch to hydrocarbons.

- Current blowing agent selection

As noted above, hydrocarbons (butane, isobut ane, pentane, isopentane), HFCs (HFC134a, HFC-152a); and hydrocarbon / CO 2 (LCD) blends, have found a range of commercial use with hydrocarbons being the dominant selection in most regions. HFC-152a also been used significantly in the United States to ov ercome local VOC emission regulations.
Few future developments are expected. Howe ver, capital investment required for the handling of flammability issues and on-going c oncerns over VOC emissions will be limiting factors in further expansion of hydrocarbon containing systems.

Board

- Current Market Trends

Extruded polystyrene board has effectively emul ated the growth of PU /PIR products in the thermal insulation sector as markets have been stimulated by increased energy efficiency in buildings. The product’s competitive position is underpinned by its particularly good moisture resistance, which has been responsible for wide spread use as a floor insulation material in Europe. In North America, the pr oduct is typically competing w ith PIR (“polyiso”) products in the residential sheathing market, as well as in a number of commercia l and industrial building applications.

- Current blowing agent selection

The following graph illustrates the rather bizarre s ituation in terms of blowing agent selection by region as it was in 2008.

31 0 5,000 10,000 15,000 20,000 25,000

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ XPS Board 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

In Europe, the primary replacement techno logies have been HFC-134a, HFC-152a and CO 2 (or CO 2 /alcohol), while in Japan th ere has also been signif icant use of hydrocarbons (notably isobutene). In North America, the tran sition away from HCFCs has been more difficult because of particular product requirements, esp ecially in the resident ial sector. HCFC-142b, therefore, remained the dominant blowing agent as at 2008. However, since then, transition to sHFCs has occurred, as companies have master ed the adoption of HFC technology for sheathing products and also achieved the relevant building code requirements.

Investment criteria continue to be a barrier to further use of CO 2 -based technologies in Europe, although pressures are likel y to increase concerning the on- going use of HFCs. A review of the F-Gas regulation is on-going in the EU and will be completed before the end of 2011. There may be some future interest in the use of HFOs for this application, but cost considerations may necessitate the use of these substances as blends with HCs and possibly HCOs (e.g. dimethyl ether).

Developing Countries

Sheet

- Current Market Trends

The market drivers are very similar to t hose described for developed countries.32 - Current blowing agent selection
Technologies have also shifted almost universally to hydrocarbon despite earlier concerns about the flammability of both the bl owing agent and the substrates on high temperature extrusion lines. There is no immediate expectation for th is sector to make any further blowing agent transitions.

Board

- Current Market Trends
There has been substantial growth in market s for XPS board in a number of Article 5 countries, most notably in China and some mi ddle-eastern countries. Th is has increased the demand for HCFCs by in excess of 15,000 tonne s per annum since 2001. However, latest information suggests that some recent fires in major Chinese cities may result in some retrenchment for both new and ex isting buildings, driv en by new fire standards. Although EPS and some EPS might be the primary culprits, the impact could be seen across all organic foam products.

- Current blowing agent selection
The industry was totally based on HCFCs in 2008, although the split between HCFC142b and HCFC-22 continues to remain unclear.

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ XPS Board 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

33 For other Article 5 countries, the relatively low cost of investment in locally produced manufacturing plant and the high demand for im proved thermal performance in buildings is expected to drive further rapi d growth of XPS board producti on. Prior to 2015, the predominant blowing agents are expected to continue to be HCFCs. Ultimately, hydrocarbons may prove the dominant blowing agents in thes e territories.32 - Current blowing agent selection
Technologies have also shifted almost universally to hydrocarbon despite earlier concerns about the flammability of both the bl owing agent and the substrates on high temperature extrusion lines. There is no immediate expectation for th is sector to make any further blowing agent transitions.

Board

- Current Market Trends
There has been substantial growth in market s for XPS board in a number of Article 5 countries, most notably in China and some mi ddle-eastern countries. Th is has increased the demand for HCFCs by in excess of 15,000 tonne s per annum since 2001. However, latest information suggests that some recent fires in major Chinese cities may result in some retrenchment for both new and ex isting buildings, driv en by new fire standards. Although EPS and some EPS might be the primary culprits, the impact could be seen across all organic foam products.

- Current blowing agent selection
The industry was totally based on HCFCs in 2008, although the split between HCFC142b and HCFC-22 continues to remain unclear.

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ XPS Board 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

33 For other Article 5 countries, the relatively low cost of investment in locally produced manufacturing plant and the high demand for im proved thermal performance in buildings is expected to drive further rapi d growth of XPS board producti on. Prior to 2015, the predominant blowing agents are expected to continue to be HCFCs. Ultimately, hydrocarbons may prove the dominant blowing agents in thes e territories.34 

### PHENOLIC FOAMS

Developed Countries

PF Boardstock

- Current Market Trends

Phenolic Foam boardstock has continued to make progress in the buoyant European market, with the key manufacturers being able to switch be tween PU boardstock and PF boardstock products, at will, against the same market specifications. This has meant that capacities can be better utilised and PU raw material shortages offset.

In Japan, the market has conti nued to be supportive of phenolic boardstock in view of its superior fire performance and highly competit ive insulation values. However, the recent earthquake and tsunami have crea ted interruptions in producti on which may have some shortterm impact on supply.

- Current blowing agent selection
The bulk of the sector is now fully switche d to hydrocarbon technologies, although this was slightly less the case in 2008 (see graph below):

0 100 200 300 400 500 600 700 800 900

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Boardstock 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

35 There is still some use of 2-chloro-propane at one facility in Europe, but otherwise the industry is expected to normalise even furt her around the hydrocarbon option.

PF Pipes and Blocks

- Current Market Trends
The market for phenolic pipe insulation continue s to be highly regionalised with the United Kingdom representing the major mark et in Europe and, perhaps, the world. This results from a specific combination of ‘reaction-to-fire’ requirements which rules out competitive materials such as PU/PIR. The future dir ection of other markets in Europe will depend on the extent to which individual countries adopt maximum smoke requirements, which can now be specified through the European cl assification system.

The production economics have also been impr oved by the introduction of continuous process technologies for the more common sizes of pipe.

- Current blowing agent selection
The choice of blowing agent for the continuous pr ocess has been hydrocarbon. This has had little effect on the overall fire performance of the pr oduct or its market acceptance. For discontinuous block processes, the choice remains s-HFCs, partic ularly for the smaller manufacturers. This is reflected in the graph below:

0 100 200 300 400 500 600

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs34 

### PHENOLIC FOAMS

Developed Countries

PF Boardstock

- Current Market Trends

Phenolic Foam boardstock has continued to make progress in the buoyant European market, with the key manufacturers being able to switch be tween PU boardstock and PF boardstock products, at will, against the same market specifications. This has meant that capacities can be better utilised and PU raw material shortages offset.

In Japan, the market has conti nued to be supportive of phenolic boardstock in view of its superior fire performance and highly competit ive insulation values. However, the recent earthquake and tsunami have crea ted interruptions in producti on which may have some shortterm impact on supply.

- Current blowing agent selection
The bulk of the sector is now fully switche d to hydrocarbon technologies, although this was slightly less the case in 2008 (see graph below):

0 100 200 300 400 500 600 700 800 900

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Boardstock 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

35 There is still some use of 2-chloro-propane at one facility in Europe, but otherwise the industry is expected to normalise even furt her around the hydrocarbon option.

PF Pipes and Blocks

- Current Market Trends
The market for phenolic pipe insulation continue s to be highly regionalised with the United Kingdom representing the major mark et in Europe and, perhaps, the world. This results from a specific combination of ‘reaction-to-fire’ requirements which rules out competitive materials such as PU/PIR. The future dir ection of other markets in Europe will depend on the extent to which individual countries adopt maximum smoke requirements, which can now be specified through the European cl assification system.

The production economics have also been impr oved by the introduction of continuous process technologies for the more common sizes of pipe.

- Current blowing agent selection
The choice of blowing agent for the continuous pr ocess has been hydrocarbon. This has had little effect on the overall fire performance of the pr oduct or its market acceptance. For discontinuous block processes, the choice remains s-HFCs, partic ularly for the smaller manufacturers. This is reflected in the graph below:

0 100 200 300 400 500 600

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Pipe 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs36 0 20 40 60 80 100 120 140 160

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Slab 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Technology choices are the same for PF Bl ock-Slab Foam, although hydrocarbon is less prevalent because no continuous pr ocess exists for this product group. Accordingly, s-HFCs are the most significant blowing agents in use, with the exception of Japan, where hydrocarbon solutions have been effectively engineered.

PF Panels

- Current Market Trends

The market for metal-faced phenolic foam panels is relatively mature in Japan. The primary products are for residential sidi ng and office partitioning. Th ese are usually discontinuously produced. The market in Europe is still in a fl edgling state and is ta rgeted at niche panel applications such as clean rooms, cold stores and computer safe rooms.

- Current blowing agent selection

Reflecting the size and maturity of the Japanese market, the technology has been able to be adapted for hydrocarbon blowing agents. In Eu rope, (most notably the UK), the size of production operations is insuffici ent to support hydrocarbon invest ments at present and s-HFCs are typically used.

37 0 100 200 300 400 500 600

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Panel 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Developing Countries

PF Boardstock

- Current Market Trends

At the present time, there are no known PF Boar dstock manufacturers in developing countries.

- Current blowing agent selection
There is currently no blowing agent consumption.

PF Pipes and Blocks

- Current Market Trends

Historically, there was some PF Block Foam manufacture in India, but this is understood to have ceased as a consequence of limited market pe netration and conversion costs out of ozone depleting substances. The only developing countryconsumption is now in South Africa, where36 0 20 40 60 80 100 120 140 160

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Slab 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Technology choices are the same for PF Bl ock-Slab Foam, although hydrocarbon is less prevalent because no continuous pr ocess exists for this product group. Accordingly, s-HFCs are the most significant blowing agents in use, with the exception of Japan, where hydrocarbon solutions have been effectively engineered.

PF Panels

- Current Market Trends

The market for metal-faced phenolic foam panels is relatively mature in Japan. The primary products are for residential sidi ng and office partitioning. Th ese are usually discontinuously produced. The market in Europe is still in a fl edgling state and is ta rgeted at niche panel applications such as clean rooms, cold stores and computer safe rooms.

- Current blowing agent selection

Reflecting the size and maturity of the Japanese market, the technology has been able to be adapted for hydrocarbon blowing agents. In Eu rope, (most notably the UK), the size of production operations is insuffici ent to support hydrocarbon invest ments at present and s-HFCs are typically used.

37 0 100 200 300 400 500 600

Europe N. America Japan RODWAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Panel 2008 ‐ Developed

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

Developing Countries

PF Boardstock

- Current Market Trends

At the present time, there are no known PF Boar dstock manufacturers in developing countries.

- Current blowing agent selection
There is currently no blowing agent consumption.

PF Pipes and Blocks

- Current Market Trends

Historically, there was some PF Block Foam manufacture in India, but this is understood to have ceased as a consequence of limited market pe netration and conversion costs out of ozone depleting substances. The only developing countryconsumption is now in South Africa, where38 European block foam technology continues to be operated – partially supplying products for the mining sector.

- Current blowing agent selection

It is understood that HCFC-141b remains the blowing agent of choice in Sout h Africa at present, although considerations are underway for a tr ansition to non-ODS alternatives. Further investigations are on-going into potent ial choices, but the scale ofthe operation might leave sHFCs as the only viable alte rnative in the short-term.

0 5 10 15 20 25 30 35 40 45 50

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

39 0 5 10 15 20 25 30 35 40 45 50

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Slab 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PF Panels

- Current Market Trends

At the present time, there are no known PF Di scontinuous Panel manufacturers in developing countries.

- Current blowing agent selection

There is currently no blowing agent consumption.38 European block foam technology continues to be operated – partially supplying products for the mining sector.

- Current blowing agent selection

It is understood that HCFC-141b remains the blowing agent of choice in Sout h Africa at present, although considerations are underway for a tr ansition to non-ODS alternatives. Further investigations are on-going into potent ial choices, but the scale ofthe operation might leave sHFCs as the only viable alte rnative in the short-term.

0 5 10 15 20 25 30 35 40 45 50

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Pipe 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

39 0 5 10 15 20 25 30 35 40 45 50

Russia &
Former Soviets NE Asia SE Asia S Asia SS Africa MENA Latin AmericaAnnualConsumption(tonnes)

Region Blowing Agent Consumption by Type ‐ PF Block

‐ Slab 2008 ‐ Developing

HFOs

CO2

HCOs

HCs

HFCs

HCFCs

CFCs

PF Panels

- Current Market Trends

At the present time, there are no known PF Di scontinuous Panel manufacturers in developing countries.

- Current blowing agent selection

There is currently no blowing agent consumption.40 

### CHAPTER 2: TECHNOLOGY OPTIONS

POLYURETHANE FOAMS

Developments on blowing agents in the PU foam sector
The primary challenge for the foam sector c ontinues to be the phase-out of HCFCs in developing countries under D ecision XIX/6. HPMPs are being developed to meet the 2013 freeze and the 10% use reduction in 2015. In deve loped countries HCFCs were completely eliminated by the middle of the last decade in the polyurethane (PU) foam sector and the substitute technologies and the usage patterns have reached a relatively mature status. The analysis of this experience al ong with the proper considerations associated with the markets differences and the scope of D ecision XIX/6 focused on alternatives that minimize the climate change impact, provides a valuab le insight for the HCFC phase-out in developing countries.

Developed Countries The section describes the blowing agents currently used in developed countries:

Table 1. Blowing Agents currentl y used in developed countries
PU RIGID FOAM Domestic refrigerators and freezers c-pentane, cyclo/iso pentane blends, HFC- 245fa, HFC-134a
Other appliances c-pentane, cyclo/iso pentane blends, HFC- 245fa, HFC365mfc/227ea blends, HFC-134a, methyl formate, CO 2 (water)
Transport & reefers c-pentane, cyclo/iso pentane blends, HFC- 245fa, HFC365mfc/227ea blends, HFC-134a

Boardstock c-pentane, n-pentane, iso pentane, cyclo/iso pentane blends, npentane/iso pentane blends, HFC- 245fa, HFC-365mfc/227ea blends

Panels – continuous c-pentane, n-pentane, iso pentane, cyclo/iso pentane blends,cyclo/n-pentane blends, n-pentane/iso pentane blends, HFC245fa, HFC-365mfc/227ea blends

Panels discontinuous HFC- 245fa, HFC-365mfc/227ea blends, HFC-134a, c-pentane, npentane, iso pentane, cyclo/iso pentane blends, n-pentane/iso pentane blends, CO 2 (water), formic acid, methyl formate Spray HFC- 245fa, HFC-365mfc/227ea, Supercritical CO 2 , CO 2 (water),

Blocks c-pentane, n-pentane, iso pentane, cyclo/iso pentane blends, npentane/iso pentane blends, HFC- 245fa, HFC-365mfc/227ea blends, methyl formate
Pipe-in-pipe c-pentane, n-pentane, HFC- 245fa, HFC-365mfc/227ea blends, CO 2 (water), methyl formate
One Component Foam Mixtures of propane, butane and dimethyl ether, HFC-134a, HFO1234ze
PU FLEXIBLE FOAM
Integral Skin CO 2 (water), HFC-134a, HFC- 245fa, HFC-365mfc/227ea blends, n-pentane, methyl formate
Shoe Soles CO 2 (water), HFC-134a
Flex moulded CO 2 (water), methyl formate

41 It is important to notice the different roles of the blowing agent in PU rigid and flexible foams. Although in both it has the primary functi on to physically expand the foaming mixture to produce the foam, in the case of rigid foam it should remain within the closed cells and contribute to the insulating performance. To fulf il this latter function, the blowing agent should have a low gaseous thermal conductivity plus a low rate of diffusion of the gas through the foam (matrix) so that the good insula ting properties are retained for many years. A low solubility of the blowing agent in the PU matrix is also require to ensure that it is retained as a gas in the foam cell avoiding the solid plasticisation and the loss of thermal insulation. In the case of domestic refrigeration high solubility of the blowing agent in the thermoplastic material of the inner lining may result in a severe deteriorati on of the mechanical strength.
In the case of flexible foam, particularly in integral skin and shoe soles, the blowing agent has a critical role in form ing a robust/aesthetic skin as a result of its condensation during the high-pressure injection pro cess. For this application a relatively low boiling point of the blowing agent is desirable. Duri ng the CFC phase-out most of the shoe sole market migrated to all water blown formulations al ong with the use of polyester polyols to meet the abrasion resistance requirements From table 1, there is wide scale use of hydrocarbons in PU foams together with HFCs in some specific applicatio ns, such as HFC 245fa in most North American domestic refrigerators and freezers, and HFC-365 mfc/227ea blends to meet the most stringent fire tests in panels. Formulations based on hyd rocarbons have been refined over the years and their insulation performance, as expressed by fo am thermal conductivity, is now similar to those for HCFC- 141b based foams. They can now also meet very stringent fire test requirements as panels or boards.

There is a clear exception to th e trend to use hydrocarbons fo r PU foams; despite trials, HCs are not used in spray foams for safety r easons. Instead, HCFC 141b has been replaced by HFC 245fa or HFC365mfc/227ea blends, often in combination with sign ificant amounts of CO 2 (water) – “reduced-HFC” technology. CO 2 (water) may be used when increasing foam thickness can compensate for the higher thermal conductiv ity of the foam. In Japan, supercritical CO 2 technology has been developed an d is used. The strengths and weaknesses of the HC and HFC technologies are described in table 2.40 

### CHAPTER 2: TECHNOLOGY OPTIONS

POLYURETHANE FOAMS

Developments on blowing agents in the PU foam sector
The primary challenge for the foam sector c ontinues to be the phase-out of HCFCs in developing countries under D ecision XIX/6. HPMPs are being developed to meet the 2013 freeze and the 10% use reduction in 2015. In deve loped countries HCFCs were completely eliminated by the middle of the last decade in the polyurethane (PU) foam sector and the substitute technologies and the usage patterns have reached a relatively mature status. The analysis of this experience al ong with the proper considerations associated with the markets differences and the scope of D ecision XIX/6 focused on alternatives that minimize the climate change impact, provides a valuab le insight for the HCFC phase-out in developing countries.

Developed Countries The section describes the blowing agents currently used in developed countries:

Table 1. Blowing Agents currentl y used in developed countries
PU RIGID FOAM Domestic refrigerators and freezers c-pentane, cyclo/iso pentane blends, HFC- 245fa, HFC-134a
Other appliances c-pentane, cyclo/iso pentane blends, HFC- 245fa, HFC365mfc/227ea blends, HFC-134a, methyl formate, CO 2 (water)
Transport & reefers c-pentane, cyclo/iso pentane blends, HFC- 245fa, HFC365mfc/227ea blends, HFC-134a

Boardstock c-pentane, n-pentane, iso pentane, cyclo/iso pentane blends, npentane/iso pentane blends, HFC- 245fa, HFC-365mfc/227ea blends

Panels – continuous c-pentane, n-pentane, iso pentane, cyclo/iso pentane blends,cyclo/n-pentane blends, n-pentane/iso pentane blends, HFC245fa, HFC-365mfc/227ea blends

Panels discontinuous HFC- 245fa, HFC-365mfc/227ea blends, HFC-134a, c-pentane, npentane, iso pentane, cyclo/iso pentane blends, n-pentane/iso pentane blends, CO 2 (water), formic acid, methyl formate Spray HFC- 245fa, HFC-365mfc/227ea, Supercritical CO 2 , CO 2 (water),

Blocks c-pentane, n-pentane, iso pentane, cyclo/iso pentane blends, npentane/iso pentane blends, HFC- 245fa, HFC-365mfc/227ea blends, methyl formate
Pipe-in-pipe c-pentane, n-pentane, HFC- 245fa, HFC-365mfc/227ea blends, CO 2 (water), methyl formate
One Component Foam Mixtures of propane, butane and dimethyl ether, HFC-134a, HFO1234ze
PU FLEXIBLE FOAM
Integral Skin CO 2 (water), HFC-134a, HFC- 245fa, HFC-365mfc/227ea blends, n-pentane, methyl formate
Shoe Soles CO 2 (water), HFC-134a
Flex moulded CO 2 (water), methyl formate

41 It is important to notice the different roles of the blowing agent in PU rigid and flexible foams. Although in both it has the primary functi on to physically expand the foaming mixture to produce the foam, in the case of rigid foam it should remain within the closed cells and contribute to the insulating performance. To fulf il this latter function, the blowing agent should have a low gaseous thermal conductivity plus a low rate of diffusion of the gas through the foam (matrix) so that the good insula ting properties are retained for many years. A low solubility of the blowing agent in the PU matrix is also require to ensure that it is retained as a gas in the foam cell avoiding the solid plasticisation and the loss of thermal insulation. In the case of domestic refrigeration high solubility of the blowing agent in the thermoplastic material of the inner lining may result in a severe deteriorati on of the mechanical strength.
In the case of flexible foam, particularly in integral skin and shoe soles, the blowing agent has a critical role in form ing a robust/aesthetic skin as a result of its condensation during the high-pressure injection pro cess. For this application a relatively low boiling point of the blowing agent is desirable. Duri ng the CFC phase-out most of the shoe sole market migrated to all water blown formulations al ong with the use of polyester polyols to meet the abrasion resistance requirements From table 1, there is wide scale use of hydrocarbons in PU foams together with HFCs in some specific applicatio ns, such as HFC 245fa in most North American domestic refrigerators and freezers, and HFC-365 mfc/227ea blends to meet the most stringent fire tests in panels. Formulations based on hyd rocarbons have been refined over the years and their insulation performance, as expressed by fo am thermal conductivity, is now similar to those for HCFC- 141b based foams. They can now also meet very stringent fire test requirements as panels or boards.

There is a clear exception to th e trend to use hydrocarbons fo r PU foams; despite trials, HCs are not used in spray foams for safety r easons. Instead, HCFC 141b has been replaced by HFC 245fa or HFC365mfc/227ea blends, often in combination with sign ificant amounts of CO 2 (water) – “reduced-HFC” technology. CO 2 (water) may be used when increasing foam thickness can compensate for the higher thermal conductiv ity of the foam. In Japan, supercritical CO 2 technology has been developed an d is used. The strengths and weaknesses of the HC and HFC technologies are described in table 2.42 Table 2. Strengths & Weaknesses of HC and HFC technologies SECTOR/OPTION STRENGTHS WEAKNESSES COMMENTS Rigid Foam Low GWP Highly flammable High conversion costs, uneconomic for SMEs. Not suitable for spray Low unit costs Low operating costs Hydrocarbons (c-pentane & n-pentane & cyclo/iso blends)

Acceptable foam properties Global industry standard Non-flammable High GWP Low conversion costs. Industry standard for spray High unit costs High operating costs, could be improved by using “HFC reduced” HFC/ CO 2 (water) formulationsHFC-245fa, HFC365mfc/HFC-227ea

Good foam properties Improved insulation (versus HC)

Flexible Foam (Integral Skin & Shoe soles) Low GWP Highly flammable High conversion costs, uneconomic for SMEs Low unit costs Low operating costs n-pentane

Good skin quality Non-flammable High GWP Low conversion
costs High unit costs High operating costs HFC-134a, HFC-245fa, HFC-365mfc/HFC-227ea

Good skin quality

The major drawback of the hydrocarbon family is their flammability. This has a strong impact on both the capital costs for processing -to ensure that safety is properly engineered- and on product handling, which is partic ularly problematic for smaller en terprises. Efforts have been made to reduce costs at the foam manufacturer s by pre-blending the hydro carbons into polyols at systems houses. The challenge is to develop a long-term stable formulation with no phase separation. A successful industrial case has been reported in Northern Europe where a system house, for some years, has been delivering formul ated polyols containing c-pentane in one-tonne containers and 200 l drums to different indust ries in Eastern and North-Eastern Europe (PROKLIMA, 2009). This approach allows redu ced investments on the user’s side without compromising the insulating effici ency and the long-term dimens ional stability performance. This experience shows that investment in one blending facility may make it possible to reduce investments in manufacturing plants. While the co st of HC storage tanks, pumps and premixing stations can be avoided, the sa fety modifications for the polyol blend storage and foaming line and the installation of proper monitoring and vent ilation systems will still be required. It is estimated that savings in increased capital cost (ICC) for the end user are in the order of 25 to 35%.

43 The technology based on CO 2 , derived from the isocyanate-w ater reaction, has been used with limited success for commercial refrigeratio n (displays, vending machines) where insulation performance is not critical. Its major drawback s are the relative poor insulating performance resulting from the relatively high lambda value of CO 2 ; the required increase in foam moulded density caused by the high permeability values of CO 2 through the polyurethane matrix; and the reduced “adhesion” to the substrates where it is applied (metal, thermopl astics), a consequence of the high amount of polyurea pres ent in the polymer. In the Japanese spray market, the use of water blown foam along with patented super-critical CO 2 technology has been developed and commercialised; however, there may be limitations in some applications that require an improved insulating performance.

There is also a small use in developed countries of methyl formate (United States, Australia) particularly for commercial refrigeration, an application where the insulating performance is not critical and some global be verage players (i.e. Coca-Cola) are requesting foams based on non-HFCs, 0 ODP substances. Furt her discussion on this technology can be found below.

Although a large proportion of the industry in developed countries has settled on hydrocarbons or HFCs as their blowing agent of choice, there are increasing pressures -in the case of HCs- to improve the thermal performance of foams, particularly in the appliance sector, and to limit the future use of saturated hydrof luorocarbons (s-HFCs) and to phase these down where possible.

In this context, there is a growing interest in the potential role of the recently developed unsaturated HFCs (HFOs) in the domestic refriger ation sector and other rigid foam applications, particularly in North America, where saturated HFCs have a significant market, and in PU Spray foam both in Europe and North America. One of these (HFC-1234ze) has found some initial use in Europe as a replacement for HFC-134a in PU One Component Foams.

These compounds represent an emerging group of blowing agents that exhibit a number of the characteristics also disp layed by saturated HFCs, but have considerably lower GWPs (< 15). The prime reason for these lower values relates to the shorter lifetime of the molecules in the atmosphere caused by the presence of a double bond between adjacent carbon atoms. Early work suggests that they deliver bette r thermal performance than thei r saturated counterparts, although toxicological work remains to be completed for those yet to be commercialised. Cost predictions are similar to saturated HFCs. Their main characteristics are presented in table 3.42 Table 2. Strengths & Weaknesses of HC and HFC technologies SECTOR/OPTION STRENGTHS WEAKNESSES COMMENTS Rigid Foam Low GWP Highly flammable High conversion costs, uneconomic for SMEs. Not suitable for spray Low unit costs Low operating costs Hydrocarbons (c-pentane & n-pentane & cyclo/iso blends)

Acceptable foam properties Global industry standard Non-flammable High GWP Low conversion costs. Industry standard for spray High unit costs High operating costs, could be improved by using “HFC reduced” HFC/ CO 2 (water) formulationsHFC-245fa, HFC365mfc/HFC-227ea

Good foam properties Improved insulation (versus HC)

Flexible Foam (Integral Skin & Shoe soles) Low GWP Highly flammable High conversion costs, uneconomic for SMEs Low unit costs Low operating costs n-pentane

Good skin quality Non-flammable High GWP Low conversion
costs High unit costs High operating costs HFC-134a, HFC-245fa, HFC-365mfc/HFC-227ea

Good skin quality

The major drawback of the hydrocarbon family is their flammability. This has a strong impact on both the capital costs for processing -to ensure that safety is properly engineered- and on product handling, which is partic ularly problematic for smaller en terprises. Efforts have been made to reduce costs at the foam manufacturer s by pre-blending the hydro carbons into polyols at systems houses. The challenge is to develop a long-term stable formulation with no phase separation. A successful industrial case has been reported in Northern Europe where a system house, for some years, has been delivering formul ated polyols containing c-pentane in one-tonne containers and 200 l drums to different indust ries in Eastern and North-Eastern Europe (PROKLIMA, 2009). This approach allows redu ced investments on the user’s side without compromising the insulating effici ency and the long-term dimens ional stability performance. This experience shows that investment in one blending facility may make it possible to reduce investments in manufacturing plants. While the co st of HC storage tanks, pumps and premixing stations can be avoided, the sa fety modifications for the polyol blend storage and foaming line and the installation of proper monitoring and vent ilation systems will still be required. It is estimated that savings in increased capital cost (ICC) for the end user are in the order of 25 to 35%.

43 The technology based on CO 2 , derived from the isocyanate-w ater reaction, has been used with limited success for commercial refrigeratio n (displays, vending machines) where insulation performance is not critical. Its major drawback s are the relative poor insulating performance resulting from the relatively high lambda value of CO 2 ; the required increase in foam moulded density caused by the high permeability values of CO 2 through the polyurethane matrix; and the reduced “adhesion” to the substrates where it is applied (metal, thermopl astics), a consequence of the high amount of polyurea pres ent in the polymer. In the Japanese spray market, the use of water blown foam along with patented super-critical CO 2 technology has been developed and commercialised; however, there may be limitations in some applications that require an improved insulating performance.

There is also a small use in developed countries of methyl formate (United States, Australia) particularly for commercial refrigeration, an application where the insulating performance is not critical and some global be verage players (i.e. Coca-Cola) are requesting foams based on non-HFCs, 0 ODP substances. Furt her discussion on this technology can be found below.

Although a large proportion of the industry in developed countries has settled on hydrocarbons or HFCs as their blowing agent of choice, there are increasing pressures -in the case of HCs- to improve the thermal performance of foams, particularly in the appliance sector, and to limit the future use of saturated hydrof luorocarbons (s-HFCs) and to phase these down where possible.

In this context, there is a growing interest in the potential role of the recently developed unsaturated HFCs (HFOs) in the domestic refriger ation sector and other rigid foam applications, particularly in North America, where saturated HFCs have a significant market, and in PU Spray foam both in Europe and North America. One of these (HFC-1234ze) has found some initial use in Europe as a replacement for HFC-134a in PU One Component Foams.

These compounds represent an emerging group of blowing agents that exhibit a number of the characteristics also disp layed by saturated HFCs, but have considerably lower GWPs (< 15). The prime reason for these lower values relates to the shorter lifetime of the molecules in the atmosphere caused by the presence of a double bond between adjacent carbon atoms. Early work suggests that they deliver bette r thermal performance than thei r saturated counterparts, although toxicological work remains to be completed for those yet to be commercialised. Cost predictions are similar to saturated HFCs. Their main characteristics are presented in table 3.44 Table 3. Saturated HFCs (HFOs)

HFO-1234ze FEA-1100 HBA-2 AFA-L1

Chemical Formula Trans- CF 3 CH=CHF Cis- CF 3 -CH=CH-CF 3 Undisclosed Undisclosed
Molecular Weight 114 164 Undisclosed Undisclosed
Boiling Point ( 0 C ) -19 32 15.3<T<32.1 10.0<T<30.0 Gas Conductivity (mW/mK @ 10 0 C) 13.0 10.7 Not Reported 15.9

Flammable Limits in Air (vol.%) None to 28 o C^ None None None

TLV or OEL (ppm) (USA) Unpublished 9.7 Undisclosed Undisclosed
GWP (100 yr time horizon) 6 9.4 <15 <15

^ Flame limits of 7.0-9.5 at 30 o C are quoted

Developing Countries

One of the major challenges of the foam indus try is the HCFC phase -out in developing countries under Decision XIX/6. This Decision calls for an accelerated phase-down of the use of HCFCs leading to their replacement, in the fo am sector, by zero ODP blowing agents. At the same time, the Executive Committee (ExCom) of the Montreal Protocol is requested, when applying funding criteria, to give priority to cost effective projects with focus on substitutes that minimize other environmental impacts, includ ing on the climate, ta king into account globalwarming potential, energy use and other relevant factors.

Today two types of polymeric foams use HCFC s as blowing agents: Polyurethane (PU) Foams (mainly HCFC-141b and some HCFC-22) a nd Extruded Polystyrene (XPS) Board Foams (HCFC-142b and HCFC-22). They compete with othe r materials, such as mineral fibres, EPS in thermal insulation and other applications. The PU foam sectors using HCFCs are insulating foams, integral skin foams and microcellular foams (shoe soles). In the last two sectors the usage is much less than in the insulating market because of the smaller overall market and the higher foam density. XPS board foams are mainly used for insulation purposes.

The main route for PU foams is to use hydrocarbons (HC), principally pentanes (npentane, c-pentane and cyclo/iso-pentane blends). Th is is particular true for the sectors where the large size of the companies (H CFC use > 50 tonnes/year) benefits the economics despite of the high conversion cost: domestic refrigeration, continuous panels and some commercial refrigeration and discontinuous pane ls manufacturers. In the case of medium size enterprises (50 tonnes/year >HCFC use >10 tonne s/year) the option of pre-ble nding hydrocarbons into polyols - described above- may represent a sustainable lo ng-term approach. The Mu ltilateral Fund and the Implementing Agencies have taken up the matter and two pilot projects have been sponsored and are under development (China and Egypt); one of them along with the introduction of a third HC stream at the mixing point. The results will be ready during 2011.

45 Although the use of HC technol ogy provides lower operating cost s than other alternatives such as HFCs, the significant capital costs for conversions ma ke unviable its application for small size enterprises (HCFC use < 10 tonnes/yr). It is estimated that the minimal Incremental Capital Costs (ICC) for the conversion to HC are in the range of USD300,000 to USD500,000.

On the other side, in addition to their high GWP, the use of saturated HFC-based technologies (HFC 245fa, HFC- 365mfc/HFC-227ea) may result in significant increases in operating costs owing to their higher unit prices and molecular weights. It is also clear that, despite of the promising results, their unsaturat ed counterparts (HFOs) are unlikely to be available in time to meet the ea rly stages (pre-2015) of the HC FC phase-out as required under Decision XIX/6. In the interim, there is evidence that some enterprises ma nufacturing appliances in developing countries are al ready blending saturated HFCs w ith hydrocarbons to meet energy requirements.

From the above considerations, HCFC phase-out in sectors that incl ude a large number of SMEs (a typical industry characteristic in the Ar ticle 5 countries) represents the most significant challenge. Many of the enterprises have little, if any, internal cap acity to optimise formulations and their capacity to handle flammable compounds is limited. There continues to be a need to characterise the performance of foams made from low-GWP alternatives in the range of applications envisaged. This is an on-going exercise, but is particularly important for technologies that do not have a si gnificant history of use in non-Ar ticle 5 countries. The role of the Pilot Projects sponsored under the Multilateral Fund are especi ally relevant here and the work of UNDP on methyl formate, for example, has already cleared the way for wider use in the flexible moulded and integral skin sector s with potential for others to follow.

In the case of rigid foam applications, perhaps the most critical case , a conventional testing programme for a new blowing agent includes 2 :

**•** Toxicology and ecotoxicology tes ting (ODP, GWP, toxicology)

**•** Processing characteristics: **9** Stability in polyol blends **9** Miscibility with polyols **9** Flow properties (flow index, minimum fill density) **9** Reaction times including jig dwell times **9** Atmospheric concentrations during processi ng and comparison with flammable limits in air **9** Effects on equipment – seals and metal parts

**•** Physical & Fire properties: **9** Closed cell content **9** Density/strength (compressi on strength) relationships **9** Dimensional stability versus temperature a nd ageing using accepted accelerated methods **9** Thermal conductivity versus temperature and ageing using accepted accelerated methods

2 For a more fundamental approach tend ing to provide a performance explana tion tests like cell gas analysis with time, water vapour transmission, glass transition temper ature over time at differe nt temperatures, etc., are desirable.44 Table 3. Saturated HFCs (HFOs)

HFO-1234ze FEA-1100 HBA-2 AFA-L1

Chemical Formula Trans- CF 3 CH=CHF Cis- CF 3 -CH=CH-CF 3 Undisclosed Undisclosed
Molecular Weight 114 164 Undisclosed Undisclosed
Boiling Point ( 0 C ) -19 32 15.3<T<32.1 10.0<T<30.0 Gas Conductivity (mW/mK @ 10 0 C) 13.0 10.7 Not Reported 15.9

Flammable Limits in Air (vol.%) None to 28 o C^ None None None

TLV or OEL (ppm) (USA) Unpublished 9.7 Undisclosed Undisclosed
GWP (100 yr time horizon) 6 9.4 <15 <15

^ Flame limits of 7.0-9.5 at 30 o C are quoted

Developing Countries

One of the major challenges of the foam indus try is the HCFC phase -out in developing countries under Decision XIX/6. This Decision calls for an accelerated phase-down of the use of HCFCs leading to their replacement, in the fo am sector, by zero ODP blowing agents. At the same time, the Executive Committee (ExCom) of the Montreal Protocol is requested, when applying funding criteria, to give priority to cost effective projects with focus on substitutes that minimize other environmental impacts, includ ing on the climate, ta king into account globalwarming potential, energy use and other relevant factors.

Today two types of polymeric foams use HCFC s as blowing agents: Polyurethane (PU) Foams (mainly HCFC-141b and some HCFC-22) a nd Extruded Polystyrene (XPS) Board Foams (HCFC-142b and HCFC-22). They compete with othe r materials, such as mineral fibres, EPS in thermal insulation and other applications. The PU foam sectors using HCFCs are insulating foams, integral skin foams and microcellular foams (shoe soles). In the last two sectors the usage is much less than in the insulating market because of the smaller overall market and the higher foam density. XPS board foams are mainly used for insulation purposes.

The main route for PU foams is to use hydrocarbons (HC), principally pentanes (npentane, c-pentane and cyclo/iso-pentane blends). Th is is particular true for the sectors where the large size of the companies (H CFC use > 50 tonnes/year) benefits the economics despite of the high conversion cost: domestic refrigeration, continuous panels and some commercial refrigeration and discontinuous pane ls manufacturers. In the case of medium size enterprises (50 tonnes/year >HCFC use >10 tonne s/year) the option of pre-ble nding hydrocarbons into polyols - described above- may represent a sustainable lo ng-term approach. The Mu ltilateral Fund and the Implementing Agencies have taken up the matter and two pilot projects have been sponsored and are under development (China and Egypt); one of them along with the introduction of a third HC stream at the mixing point. The results will be ready during 2011.

45 Although the use of HC technol ogy provides lower operating cost s than other alternatives such as HFCs, the significant capital costs for conversions ma ke unviable its application for small size enterprises (HCFC use < 10 tonnes/yr). It is estimated that the minimal Incremental Capital Costs (ICC) for the conversion to HC are in the range of USD300,000 to USD500,000.

On the other side, in addition to their high GWP, the use of saturated HFC-based technologies (HFC 245fa, HFC- 365mfc/HFC-227ea) may result in significant increases in operating costs owing to their higher unit prices and molecular weights. It is also clear that, despite of the promising results, their unsaturat ed counterparts (HFOs) are unlikely to be available in time to meet the ea rly stages (pre-2015) of the HC FC phase-out as required under Decision XIX/6. In the interim, there is evidence that some enterprises ma nufacturing appliances in developing countries are al ready blending saturated HFCs w ith hydrocarbons to meet energy requirements.

From the above considerations, HCFC phase-out in sectors that incl ude a large number of SMEs (a typical industry characteristic in the Ar ticle 5 countries) represents the most significant challenge. Many of the enterprises have little, if any, internal cap acity to optimise formulations and their capacity to handle flammable compounds is limited. There continues to be a need to characterise the performance of foams made from low-GWP alternatives in the range of applications envisaged. This is an on-going exercise, but is particularly important for technologies that do not have a si gnificant history of use in non-Ar ticle 5 countries. The role of the Pilot Projects sponsored under the Multilateral Fund are especi ally relevant here and the work of UNDP on methyl formate, for example, has already cleared the way for wider use in the flexible moulded and integral skin sector s with potential for others to follow.

In the case of rigid foam applications, perhaps the most critical case , a conventional testing programme for a new blowing agent includes 2 :

**•** Toxicology and ecotoxicology tes ting (ODP, GWP, toxicology)

**•** Processing characteristics: **9** Stability in polyol blends **9** Miscibility with polyols **9** Flow properties (flow index, minimum fill density) **9** Reaction times including jig dwell times **9** Atmospheric concentrations during processi ng and comparison with flammable limits in air **9** Effects on equipment – seals and metal parts

**•** Physical & Fire properties: **9** Closed cell content **9** Density/strength (compressi on strength) relationships **9** Dimensional stability versus temperature a nd ageing using accepted accelerated methods **9** Thermal conductivity versus temperature and ageing using accepted accelerated methods

2 For a more fundamental approach tend ing to provide a performance explana tion tests like cell gas analysis with time, water vapour transmission, glass transition temper ature over time at differe nt temperatures, etc., are desirable.46 **9** Foam friability **9** Adhesion to different substrates **9** Fire code testing for construction industry foam-based components

**•** Trials under commercial production conditions and long term testing of articles

For integral skin and shoe-soles, open celle d applications where the blowing agent does not remain in the product, the testing programme on physical properties s hould include the skin appearance and related properties like abrasion resistance.

In addition to the option of pre-blended HCs into the polyols, new technology alternatives for the SMEs are emerging or have recently emer ged: methylal, methyl formate and modified water blown formulations.

Methylal , also called dimethoxymethane, is a fl ammable liquid with a negligible GWP and a boiling point of 42 oC. To date, it has been marketed primarily within the thermoplastic foam sector (extruded polystyren e and polyolefin) as a co-blowing agent with HFC-134a to date.

The use of methylal as a co-blowing agen t in conjunction with hydrocarbons and HFCs for PU rigid foam applications (domestic refrig eration, panels, pipe in sulation and spray) has been described in the literature . It is claimed (Lambiotte, 2006) that in continuous panels it promotes blending in the mixing head and improve s the miscibility of pe ntane, the foam flow and uniformity, the adhesion to metal surfaces an d the insulation properties by reducing the cell size. In discontinuous panels, th e addition of a low percentage of methylal to HFCs (245fa, 365mfc or 134a) would make it possi ble to prepare pre-blends with polyols of low flammability with no detrimental effect on the fire performance of the foam. As in the case of hydrocarbons Methylal would reduce the cost and improve the miscibility, the foam flow and uniformity the adhesion to metal surfaces.

There is no known use of methylal as sole auxiliary blowing ag ent in PU foam. By decision 58/30 the ExCom approved a demonstrati on project to assess its use as a possible replacement of HCFCs in developing countries. The final report will be issued during 2011 but the partial results in integral skin/microcellular foams already released show an excellent skin formation compared to HCFC-141b.

However, the flammability of the methylal/polyols blends is a major point of concern. Data recently reported shows that the addition of more than 3 part s of methylal brings the flash point of the blend down to values lower than 35 oC, similar to those obt ained with hydrocarbons (InterTox, 2010). According to the Global Harmonised System such t ype of blends are classified as a flammable liquid of category 3. The impact of the increased capital cost needed to handle a blend of these characteristics at the end user can make the use of met hylal prohibited for the SMEs.

Methyl Formate (MF), also called methyl-methanoate , is a flammable liquid with a negligible GWP and a boiling point of 31.5 oC. Foam Supplies, Inc. (FSI) has promoted its use as a blowing agent in PU foams from 2000 onwar ds. The company filed on December 18th, 2001,

47 for a US patent, which was issued on June 22 nd , 2004. The use of this technology has grown significantly in the last four y ears, although continues to be very small in size. For all foam applications 365 tones were consumed worl dwide in 2009 and around 1,000 in 2010, replacing over 2,000 tonnes of HCFC-141b 3

. It is reported that MF is fi nding increased use in the flexib le moulded and integral skin foam applications. Consumption in Australia, South Africa and Brazil has been established. Table 4 describes the strengths and weaknesse s of the low GWP alternatives for these applications.

The use of MF is also occurring in rigid fo am applications, particularly in commercial refrigeration and discontinuous steel-faced panels. Additional work is progressing in the US, UK and elsewhere to broaden this range of us e, but with mixed levels of success.

Table 4. Alternate technologies for Integral Skin Foam & Shoe-soles
SECTOR/OPTION STRENGTHS WEAKNESSES COMMENTS Methyl formate (MF) Low GWP Flam mable Conversion costs to be determined
Moderate unit costs Flammability of polyol/MF blends should be checked Good skin quality Moderate operating
costs Patented technology. Commercial restriction CO 2 (water) Low GWP Poor skin quality Suitable skin mayrequire in-mouldcoating – added
expense Low conversion costs Well proven in shoesoles - used with polyester polyols n-pentane Low GWP Highly flammable High conversion, uneconomic for SMEs Low unit costs Low operating costs Good skin quality Well proven in application

There are some technical issues that would se em to act as barriers to the use in rigid polyurethane insulating foams of MF as a sole blowing agent and w ould also inhibit its use as a co-blowing agent in systems such as those primarily blown with CO 2 (water)-blown. These issues can be documented as follows:

**•** There is concern that measures to manage fla mmability for MF may require system houses to reformulate with more compatible polyols for ri gid foam applications in order to reduce the risk. In some cases it may be more productive to blend methyl formate in the isocyanate

3 In its 2006 assessment report the FTOC estimated the global market of blowing agent for the incumbent foam applications in the year 2005 at around 360,000 tonnes.46 **9** Foam friability **9** Adhesion to different substrates **9** Fire code testing for construction industry foam-based components

**•** Trials under commercial production conditions and long term testing of articles

For integral skin and shoe-soles, open celle d applications where the blowing agent does not remain in the product, the testing programme on physical properties s hould include the skin appearance and related properties like abrasion resistance.

In addition to the option of pre-blended HCs into the polyols, new technology alternatives for the SMEs are emerging or have recently emer ged: methylal, methyl formate and modified water blown formulations.

Methylal , also called dimethoxymethane, is a fl ammable liquid with a negligible GWP and a boiling point of 42 oC. To date, it has been marketed primarily within the thermoplastic foam sector (extruded polystyren e and polyolefin) as a co-blowing agent with HFC-134a to date.

The use of methylal as a co-blowing agen t in conjunction with hydrocarbons and HFCs for PU rigid foam applications (domestic refrig eration, panels, pipe in sulation and spray) has been described in the literature . It is claimed (Lambiotte, 2006) that in continuous panels it promotes blending in the mixing head and improve s the miscibility of pe ntane, the foam flow and uniformity, the adhesion to metal surfaces an d the insulation properties by reducing the cell size. In discontinuous panels, th e addition of a low percentage of methylal to HFCs (245fa, 365mfc or 134a) would make it possi ble to prepare pre-blends with polyols of low flammability with no detrimental effect on the fire performance of the foam. As in the case of hydrocarbons Methylal would reduce the cost and improve the miscibility, the foam flow and uniformity the adhesion to metal surfaces.

There is no known use of methylal as sole auxiliary blowing ag ent in PU foam. By decision 58/30 the ExCom approved a demonstrati on project to assess its use as a possible replacement of HCFCs in developing countries. The final report will be issued during 2011 but the partial results in integral skin/microcellular foams already released show an excellent skin formation compared to HCFC-141b.

However, the flammability of the methylal/polyols blends is a major point of concern. Data recently reported shows that the addition of more than 3 part s of methylal brings the flash point of the blend down to values lower than 35 oC, similar to those obt ained with hydrocarbons (InterTox, 2010). According to the Global Harmonised System such t ype of blends are classified as a flammable liquid of category 3. The impact of the increased capital cost needed to handle a blend of these characteristics at the end user can make the use of met hylal prohibited for the SMEs.

Methyl Formate (MF), also called methyl-methanoate , is a flammable liquid with a negligible GWP and a boiling point of 31.5 oC. Foam Supplies, Inc. (FSI) has promoted its use as a blowing agent in PU foams from 2000 onwar ds. The company filed on December 18th, 2001,

47 for a US patent, which was issued on June 22 nd , 2004. The use of this technology has grown significantly in the last four y ears, although continues to be very small in size. For all foam applications 365 tones were consumed worl dwide in 2009 and around 1,000 in 2010, replacing over 2,000 tonnes of HCFC-141b 3

. It is reported that MF is fi nding increased use in the flexib le moulded and integral skin foam applications. Consumption in Australia, South Africa and Brazil has been established. Table 4 describes the strengths and weaknesse s of the low GWP alternatives for these applications.

The use of MF is also occurring in rigid fo am applications, particularly in commercial refrigeration and discontinuous steel-faced panels. Additional work is progressing in the US, UK and elsewhere to broaden this range of us e, but with mixed levels of success.

Table 4. Alternate technologies for Integral Skin Foam & Shoe-soles
SECTOR/OPTION STRENGTHS WEAKNESSES COMMENTS Methyl formate (MF) Low GWP Flam mable Conversion costs to be determined
Moderate unit costs Flammability of polyol/MF blends should be checked Good skin quality Moderate operating
costs Patented technology. Commercial restriction CO 2 (water) Low GWP Poor skin quality Suitable skin mayrequire in-mouldcoating – added
expense Low conversion costs Well proven in shoesoles - used with polyester polyols n-pentane Low GWP Highly flammable High conversion, uneconomic for SMEs Low unit costs Low operating costs Good skin quality Well proven in application

There are some technical issues that would se em to act as barriers to the use in rigid polyurethane insulating foams of MF as a sole blowing agent and w ould also inhibit its use as a co-blowing agent in systems such as those primarily blown with CO 2 (water)-blown. These issues can be documented as follows:

**•** There is concern that measures to manage fla mmability for MF may require system houses to reformulate with more compatible polyols for ri gid foam applications in order to reduce the risk. In some cases it may be more productive to blend methyl formate in the isocyanate

3 In its 2006 assessment report the FTOC estimated the global market of blowing agent for the incumbent foam applications in the year 2005 at around 360,000 tonnes.48 component to obtain the required foam prope rties whilst avoiding flammable blends. The additional health risk associated with th e isocyanate handling needs to be managed.

According to the United Nations Global Harmonised Systems a liquid blend is classified as flammable in the number 3 cate gory when exhibits a flash point between 23 and 60 oC. Additionally, it is stated that “ liquids with a flash point of more than 35 °C may be regarded as non-flammable liquids for some re gulatory purposes (e.g. transport) if negative results have been obtained in th e sustained combustibility test (which is the MF case)...” The current fully formulated polyols used in developing countries have HCFC-141b concentrations around 18 %, which -applying the ideal gas law- correspond to a MF concentration of 10.1 % 4 . At this concentration, according to the supplier ́s data, virtually all type of polyols will result in MF/polyol ble nds with flash points lower than 35 oC (Foam Supplies, Presentation given to the FTOC, Salt Lake City, 2006). To avoid the implied safety risk a significant reformulation work is requi red. This is particularly important for spray foam, an application where the foam injection process is not controlled.

**•** The gaseous thermal conductivity of MF is intermediate be tween HCFC-141b and c-pentane and would suggest the potential for foams with good thermal performance. However, MF is a potent solvent for the polyurethane matrix and the addition of MF either on its own or as a co-blowing agent with CO 2 (water) results -as recently reported- in a significant reduction in compressive strength (shrinkage). Such effects can be countered either by reducing the level of the MF component present, or by increasing the density of the foam. The former reduces, or even nullifies, any incremental benefit in th ermal performance, while the latter increases weight and cost and, in doing s o, may not be technically or economically viable. If co-blown with CO 2 (water) the rapid aging of therma l conductivity, char acteristic of CO 2 (water) systems, is also likely to be evident. Where shrinkage occurs, insufficient adhesion to metal substrates is typically observed within di scontinuous sandwich pa nel trials. Again, the plasticising effect may be count ered by increasing density wher e this is a commercial option.

**•** There is a need for further aged data to assess the trends in thermal insulation performance and dimensional stability with time. As has al ready been noted, the current analysis suggests that there will be a very fine balance between these two characte ristics even in the short-term. Therefore, long-term behaviour patterns are a part icular area of focus at this time. There is a possibility that the operational window could be too narrow fo r commercial viability in some applications. The elucidation of the long-term performance is critically important in applications where the thermal performance is e xpected to be maintained for periods of up to 50 years.

4 The ‘minority view’ contends that applying the ‘ideal gas law’ is not correct in practice. However, it is acknowledged that the fl ash points associated with thes e polyol blends can be below 35 o C, creating the need to split the methyl formate component between the polyol and isocyanate streams. 49 **•** When MF is used as a co-blowing agent with other added blowing agents (e.g. hydrocarbons), it has the potentia l to improve thermal performance by favourably impacting the morphology of cells – usually by making th e average cell size smaller and the cell size more uniform. This is an effect beyond the gaseous thermal conductivity itself and may result in the increasing use of MF as a comp onent of blends, partic ularly in place of cpentane if this continues to remain in short supply.

**•** There does not yet appear to be evidence available related to the levels of MF in the atmosphere for several production processes. In pa rticular, there is littl e experience of using MF-based systems for spray foam.

**•** There is a further concern about the stability of MF owing to the observed (by cell gas analysis) hydrolysis to formic acid, CO 2 and CO. This would serve to reduce the concentration of MF in the foam cells and pot entially contribute to further deterioration in thermal performance.

**•** The presence of formic acid, either from brea kdown of methyl formate, or through deliberate addition, can lead to corrosi on of dispensing machine components (Cannon, Brazil, 2010) 5

. Machinery suppliers have investigated this eff ect and identified a number of components that would need to be monitored and replaced at regular intervals.

Water Blown Formulations . As mentioned before, histor ically the development of water blown foams has been a real challenge due to its intrinsic physical hurdles such as higher thermal conductivity, lower foam dimensional stab ility -which requires and increased moulded density-, and higher surface brittleness, resulti ng in a potentially weaker adhesion to metal facings. As result, the use of all water blown foam in the industry is today still limited.

However, global system houses have recentl y reported the development of new water blown technology characterized by an improved performance that can now be considered in line with HCFC low-level technologies -characterized by relative high foam lambda values- (3rd Polyurethane Exhibition & Conference in Indi a - PU TECH 2011). This solution, focused on addressing the discontinuous panels and commer cial refrigeration app lications, leaves the opening to be converted later on into co-blowing with physical blowing agents by the time when new proven low ODP low GWP non-flammab le solutions will be available.

It is claimed that, as a result of improved fl ow and optimized density distribution, applied densities are now in the same range of HCFC low-level technology with minimum impact on foam dimensional stability and mechanical properties. The systems would allow easy filling of the cavities and could be proces sed with a mould temperature of 40°C. Typical initial thermal conductivity is in the range of 22-23 mW/mK (measur ed at 10°C), relatively higher compared to pentane and/or some HFCs blown systems but s till acceptable for commercial refrigeration and discontinuous panels.

5 The ‘minority view’ continues to challenge this assertion, although, as the text explains, the machinery suppliers are already taking action.48 component to obtain the required foam prope rties whilst avoiding flammable blends. The additional health risk associated with th e isocyanate handling needs to be managed.

According to the United Nations Global Harmonised Systems a liquid blend is classified as flammable in the number 3 cate gory when exhibits a flash point between 23 and 60 oC. Additionally, it is stated that “ liquids with a flash point of more than 35 °C may be regarded as non-flammable liquids for some re gulatory purposes (e.g. transport) if negative results have been obtained in th e sustained combustibility test (which is the MF case)...” The current fully formulated polyols used in developing countries have HCFC-141b concentrations around 18 %, which -applying the ideal gas law- correspond to a MF concentration of 10.1 % 4 . At this concentration, according to the supplier ́s data, virtually all type of polyols will result in MF/polyol ble nds with flash points lower than 35 oC (Foam Supplies, Presentation given to the FTOC, Salt Lake City, 2006). To avoid the implied safety risk a significant reformulation work is requi red. This is particularly important for spray foam, an application where the foam injection process is not controlled.

**•** The gaseous thermal conductivity of MF is intermediate be tween HCFC-141b and c-pentane and would suggest the potential for foams with good thermal performance. However, MF is a potent solvent for the polyurethane matrix and the addition of MF either on its own or as a co-blowing agent with CO 2 (water) results -as recently reported- in a significant reduction in compressive strength (shrinkage). Such effects can be countered either by reducing the level of the MF component present, or by increasing the density of the foam. The former reduces, or even nullifies, any incremental benefit in th ermal performance, while the latter increases weight and cost and, in doing s o, may not be technically or economically viable. If co-blown with CO 2 (water) the rapid aging of therma l conductivity, char acteristic of CO 2 (water) systems, is also likely to be evident. Where shrinkage occurs, insufficient adhesion to metal substrates is typically observed within di scontinuous sandwich pa nel trials. Again, the plasticising effect may be count ered by increasing density wher e this is a commercial option.

**•** There is a need for further aged data to assess the trends in thermal insulation performance and dimensional stability with time. As has al ready been noted, the current analysis suggests that there will be a very fine balance between these two characte ristics even in the short-term. Therefore, long-term behaviour patterns are a part icular area of focus at this time. There is a possibility that the operational window could be too narrow fo r commercial viability in some applications. The elucidation of the long-term performance is critically important in applications where the thermal performance is e xpected to be maintained for periods of up to 50 years.

4 The ‘minority view’ contends that applying the ‘ideal gas law’ is not correct in practice. However, it is acknowledged that the fl ash points associated with thes e polyol blends can be below 35 o C, creating the need to split the methyl formate component between the polyol and isocyanate streams. 49 **•** When MF is used as a co-blowing agent with other added blowing agents (e.g. hydrocarbons), it has the potentia l to improve thermal performance by favourably impacting the morphology of cells – usually by making th e average cell size smaller and the cell size more uniform. This is an effect beyond the gaseous thermal conductivity itself and may result in the increasing use of MF as a comp onent of blends, partic ularly in place of cpentane if this continues to remain in short supply.

**•** There does not yet appear to be evidence available related to the levels of MF in the atmosphere for several production processes. In pa rticular, there is littl e experience of using MF-based systems for spray foam.

**•** There is a further concern about the stability of MF owing to the observed (by cell gas analysis) hydrolysis to formic acid, CO 2 and CO. This would serve to reduce the concentration of MF in the foam cells and pot entially contribute to further deterioration in thermal performance.

**•** The presence of formic acid, either from brea kdown of methyl formate, or through deliberate addition, can lead to corrosi on of dispensing machine components (Cannon, Brazil, 2010) 5

. Machinery suppliers have investigated this eff ect and identified a number of components that would need to be monitored and replaced at regular intervals.

Water Blown Formulations . As mentioned before, histor ically the development of water blown foams has been a real challenge due to its intrinsic physical hurdles such as higher thermal conductivity, lower foam dimensional stab ility -which requires and increased moulded density-, and higher surface brittleness, resulti ng in a potentially weaker adhesion to metal facings. As result, the use of all water blown foam in the industry is today still limited.

However, global system houses have recentl y reported the development of new water blown technology characterized by an improved performance that can now be considered in line with HCFC low-level technologies -characterized by relative high foam lambda values- (3rd Polyurethane Exhibition & Conference in Indi a - PU TECH 2011). This solution, focused on addressing the discontinuous panels and commer cial refrigeration app lications, leaves the opening to be converted later on into co-blowing with physical blowing agents by the time when new proven low ODP low GWP non-flammab le solutions will be available.

It is claimed that, as a result of improved fl ow and optimized density distribution, applied densities are now in the same range of HCFC low-level technology with minimum impact on foam dimensional stability and mechanical properties. The systems would allow easy filling of the cavities and could be proces sed with a mould temperature of 40°C. Typical initial thermal conductivity is in the range of 22-23 mW/mK (measur ed at 10°C), relatively higher compared to pentane and/or some HFCs blown systems but s till acceptable for commercial refrigeration and discontinuous panels.

5 The ‘minority view’ continues to challenge this assertion, although, as the text explains, the machinery suppliers are already taking action.50 It is also reported that the addition of formic acid as chemical blowing agent to these systems can result in quantified improvements in foam aesthetic, flow, de nsity distribution and adhesion even at low mould temperatures. Nevert heless, some drawbacks have been identified and need to be taken into consideration. They are linked to potential corrosion, which requires the involvement of equipment suppliers to check the equipment suitability, and the eventual release of carbon monoxide that makes it n ecessary the checking of the atmospheric concentrations and proper ventilation. Despite thes e drawbacks, this technology is being used in developed countries where enhanced flow, lo wer density and improved aesthetics are key requirements, i.e. the production of sandwic h panels for cold store applications.

51 

### PHENOLIC FOAMS

Historically significant pheno lic foam markets were developed in Europe and Japan based on a combination of Boardstock and Bloc k/Pipe products. The development of similar markets in North America was thwarted by poor experience with a specific roofing board technology (Koppers) that created co rrosion problems on steel-decks.

A further traditional applicati on of phenolic foam has been as floral foam. The primary brand globally is known as ‘Oasis’. However, th is material has never significantly been blown with ozone depleting substances, except in the case of small ‘me too’ producers. It is therefore not the prime focus of attention in this report.

PF Boardstock

The traditional blowing agent for phenolic boardstock was CFC-11, although this was rapidly superseded by HCFC-141b. The use of HC FC-141b presented a part icular challenge for the phenolic emulsion chemistry b ecause of its solubility and th e major technology holders found it necessary to modify the blowing agent with add itives to make it less soluble in the foam mix.

In the transition that took place from HCFC-141b in Europe , it became self-evident that the phenolic product itself was sufficiently robus t in its fire perfor mance to accommodate hydrocarbon blowing agents for the bulk of e nd-uses. Therefore, the bulk of continuous processes are now based on n-pentane, either on its own or in blends with other hydrocarbons. One technology in Europe had moved directly from CFC-11 to 2-chloro-propane and continues to use this blowing agent as th e basis for its product range.

There is limited use for saturated HFCs in these continuous processes, since thermalperformance based on optimised hydrocarbon formulations is seen as sufficient for most enduses. Although it is not yet clear how the emer gence of unsaturated HFCs might affect the blowing agent choices for future phenolic boardst ock formulations, the overall performance of the various hydrocarbon-based te chnologies make it unlikely th at there will be further technology transitions in the short term.

There has been little, if a ny, implementation of phenolic foam boardstock facilities in developing countries to date, so any future investment is likel y to be based completely on technology transfer from Europe or elsewhere.

PF Blocks & Pipe Sections

As with other phenolic foam product/process types, except for the floral foam industry, CFC-11 was the basic blowing agent of choice. In some cases, the boiling point of the blowing agent was modified by using CFC-11/CFC-113 ble nds in order to ensure the appropriate rise/cure profile. This was particularly important for phenolic chemistry where the sensitivity between temperature and cu re rate is high. The reduction in the latent heat of ev aporation in the early stages of the reaction helped to en sure appropriate processing times.50 It is also reported that the addition of formic acid as chemical blowing agent to these systems can result in quantified improvements in foam aesthetic, flow, de nsity distribution and adhesion even at low mould temperatures. Nevert heless, some drawbacks have been identified and need to be taken into consideration. They are linked to potential corrosion, which requires the involvement of equipment suppliers to check the equipment suitability, and the eventual release of carbon monoxide that makes it n ecessary the checking of the atmospheric concentrations and proper ventilation. Despite thes e drawbacks, this technology is being used in developed countries where enhanced flow, lo wer density and improved aesthetics are key requirements, i.e. the production of sandwic h panels for cold store applications.

51 

### PHENOLIC FOAMS

Historically significant pheno lic foam markets were developed in Europe and Japan based on a combination of Boardstock and Bloc k/Pipe products. The development of similar markets in North America was thwarted by poor experience with a specific roofing board technology (Koppers) that created co rrosion problems on steel-decks.

A further traditional applicati on of phenolic foam has been as floral foam. The primary brand globally is known as ‘Oasis’. However, th is material has never significantly been blown with ozone depleting substances, except in the case of small ‘me too’ producers. It is therefore not the prime focus of attention in this report.

PF Boardstock

The traditional blowing agent for phenolic boardstock was CFC-11, although this was rapidly superseded by HCFC-141b. The use of HC FC-141b presented a part icular challenge for the phenolic emulsion chemistry b ecause of its solubility and th e major technology holders found it necessary to modify the blowing agent with add itives to make it less soluble in the foam mix.

In the transition that took place from HCFC-141b in Europe , it became self-evident that the phenolic product itself was sufficiently robus t in its fire perfor mance to accommodate hydrocarbon blowing agents for the bulk of e nd-uses. Therefore, the bulk of continuous processes are now based on n-pentane, either on its own or in blends with other hydrocarbons. One technology in Europe had moved directly from CFC-11 to 2-chloro-propane and continues to use this blowing agent as th e basis for its product range.

There is limited use for saturated HFCs in these continuous processes, since thermalperformance based on optimised hydrocarbon formulations is seen as sufficient for most enduses. Although it is not yet clear how the emer gence of unsaturated HFCs might affect the blowing agent choices for future phenolic boardst ock formulations, the overall performance of the various hydrocarbon-based te chnologies make it unlikely th at there will be further technology transitions in the short term.

There has been little, if a ny, implementation of phenolic foam boardstock facilities in developing countries to date, so any future investment is likel y to be based completely on technology transfer from Europe or elsewhere.

PF Blocks & Pipe Sections

As with other phenolic foam product/process t ypes, except for the floral foam industry, CFC-11 was the basic blowing agent of choice. In some cases, the boiling point of the blowing agent was modified by using CFC-11/CFC-113 ble nds in order to ensure the appropriate rise/cure profile. This was particularly important for phenolic chemistry where the sensitivity between temperature and cu re rate is high. The reduction in the latent heat of ev aporation in the early stages of the reaction helped to en sure appropriate processing times.52 In similar fashion to the phenolic boardstock sector, the first transition was to HCFC141b, with the same use of additives to reduce sol ubility of the blowing agent. In moving from HCFC-141b under the regul atory pressures in bot h Europe and North America, the industry initially moved to saturated HFCs. The choi ce was typically HFC-365mfc/227ea for boiling point reasons (as for CFC-11/CFC- 113 blends). There is still a lack of widespread use of hydrocarbons in phenolic block proc esses for insulation purposes, although its use continues for floral foams. The introduction of a continuous pipe section process has enabled reduction in foam losses, but has also enabled a switch in blowing agent to hydrocarbons, based on the more controllable environment. The bulk of phenolic pi pe section supply in the UK is now based on this technology.

It should be noticed that phe nolic foam continues to be so mething of a niche product in most global markets and has seen little success to date in developing countries. However, its innate potential continues to be recognised in a number of impor tant and growing markets. In general terms, it is believed that any further development of a manufacturing base in developing countries will be supported by comprehensive technology transfer from one of the current technology holders.

As a consequence, there seems to be little requirement for support for the transition of existing phenolic foam faciliti es in developing countries.

53 

### THERMOPLASTIC FOAMS (POLYOLEFIN & XPS)

Extruded thermoplastic foams are the only one s that have historically used ozone depleting substances. In the case of extruded polystyrene, products fall into two categories: ‘board’ and ‘sheet’, with ‘board’ being us ed for a variety of insulation, buoyancy and recreational activitie s, while ‘sheet’ has been focused on food and othe r packaging. Polyolefin (both polyethylene and polypropylene) foams have al so found uses in these sectors, but the use of polyolefin foams in insulating applica tions has been more limited.

Equipment for the manufacture of extruded ther moplastic products varies substantially by region and application. In North America, the manufacturing lines tend to be long, for optimum speed and also capable of producing wide board s (typically 1.2 metres) at thicknesses down to 25mm. This requirement necessitates a substantia l engineering solution and makes the transfer from one blowing agent to another very cha llenging. In Europe, the requirements are more modest, with many lines generatin g product at a maximum of 0.6 metr es in width and at greater thicknesses. In South East Asia (most not ably China), where the demand for extruded polystyrene foam is growing at its fastest, the technical and pr ocessing requirements are still more limited. In many cases, the polystyrene be ing used for extrusion has a high recycled content, making it less easy to pr ocess. Products generated in this scenario tend to be lower grade than in North America and Europe and are typically processed on 0.6 metre lines.

Most thermoplastic foams still depending on HC FCs have used a combination of HCFC142b and HCFC-22. The proportions of each have varied considerably depending on the application and, in some instances, each blowing agent has been used in isolation. Alternatives to HCFC-142b/22 include, saturated and unsaturated HFCs, hydrocarbons, CO 2 and CO 2 /ethanol. CO 2 , in isolation, has been found to be particular ly difficult to process, which is one of the reasons why combinations with oxygenated hydro carbons have been explored. Even then, there have been some shortcomings in the technology that have limited processing speeds and product
ranges.

The unsaturated HFCs have the potential to provide the best solution from a purely technical and environmental perspective. Hydroc arbons also offer a significant solution provided that the flammability issues can be managed at both product and process level. The extruded foam industry has had significant experience of managing hydrocarbons in the ‘sheet’ sector, which tended to bypass HCFCs a nd move straight to hydrocarbons when phasing out of CFCs. However, the experience of fires was commonplace and led some to conclude that this was not really a sustainable solution. Nevertheless, few ‘sheet’ manufacturers have stepped back from their choice and have presumab ly found coping strategies.

There is an additional challenge for ‘boa rd’ products, however. “Board” products are relatively thick for both construc tion and packaging applications. In developed countries where hydrocarbons have been adopted (p articularly in polyolefin foams) , this led to a particular problem with boards in storage and transport. In essence, the rate of diffusion of hydrocarbon out of the products was not suffici ently fast after production to a void the build-up of flammable gases in the post-production areas. This led to so me incidents. The matter was finally addressed52 In similar fashion to the phenolic boardstock sector, the first transition was to HCFC141b, with the same use of additives to reduce sol ubility of the blowing agent. In moving from HCFC-141b under the regul atory pressures in bot h Europe and North America, the industry initially moved to saturated HFCs. The choi ce was typically HFC-365mfc/227ea for boiling point reasons (as for CFC-11/CFC- 113 blends). There is still a lack of widespread use of hydrocarbons in phenolic block proc esses for insulation purposes, although its use continues for floral foams. The introduction of a continuous pipe section process has enabled reduction in foam losses, but has also enabled a switch in blowing agent to hydrocarbons, based on the more controllable environment. The bulk of phenolic pi pe section supply in the UK is now based on this technology.

It should be noticed that phe nolic foam continues to be so mething of a niche product in most global markets and has seen little success to date in developing countries. However, its innate potential continues to be recognised in a number of impor tant and growing markets. In general terms, it is believed that any further development of a manufacturing base in developing countries will be supported by comprehensive technology transfer from one of the current technology holders.

As a consequence, there seems to be little requirement for support for the transition of existing phenolic foam faciliti es in developing countries.

53 

### THERMOPLASTIC FOAMS (POLYOLEFIN & XPS)

Extruded thermoplastic foams are the only one s that have historically used ozone depleting substances. In the case of extruded polystyrene, products fall into two categories: ‘board’ and ‘sheet’, with ‘board’ being us ed for a variety of insulation, buoyancy and recreational activitie s, while ‘sheet’ has been focused on food and othe r packaging. Polyolefin (both polyethylene and polypropylene) foams have al so found uses in these sectors, but the use of polyolefin foams in insulating applica tions has been more limited.

Equipment for the manufacture of extruded ther moplastic products varies substantially by region and application. In North America, the manufacturing lines tend to be long, for optimum speed and also capable of producing wide board s (typically 1.2 metres) at thicknesses down to 25mm. This requirement necessitates a substantia l engineering solution and makes the transfer from one blowing agent to another very cha llenging. In Europe, the requirements are more modest, with many lines generatin g product at a maximum of 0.6 metr es in width and at greater thicknesses. In South East Asia (most not ably China), where the demand for extruded polystyrene foam is growing at its fastest, the technical and pr ocessing requirements are still more limited. In many cases, the polystyrene be ing used for extrusion has a high recycled content, making it less easy to pr ocess. Products generated in this scenario tend to be lower grade than in North America and Europe and are typically processed on 0.6 metre lines.

Most thermoplastic foams still depending on HC FCs have used a combination of HCFC142b and HCFC-22. The proportions of each have varied considerably depending on the application and, in some instances, each blowing agent has been used in isolation. Alternatives to HCFC-142b/22 include, saturated and unsaturated HFCs, hydrocarbons, CO 2 and CO 2 /ethanol. CO 2 , in isolation, has been found to be particular ly difficult to process, which is one of the reasons why combinations with oxygenated hydro carbons have been explored. Even then, there have been some shortcomings in the technology that have limited processing speeds and product
ranges.

The unsaturated HFCs have the potential to provide the best solution from a purely technical and environmental perspective. Hydroc arbons also offer a significant solution provided that the flammability issues can be managed at both product and process level. The extruded foam industry has had significant experience of managing hydrocarbons in the ‘sheet’ sector, which tended to bypass HCFCs a nd move straight to hydrocarbons when phasing out of CFCs. However, the experience of fires was commonplace and led some to conclude that this was not really a sustainable solution. Nevertheless, few ‘sheet’ manufacturers have stepped back from their choice and have presumab ly found coping strategies.

There is an additional challenge for ‘boa rd’ products, however. “Board” products are relatively thick for both construc tion and packaging applications. In developed countries where hydrocarbons have been adopted (p articularly in polyolefin foams) , this led to a particular problem with boards in storage and transport. In essence, the rate of diffusion of hydrocarbon out of the products was not suffici ently fast after production to a void the build-up of flammable gases in the post-production areas. This led to so me incidents. The matter was finally addressed54 by most manufacturers through the use of perfor ating equipment to re lease the hydrocarbon blowing agent physically.

Another major challenge for the thermoplas tic foams sector lies in dealing with investment costs and/or blowing agent availabili ty. The following table illustrates the fact that penalties are likely to be faced either in the context of investment cost (e.g. hydrocarbons or CO 2 ) or in operating costs and ava ilability (saturated and unsatur ated HFCs). However, it should be noted that HFC-134a is relatively widespread because of its existing use as a refrigerant.

Blowing Agent Criterion HCFC142b/22 Hydrocarbons Saturated HFCs Unsaturated HFCs (HFOs) CO 2 CO 2 /ethanol

Investment Costs + ++/+++ + + +++ ++/+++ Operating Costs ++ + ++/+++ +++ +/++ +/++ Widespread Availability ++ ++ +/++ + +/++ +/++ Potential to blend ++ ++/+++ +++ ++ ++/+++ ++/+++

+++ High; ++ Medium; + Low;

An additional factor to consider is the lead time that would be required for further conversion, especially for non-Arti cle 5 countries, bearing in mind the testing necessary to meet strict building codes.

Extruded Polystyrene (XPS) Board

The use of extruded polystyrene is primarily in the construction sector where it is used for a variety of insulation purposes, both in walls a nd roofs, but most notably in floors, where the product has specific competitive advantages. The product has competed succ essfully against both rigid polyurethane foams and mineral fibre in all the major regions of the world, although its mode of success has varied depending on the regi onal demand patterns. This point speaks to the versatility of extruded polyst yrene in its application.

The whole extruded thermoplastic foam sect or was established on the ease of use of CFC-12 as a blowing agent. It wa s only when the phase-out of CF Cs was required that the split between choices for ‘board’ and ‘sheet’ materi als occurred. Sheet products moved predominantly to hydrocarbons, while board produ cts chose to use HCFC-142b/22 bl ends for the most part, in order to retain the requisite thermal performance.

When the blend was chosen, it was known that the cell wall perm eability of HCFC-142b was significantly lower than that of HCFC-22. Th erefore, the long-term thermal performance of products would largely be determined by the proportion of HCFC-142b in the blend and its subsequent retention. Since HCFC-22 is a major refr igerant, its availability has been greater, and its price lower, throughout its pe riod of use. This has been pa rticularly important in some developing country regions where access to HC FC-142b has been more difficult and the cost significantly higher. Sin ce some product and building codes w ill have been written around the sole use of HCFC-22, it may make the transitiona l hurdle a little easier when phase-out of HCFCs is finally embraced.

55 The extruded polystyrene sector is continuing to grow rapidly in China and elsewhere in Asia and practical transitional solutions will be e ssential. It seems unlikel y that either saturated or unsaturated HFCs will make major in-roads in th e markets for reasons of cost and availability. Therefore, the most likely solution will be base d on hydrocarbons, on their own or in blends. The level of investment needed to support this is un clear, but, since the plan ts are relatively small, and there is parallel experience with extruded poly styrene sheet, it may be that the transition will be less challenging than currently envisaged. CO 2 seems unlikely as a solution in isolation.

The extrusion process remains highly emissive, and this puts a particular burden on the avoidance of high GWP solutions, such as saturated HFCs. The only time when such an approach might be justified is in applications and jurisdictions where thermal performance is absolutely paramount. In these cases, it may be possible to make further transitions from saturated to unsaturated HFCs in due course.

Polyolefin Foams

Polyolefin foams have made less penetration in to the construction markets that have been the bedrock of the extruded polys tyrene industry. The one exception to this has been in the pipe insulation sector, where the a dded resilience offered by the product has proved of substantial value. The primary use for polyolefin foams has been as a high performance packaging material – particularly when used for the packaging of delicate, high value equipment.

The choice of blowing in the polyolefin foam sector has followed a very similar pattern to that of extruded polystyrene foam. However, because of the lack of a large demand for insulating properties, the industry switched more fully to hydrocarbons when transitioning from CFCs. The remaining use of HCFCs in this produc t sector is much more limited than in the extruded polystyrene sector. Neve rtheless, where use does exist -possibly in goods related to recreational applications- techni cal assistance may be necessary to ensure that appropriate precautions are taken in any final switch to hydrocarbons.

The polyolefin foam sector is only seen to present a limited challenge in the efforts to phase of HCFCs under Decision XIX/ 6. It would appear that relevant climate-positive solutions are available and that widespread experience exis ts concerning their use. There may be some, as yet, unidentified niche applications that could present more of a challenge, but no evident has yet emerged to this effect.54 by most manufacturers through the use of perfor ating equipment to re lease the hydrocarbon blowing agent physically.

Another major challenge for the thermoplas tic foams sector lies in dealing with investment costs and/or blowing agent availabili ty. The following table illustrates the fact that penalties are likely to be faced either in the context of investment cost (e.g. hydrocarbons or CO 2 ) or in operating costs and ava ilability (saturated and unsatur ated HFCs). However, it should be noted that HFC-134a is relatively widespread because of its existing use as a refrigerant.

Blowing Agent Criterion HCFC142b/22 Hydrocarbons Saturated HFCs Unsaturated HFCs (HFOs) CO 2 CO 2 /ethanol

Investment Costs + ++/+++ + + +++ ++/+++ Operating Costs ++ + ++/+++ +++ +/++ +/++ Widespread Availability ++ ++ +/++ + +/++ +/++ Potential to blend ++ ++/+++ +++ ++ ++/+++ ++/+++

+++ High; ++ Medium; + Low;

An additional factor to consider is the lead time that would be required for further conversion, especially for non-Arti cle 5 countries, bearing in mind the testing necessary to meet strict building codes.

Extruded Polystyrene (XPS) Board

The use of extruded polystyrene is primarily in the construction sector where it is used for a variety of insulation purposes, both in walls a nd roofs, but most notably in floors, where the product has specific competitive advantages. The product has competed succ essfully against both rigid polyurethane foams and mineral fibre in all the major regions of the world, although its mode of success has varied depending on the regi onal demand patterns. This point speaks to the versatility of extruded polyst yrene in its application.

The whole extruded thermoplastic foam sect or was established on the ease of use of CFC-12 as a blowing agent. It wa s only when the phase-out of CF Cs was required that the split between choices for ‘board’ and ‘sheet’ materi als occurred. Sheet products moved predominantly to hydrocarbons, while board produ cts chose to use HCFC-142b/22 bl ends for the most part, in order to retain the requisite thermal performance.

When the blend was chosen, it was known that the cell wall perm eability of HCFC-142b was significantly lower than that of HCFC-22. Th erefore, the long-term thermal performance of products would largely be determined by the proportion of HCFC-142b in the blend and its subsequent retention. Since HCFC-22 is a major refr igerant, its availability has been greater, and its price lower, throughout its pe riod of use. This has been pa rticularly important in some developing country regions where access to HC FC-142b has been more difficult and the cost significantly higher. Sin ce some product and building codes w ill have been written around the sole use of HCFC-22, it may make the transitiona l hurdle a little easier when phase-out of HCFCs is finally embraced.

55 The extruded polystyrene sector is continuing to grow rapidly in China and elsewhere in Asia and practical transitional solutions will be e ssential. It seems unlikel y that either saturated or unsaturated HFCs will make major in-roads in th e markets for reasons of cost and availability. Therefore, the most likely solution will be base d on hydrocarbons, on their own or in blends. The level of investment needed to support this is un clear, but, since the plan ts are relatively small, and there is parallel experience with extruded poly styrene sheet, it may be that the transition will be less challenging than currently envisaged. CO 2 seems unlikely as a solution in isolation.

The extrusion process remains highly emissive, and this puts a particular burden on the avoidance of high GWP solutions, such as saturated HFCs. The only time when such an approach might be justified is in applications and jurisdictions where thermal performance is absolutely paramount. In these cases, it may be possible to make further transitions from saturated to unsaturated HFCs in due course.

Polyolefin Foams

Polyolefin foams have made less penetration in to the construction markets that have been the bedrock of the extruded polys tyrene industry. The one exception to this has been in the pipe insulation sector, where the a dded resilience offered by the product has proved of substantial value. The primary use for polyolefin foams has been as a high performance packaging material – particularly when used for the packaging of delicate, high value equipment.

The choice of blowing in the polyolefin foam sector has followed a very similar pattern to that of extruded polystyrene foam. However, because of the lack of a large demand for insulating properties, the industry switched more fully to hydrocarbons when transitioning from CFCs. The remaining use of HCFCs in this produc t sector is much more limited than in the extruded polystyrene sector. Neve rtheless, where use does exist -possibly in goods related to recreational applications- techni cal assistance may be necessary to ensure that appropriate precautions are taken in any final switch to hydrocarbons.

The polyolefin foam sector is only seen to present a limited challenge in the efforts to phase of HCFCs under Decision XIX/ 6. It would appear that relevant climate-positive solutions are available and that widespread experience exis ts concerning their use. There may be some, as yet, unidentified niche applications that could present more of a challenge, but no evident has yet emerged to this effect.56 

### CHAPTER 3: BANKS AND RECOVERY OPTIONS

RECENT TEAP WORK ON THIS ISSUE The Technology and Economic Assessment Panel (TEAP) of the Montreal Protocol has been actively quantifying and locating banks of ODS in a series of studies responding to decisions of the Parties. The latest of th ese was Decision XX/7 which initiated the most comprehensive review of banks and potential mitigation options yet.
The Task Force convened by the TEAP to comple te this work reported in two separate reports: Phase 1 in June 2009 and Phase 2 in Oc tober 2009. The second of these reports focused particularly on the quantification of savings that could be achieve d, the timing at which recovery and destruction would be required and the cost of so doing. As had been the case in earlier studies, the TEAP Task Force divi ded the ODS Banks into three major categories of ‘effort’: low, medium and high. Although ‘effort’ is partially a synonym for ‘cost’, this is not completely the case, since there is some adjustment for the f act that the relative costs of some sectors, such as foams, will always be higher than other sectors, such as refrigeration. Rather than having all refrigerant recovery in the ‘low ’ category and all foam in the ‘h igh’ category, there is some offsetting to allow a level of differentiation w ithin each sector. Note that although the emphasis of the research was on reducing ODS emissions, mo st of the conclusions could also apply to reducing HFC emissions as well.
The TEAP analysis also recognized that rec overy from densely populated (urban) areas would be easier than from sparse ly populated (rural) areas. Its fu ll analysis is summarized in the following table:

Sector Low Effort Medium Effort High Effort

Domestic Refrigeration – Refrigerant DP SP Domestic Refrigeration – Blowing Agent DP SP Commercial Refrigeration – Refrigerant DP SP Commercial Refrigeration – Blowing Agent DP SP Transport Refrigeration – Refrigerant DP/SP Transport Refrigeration – Blowing Agent DP/SP Industrial Refrigeration – Refrigerant DP/SP Stationary Air Conditioning – Refrigerant DP SP Other Stationary Air Conditioning – Refrigerant DP SP Mobile Air Conditioning – Refrigerant DP SP Steel-faced Panels – Blowing Agent DP SP XPS Foams – Blowing Agent DP/SP* PU Boardstock – Blowing Agent DP/SP* PU Spray – Blowing Agent DP*/SP* PU Block – Pipe DP SP PU Block – Slab DP SP Other PU Foams – Blowing Agent DP/SP* Halon – Fire Suppression DP SP DP = Densely Populated Areas; SP = Sp arsely Populated Areas * Still technically unproven

57 This table underlined the fact that, even befo re cost elements were explicitly addressed, the management of existing ODS banks, in foams, was seen as representing the most significant challenge (largely high effort). Indeed, in some instances (e.g., PU Spray Foams) it was acknowledged that recovery and destruction of blowing agents from those sources was still globally unproven technically. This reflects the fact that flows of ODS into building demolition waste streams are still in their infancy and there is little global experien ce as yet in managing such materials. Even in Japan, where the regulation of demolition processes attracts high levels of compliance, a study on ODS Bank Management in the built environm ent conducted by the Japan Technical Committee on Construction Materials (JTCCM) in the period 2002-2005 concluded that it was not possible to mandate the recovery a nd destruction of ODS in buildings because of continuing uncertainties about techni cal feasibility and economic impacts. Of course, this is not to rule out the likelihood that experience will spawn i nnovation and technological development in this area. However, the Japanese vi ew was that this is best achieved by voluntary action, often supported by incentives, rather than unenforceable legislation.

The main conclusions from this work were that the refrigerant banks represented the most cost-effective ODS bank management opti ons (as measured in $ per tonne of CO 2 saved), partially because of their easie r accessibility and pa rtially because the baseline emissions for refrigerants are higher than for foams, which te nd to display relatively low emissions during the majority of their lifecycles.

For appliances, it was clear that measures to manage ODS banks would need to be implemented within the next five years, even in developing countries, if the main ozone and climate benefits arising from CFC recovery and de struction were to be realised. This fact is highlighted in the next section where the loca tion of ODS banks on foams is analysed for 2008.

For foams, the main areas where recovery at en d-of-life could be legitimately expected at low/medium effort, were identified as:

**•** Domestic Appliances

**•** Commercial Refrigeration

**•** Steel-faced panels

**•** Block Pipe Section & Slab
Progress on recovery and destru ction from these product areas are reviewed further in the later sections of this chapter.

BANK ESTIMATES IN 2008

In the period leading up to the preparation of this report, it had been anticipated that the Committee would provide baseline bank estimates for 2020. However, in view of the large uncertainties still associ ated with the selection of alternatives and the sensitivities involved in making quantitative predictions about future consum ption, it was decided to limit this chapter to the assessment of banks as at 2008.56 

### CHAPTER 3: BANKS AND RECOVERY OPTIONS

RECENT TEAP WORK ON THIS ISSUE The Technology and Economic Assessment Panel (TEAP) of the Montreal Protocol has been actively quantifying and locating banks of ODS in a series of studies responding to decisions of the Parties. The latest of th ese was Decision XX/7 which initiated the most comprehensive review of banks and potential mitigation options yet.
The Task Force convened by the TEAP to comple te this work reported in two separate reports: Phase 1 in June 2009 and Phase 2 in Oc tober 2009. The second of these reports focused particularly on the quantification of savings that could be achieve d, the timing at which recovery and destruction would be required and the cost of so doing. As had been the case in earlier studies, the TEAP Task Force divi ded the ODS Banks into three major categories of ‘effort’: low, medium and high. Although ‘effort’ is partially a synonym for ‘cost’, this is not completely the case, since there is some adjustment for the f act that the relative costs of some sectors, such as foams, will always be higher than other sectors, such as refrigeration. Rather than having all refrigerant recovery in the ‘low ’ category and all foam in the ‘h igh’ category, there is some offsetting to allow a level of differentiation w ithin each sector. Note that although the emphasis of the research was on reducing ODS emissions, mo st of the conclusions could also apply to reducing HFC emissions as well.
The TEAP analysis also recognized that rec overy from densely populated (urban) areas would be easier than from sparse ly populated (rural) areas. Its fu ll analysis is summarized in the following table:

Sector Low Effort Medium Effort High Effort

Domestic Refrigeration – Refrigerant DP SP Domestic Refrigeration – Blowing Agent DP SP Commercial Refrigeration – Refrigerant DP SP Commercial Refrigeration – Blowing Agent DP SP Transport Refrigeration – Refrigerant DP/SP Transport Refrigeration – Blowing Agent DP/SP Industrial Refrigeration – Refrigerant DP/SP Stationary Air Conditioning – Refrigerant DP SP Other Stationary Air Conditioning – Refrigerant DP SP Mobile Air Conditioning – Refrigerant DP SP Steel-faced Panels – Blowing Agent DP SP XPS Foams – Blowing Agent DP/SP* PU Boardstock – Blowing Agent DP/SP* PU Spray – Blowing Agent DP*/SP* PU Block – Pipe DP SP PU Block – Slab DP SP Other PU Foams – Blowing Agent DP/SP* Halon – Fire Suppression DP SP DP = Densely Populated Areas; SP = Sp arsely Populated Areas * Still technically unproven

57 This table underlined the fact that, even befo re cost elements were explicitly addressed, the management of existing ODS banks, in foams, was seen as representing the most significant challenge (largely high effort). Indeed, in some instances (e.g., PU Spray Foams) it was acknowledged that recovery and destruction of blowing agents from those sources was still globally unproven technically. This reflects the fact that flows of ODS into building demolition waste streams are still in their infancy and there is little global experien ce as yet in managing such materials. Even in Japan, where the regulation of demolition processes attracts high levels of compliance, a study on ODS Bank Management in the built environm ent conducted by the Japan Technical Committee on Construction Materials (JTCCM) in the period 2002-2005 concluded that it was not possible to mandate the recovery a nd destruction of ODS in buildings because of continuing uncertainties about techni cal feasibility and economic impacts. Of course, this is not to rule out the likelihood that experience will spawn i nnovation and technological development in this area. However, the Japanese vi ew was that this is best achieved by voluntary action, often supported by incentives, rather than unenforceable legislation.

The main conclusions from this work were that the refrigerant banks represented the most cost-effective ODS bank management opti ons (as measured in $ per tonne of CO 2 saved), partially because of their easie r accessibility and pa rtially because the baseline emissions for refrigerants are higher than for foams, which te nd to display relatively low emissions during the majority of their lifecycles.

For appliances, it was clear that measures to manage ODS banks would need to be implemented within the next five years, even in developing countries, if the main ozone and climate benefits arising from CFC recovery and de struction were to be realised. This fact is highlighted in the next section where the loca tion of ODS banks on foams is analysed for 2008.

For foams, the main areas where recovery at en d-of-life could be legitimately expected at low/medium effort, were identified as:

**•** Domestic Appliances

**•** Commercial Refrigeration

**•** Steel-faced panels

**•** Block Pipe Section & Slab
Progress on recovery and destru ction from these product areas are reviewed further in the later sections of this chapter.

BANK ESTIMATES IN 2008

In the period leading up to the preparation of this report, it had been anticipated that the Committee would provide baseline bank estimates for 2020. However, in view of the large uncertainties still associ ated with the selection of alternatives and the sensitivities involved in making quantitative predictions about future consum ption, it was decided to limit this chapter to the assessment of banks as at 2008.58 The following tables provide a summary of th e banks of blowing agents contained within foams in developed and deve loping countries for 2008.

Foam Banks ‐ Developed Countries ‐ 2008

CFCs HCFCs HFCs HCs Other Total % CFC*
Available % HCFC*
Available

PU ‐ Dom. Appliances 283528 144834 55607 224807 0 708776 21.59% 99.80%
PU ‐ Other Appliances 27324 68954 22953 17789 255 137275 46.30% 99.88%
PU ‐ Reefers 12342 18639 6816 6970 0 44767 28.33% 98.83%

Total Appliances 323194 232427 85376 249566 255 890818 23.94% 99.75%

36.28% 26.09% 9.58% 28.02% 0.03%

PU ‐ Boardstock 616683 297973 7560 383219 0 1305435 100.00% 100.00%
PU ‐ Continuous Panel 147619 56633 21552 116124 0 341928 100.00% 100.00%
PU ‐ Disc. Panel 123785 85377 38707 20801 0 268670 100.00% 100.00%
PU ‐ Spray 97608 102470 40733 0 523 241334 100.00% 100.00%
PU ‐ Block

‐ Pipe 10220 4660 1631 3379 0 19890 18.74% 98.15%
PU ‐ Block

‐ Slab 26168 12192 4110 8573 0 51043 27.11% 98.64%
PU ‐ Pipe

‐ in

‐ Pipe 38950 15506 3531 10767 0 68754 100.00% 100.00%
XPS ‐ Board 250016 369145 26339 28113 0 673613 100.00% 100.00%
PE ‐ Block

‐ Pipe 8033 5183 516 8055 0 21787 18.74% 98.15%
PE ‐ Block

‐ Slab 8057 3317 643 9234 0 21251 27.11% 98.64%
PF ‐ Boardstock 10699 6724 1772 13741 0 32936 100.00% 100.00%
PF ‐ Disc. Panel 4364 3640 559 3399 0 11962 100.00% 100.00%
PF ‐ Block

‐ Pipe 3865 3153 1038 2849 0 10905 18.74% 98.15%
PF ‐ Block

‐ Slab 1185 987 626 606 0 3404 27.11% 98.64%

Total Constr./Other 1347252 966960 149317 608860 523 3072912 96.75% 99.95%

43.84% 31.47% 4.86% 19.81% 0.02%

Grand Total 1670446 1199387 234693 858426 778 3963730 82.66% 99.91%

42.14% 30.26% 5.92% 21.66% 0.02%

* Availability based on correction for banks already in waste stream

The table shows that only around 24% of CFC blowing agent banks remains available in Domestic Appliance Foams with the remainder already in landfill. By contrast , most the HCFC remains available. For the ‘construction and other’ foams, only the products produced from block foams have significantly reached their end-of-life and entered in to the waste stream. The opportunity for recovery from products is, therefore, still substantial if approp riate techniques can be developed to recovery and destroy blowing agents economically.

59 Foam Banks ‐ Developing Countries ‐ 2008

CFCs HCFCs HFCs HCs Other Total % CFC*
Available % HCFC*
Available

PU ‐ Dom. Appliances 241750 108607 1217 181904 0 533478 72.98% 100.00%
PU ‐ Other Appliances 7977 16902 0 0 0 24879 85.93% 100.00%
PU ‐ Reefers 14850 23767 531 0 0 39148 81.91% 100.00%

Total Appliances 264577 149276 1748 181904 0 597505 73.87% 100.00%

44.28% 24.98% 0.29% 30.44% 0.00%

PU ‐ Boardstock 1709 0 0 784 0 2493 100.00% N/A

PU ‐ Continuous Panel 22306 9092 0 2621 0 34019 100.00% 100.00%
PU ‐ Disc. Panel 55536 34961 0 4205 0 94702 100.00% 100.00%
PU ‐ Spray 60232 37146 0 0 0 97378 100.00% 100.00%
PU ‐ Block

‐ Pipe 8011 2953 0 0 0 10964 67.58% 100.00%
PU ‐ Block

‐ Slab 12509 4562 0 0 0 17071 75.55% 100.00%
PU ‐ Pipe

‐ in

‐ Pipe 42387 21122 0 227 0 63736 100.00% 100.00%
XPS ‐ Board 70311 184277 0 44 0 254632 100.00% 100.00%
PE ‐ Block

‐ Pipe 8815 0 0 4898 0 13713 67.58% N/A

PE ‐ Block

‐ Slab 10975 0 0 5324 0 16299 75.55% N/A

PF ‐ Block

‐ Pipe 782 198 0 0 0 980 67.58% 100.00%
PF ‐ Block

‐ Slab 782 198 0 0 0 980 75.55% 100.00%

Total Constr./Other 294355 294509 0 18103 0 606967 96.04% 100.00%

48.50% 48.52% 0.00% 2.98% 0.00%

Grand Total 558932 443785 1748 200007 0 1204472 85.55% 100.00%

46.40% 36.84% 0.15% 16.61% 0.00%

* Availability based on correction for banks already in waste stream

By way of contrast to the developed country scenario, approximately 73% of banked CFCs in domestic appliance foams were still available for r ecovery and destruction in 2008. There are no significant HCFCs already in the waste stream and th ese remain available for recovery and destruction where economically viable.58 The following tables provide a summary of th e banks of blowing agents contained within foams in developed and deve loping countries for 2008.

Foam Banks ‐ Developed Countries ‐ 2008

CFCs HCFCs HFCs HCs Other Total % CFC*
Available % HCFC*
Available

PU ‐ Dom. Appliances 283528 144834 55607 224807 0 708776 21.59% 99.80%
PU ‐ Other Appliances 27324 68954 22953 17789 255 137275 46.30% 99.88%
PU ‐ Reefers 12342 18639 6816 6970 0 44767 28.33% 98.83%

Total Appliances 323194 232427 85376 249566 255 890818 23.94% 99.75%

36.28% 26.09% 9.58% 28.02% 0.03%

PU ‐ Boardstock 616683 297973 7560 383219 0 1305435 100.00% 100.00%
PU ‐ Continuous Panel 147619 56633 21552 116124 0 341928 100.00% 100.00%
PU ‐ Disc. Panel 123785 85377 38707 20801 0 268670 100.00% 100.00%
PU ‐ Spray 97608 102470 40733 0 523 241334 100.00% 100.00%
PU ‐ Block

‐ Pipe 10220 4660 1631 3379 0 19890 18.74% 98.15%
PU ‐ Block

‐ Slab 26168 12192 4110 8573 0 51043 27.11% 98.64%
PU ‐ Pipe

‐ in

‐ Pipe 38950 15506 3531 10767 0 68754 100.00% 100.00%
XPS ‐ Board 250016 369145 26339 28113 0 673613 100.00% 100.00%
PE ‐ Block

‐ Pipe 8033 5183 516 8055 0 21787 18.74% 98.15%
PE ‐ Block

‐ Slab 8057 3317 643 9234 0 21251 27.11% 98.64%
PF ‐ Boardstock 10699 6724 1772 13741 0 32936 100.00% 100.00%
PF ‐ Disc. Panel 4364 3640 559 3399 0 11962 100.00% 100.00%
PF ‐ Block

‐ Pipe 3865 3153 1038 2849 0 10905 18.74% 98.15%
PF ‐ Block

‐ Slab 1185 987 626 606 0 3404 27.11% 98.64%

Total Constr./Other 1347252 966960 149317 608860 523 3072912 96.75% 99.95%

43.84% 31.47% 4.86% 19.81% 0.02%

Grand Total 1670446 1199387 234693 858426 778 3963730 82.66% 99.91%

42.14% 30.26% 5.92% 21.66% 0.02%

* Availability based on correction for banks already in waste stream

The table shows that only around 24% of CFC blowing agent banks remains available in Domestic Appliance Foams with the remainder already in landfill. By contrast , most the HCFC remains available. For the ‘construction and other’ foams, only the products produced from block foams have significantly reached their end-of-life and entered in to the waste stream. The opportunity for recovery from products is, therefore, still substantial if approp riate techniques can be developed to recovery and destroy blowing agents economically.

59 Foam Banks ‐ Developing Countries ‐ 2008

CFCs HCFCs HFCs HCs Other Total % CFC*
Available % HCFC*
Available

PU ‐ Dom. Appliances 241750 108607 1217 181904 0 533478 72.98% 100.00%
PU ‐ Other Appliances 7977 16902 0 0 0 24879 85.93% 100.00%
PU ‐ Reefers 14850 23767 531 0 0 39148 81.91% 100.00%

Total Appliances 264577 149276 1748 181904 0 597505 73.87% 100.00%

44.28% 24.98% 0.29% 30.44% 0.00%

PU ‐ Boardstock 1709 0 0 784 0 2493 100.00% N/A

PU ‐ Continuous Panel 22306 9092 0 2621 0 34019 100.00% 100.00%
PU ‐ Disc. Panel 55536 34961 0 4205 0 94702 100.00% 100.00%
PU ‐ Spray 60232 37146 0 0 0 97378 100.00% 100.00%
PU ‐ Block

‐ Pipe 8011 2953 0 0 0 10964 67.58% 100.00%
PU ‐ Block

‐ Slab 12509 4562 0 0 0 17071 75.55% 100.00%
PU ‐ Pipe

‐ in

‐ Pipe 42387 21122 0 227 0 63736 100.00% 100.00%
XPS ‐ Board 70311 184277 0 44 0 254632 100.00% 100.00%
PE ‐ Block

‐ Pipe 8815 0 0 4898 0 13713 67.58% N/A

PE ‐ Block

‐ Slab 10975 0 0 5324 0 16299 75.55% N/A

PF ‐ Block

‐ Pipe 782 198 0 0 0 980 67.58% 100.00%
PF ‐ Block

‐ Slab 782 198 0 0 0 980 75.55% 100.00%

Total Constr./Other 294355 294509 0 18103 0 606967 96.04% 100.00%

48.50% 48.52% 0.00% 2.98% 0.00%

Grand Total 558932 443785 1748 200007 0 1204472 85.55% 100.00%

46.40% 36.84% 0.15% 16.61% 0.00%

* Availability based on correction for banks already in waste stream

By way of contrast to the developed country scenario, approximately 73% of banked CFCs in domestic appliance foams were still available for r ecovery and destruction in 2008. There are no significant HCFCs already in the waste stream and th ese remain available for recovery and destruction where economically viable.60 RECOVERY ACTIVITIES IN THE APPLIANCE SECTOR

Experiences to date – Developed Countries

In contrast to the challenges of the building s ector, there is considerably more experience in managing foams from appliances and commercia l refrigeration equipment. In several regions of the world, including Europe and Japan the recovery of blowing agents from domestic refrigerators and freezers has been required. This has been extended over time to cover other types of appliance. In the case of Europe this has b een driven by product lifecycle legislation such as the WEEE 6 Regulation rather than the ozone re gulations per se, although efforts have been made to ensure that both regulatory strands are complementary to one another.

This said, there have been on-going concerns in Europe about the percentage of end-oflife appliances being de-manufactur ed in line with the legislative requirements as well as the maintenance of adequate standards for recove ry and destruction within those operations designated to manage the process. Even in Germany, a recent study uncovered a number of failures to uphold the existing stan dards. Further investigation reve aled that the most likely cause of these malpractices has been th e over-capacity in the sector, with prices for the de-manufacture of domestic refrigerator s dropping from their initial levels in excess of $25/unit to values as low as $8/unit.

Another factor to consider here is that voluntary carbon finance cannot be leveraged in the region, even though the re levant methodologies (Voluntary Carbon Standard (VCS) and Climate Action Reserve (CAR)) apply to these r ecovery and destruction operations. This is because the market sees no ‘additionality’ from ODS recovery and destruction in regions where the measure is already mandated. Even if such funding were to be available, its contribution would be less substantial for HCFC recovery and destruction than for CFC recovery and destruction. This observation arises from the lower GWP of HCFCs in comparison with CFCs. This issue is dealt with further within the following developing country discussion, where a further analysis by TEAP is presented.

In North America, there is still no federal re quirement for the recove ry of blowing agent from foams in appliances. However, there are a nu mber of state level initiatives which encourage recovery and destruction. California is looking at the option of using their wider cap-and-trade mechanisms for the inclusion of ODS recove ry, using the Climate Action Reserve methodology as a basis. However, this methodology necessarily needs to take a conservative view on savings and the uncertainties around anaerobic degradation of ODS in landfills has led to lower baseline emission estimates and a reduction in the realisable savings from end-of-life measures. With the low current valuation of carbon, even on exchange s with high reputations such as CAR, the financial incentives may be insufficient to enc ourage widespread recove ry and destruction of foam blowing agents, despite the adoption of se mi-automated processes with lower investment
costs.

6 WEEE – ‘Waste Electrical and Electronic Equipment’ 61 The other driver for recovery of ODS in appliances in North America has been the introduction of energy efficiency schemes, prom oted by the energy suppl y companies to reduce demand in vulnerable regions of th e territory. However, these sche mes are not obliged to recover ODS and it is often left to the environmental consciousness of the individual companies to influence decisions to in clude recovery from units. This is ev en more the case for blowing agents than it is for refrigerants, since blowing agents are furt her along the cost-abatement curve.

Experiences to date – Developing Countries

An additional piece of analysis of the TEAP data for developing countries, as presented at the July 2010 Geneva Workshop on ODS Bank Management, illustrated the significant difference between CFC and HCFC recovery in terms of cost-effectiveness. Depending on location (urban or rural) the cost of recovery and destruction of HCFCs in appliance foam can range from $60-$90 per tCO 2 -eq. saved or even more in devel oped countries where transport and labour costs are higher. This comp ares to a figure of $10 per tCO 2 -eq. saved for CFCs where the opportunity exists for both the refrigerant and fo am blowing agent to be recovered at the same time. The analysis doesn’t take into account the recovery of HFC-134a refrigerant in the appliance, which can, of course, provide additional climate bene fit for a given investment under appropriate circumstances.

Average Cost Effectiveness of Climate Savings

0 200 400 600 800 1,000 1,200 1,400 1,600

0 10 20 30 40 50 60 70 80 90 100 Cost Effectiveness ($ per tonne CO2 saved)Total Potential Saving (Mtonnes CO2 saved)

CFC
HCFC 

# Potential for Recovery vs. Cost Effectiveness
The Impact of Dealing with Appliances (2010-2030)

Refrigerant only Refrigerant & CFC Foam HCFC Foam in Appliances60 RECOVERY ACTIVITIES IN THE APPLIANCE SECTOR

Experiences to date – Developed Countries

In contrast to the challenges of the building s ector, there is considerably more experience in managing foams from appliances and commercia l refrigeration equipment. In several regions of the world, including Europe and Japan the recovery of blowing agents from domestic refrigerators and freezers has been required. This has been extended over time to cover other types of appliance. In the case of Europe this has b een driven by product lifecycle legislation such as the WEEE 6 Regulation rather than the ozone re gulations per se, although efforts have been made to ensure that both regulatory strands are complementary to one another.

This said, there have been on-going concerns in Europe about the percentage of end-oflife appliances being de-manufactur ed in line with the legislative requirements as well as the maintenance of adequate standards for recove ry and destruction within those operations designated to manage the process. Even in Germany, a recent study uncovered a number of failures to uphold the existing stan dards. Further investigation reve aled that the most likely cause of these malpractices has been th e over-capacity in the sector, with prices for the de-manufacture of domestic refrigerator s dropping from their initial levels in excess of $25/unit to values as low as $8/unit.

Another factor to consider here is that voluntary carbon finance cannot be leveraged in the region, even though the re levant methodologies (Voluntary Carbon Standard (VCS) and Climate Action Reserve (CAR)) apply to these r ecovery and destruction operations. This is because the market sees no ‘additionality’ from ODS recovery and destruction in regions where the measure is already mandated. Even if such funding were to be available, its contribution would be less substantial for HCFC recovery and destruction than for CFC recovery and destruction. This observation arises from the lower GWP of HCFCs in comparison with CFCs. This issue is dealt with further within the following developing country discussion, where a further analysis by TEAP is presented.

In North America, there is still no federal re quirement for the recove ry of blowing agent from foams in appliances. However, there are a nu mber of state level initiatives which encourage recovery and destruction. California is looking at the option of using their wider cap-and-trade mechanisms for the inclusion of ODS recove ry, using the Climate Action Reserve methodology as a basis. However, this methodology necessarily needs to take a conservative view on savings and the uncertainties around anaerobic degradation of ODS in landfills has led to lower baseline emission estimates and a reduction in the realisable savings from end-of-life measures. With the low current valuation of carbon, even on exchange s with high reputations such as CAR, the financial incentives may be insufficient to enc ourage widespread recove ry and destruction of foam blowing agents, despite the adoption of se mi-automated processes with lower investment
costs.

6 WEEE – ‘Waste Electrical and Electronic Equipment’ 61 The other driver for recovery of ODS in appliances in North America has been the introduction of energy efficiency schemes, prom oted by the energy suppl y companies to reduce demand in vulnerable regions of th e territory. However, these sche mes are not obliged to recover ODS and it is often left to the environmental consciousness of the individual companies to influence decisions to in clude recovery from units. This is ev en more the case for blowing agents than it is for refrigerants, since blowing agents are furt her along the cost-abatement curve.

Experiences to date – Developing Countries

An additional piece of analysis of the TEAP data for developing countries, as presented at the July 2010 Geneva Workshop on ODS Bank Management, illustrated the significant difference between CFC and HCFC recovery in terms of cost-effectiveness. Depending on location (urban or rural) the cost of recovery and destruction of HCFCs in appliance foam can range from $60-$90 per tCO 2 -eq. saved or even more in devel oped countries where transport and labour costs are higher. This comp ares to a figure of $10 per tCO 2 -eq. saved for CFCs where the opportunity exists for both the refrigerant and fo am blowing agent to be recovered at the same time. The analysis doesn’t take into account the recovery of HFC-134a refrigerant in the appliance, which can, of course, provide additional climate bene fit for a given investment under appropriate circumstances.

Average Cost Effectiveness of Climate Savings

0 200 400 600 800 1,000 1,200 1,400 1,600

0 10 20 30 40 50 60 70 80 90 100 Cost Effectiveness ($ per tonne CO2 saved)Total Potential Saving (Mtonnes CO2 saved)

CFC
HCFC 

# Potential for Recovery vs. Cost Effectiveness
The Impact of Dealing with Appliances (2010-2030)

Refrigerant only Refrigerant & CFC Foam HCFC Foam in Appliances62 One of the other factors to consider is that waste streams are unlikely to be segregated by blowing agent type and the cost-effectiveness w ill vary according to the product mix arriving at end-of-life on an annual basis. The following gr aph illustrates how this might change with time for appliances in developing co untries. It can be seen thatthe period of greatest costeffectiveness is between now and 2020. After that time, higher carbon prices would be needed to support the cost-effectiven ess of recovery of predominantly HCFCs.

Cost Effectiveness Ranges for ODS & ODS Substitute Bank Management in Developing Countries (Appliances & Foams)

0 10 20 30 40 50 60 70 80 90 100

2010 2 0 1 1 2012 2 0 1 3 2

0 1 4 2015 2016 2 0 1 7 2018 2 0 1 9 2

0 2 0 2021 2022 2 0 2 3 2024 2 0 2 5 2

0 2 6 2027 2 0 2 8 2

0 2 9 2030

YearCosts ($ per tonne CO2saved)
Low Effort - Lower Bound

Low Effort - Upper Bound

Low/Medium Effort - Lower Bound

Low/Medium Effort - Upper Bound

RECOVERY ACTIVITIES IN THE BUILT ENVIRONMENT

Experiences to date by Region (incl. logistics)

As noted in the earlier sections of this Ch apter, the only low/medium effort recovery options for foams in the buildings sector are found in the buildin g services (e.g. pipe and duct insulation) and in certain forms of prefabricated construction (e.g. steel-faced panels).

In practice, the quantity of bl ock manufactured and used glob ally for pipe insulation and other building services pr oducts (e.g. duct insulati on) is relatively small as a proportion of the total. Where pipe section is produced from bl ock (or, indeed, extruded from thermoplastic foams), there is a potential fo r recovery during decommissioning. This may also be the case for block foam prefabricated for use in composite panels.

For steel-faced panels there is also some relevant experien ce, since these products tend to be used on buildings in Europe with shorter av erage life-times than traditional constructions (typically 30 years). Although these are only now reaching the waste stream in any number, the

63 potential to use existing refrigerator de-manuf acturing equipment or ev en direct incineration exists. In most cases, the presence of the steel facings also adds to the economic case since these can be recovered and recycled. Nevertheless, ac ross the European Union’s 27 member states (EU-27) there is a large range of demolition waste practice. Only where waste segregation is already highly advanced (e.g., Au stria) does the economics of rec overy and destru ction stack-up. This is demonstrated in the following table, although it should be noted that the final relative cost-effectiveness (in cost per tonne of CO 2 saved) between appliances and panels will depend on the blowing agent mix reaching the waste stream:



## Cost effectiveness – Panels vs. Appliances

Tonnage

Band Domestic Appliance JTCCM (Japan) Kingspan Panels (trial projects) Austria Study

Destruction Transport

Sorting Dismantling

-------

-------

€ 40-50 € 25-35 € 55-65

€ 3-4

€ 20-25 € 20-25 €65-90

€ 4-6

€ 25-35

€ 5-10 Discounted!

€ 20-30

(based on steel-faced panels @ €200/te)

Per kg of blowing agent Discounted!

Total € 65-85 € 98-119 € 99-141 € 20-30

There is therefore some reticence within some Member States to see any move towards a mandated recovery and destruction requirement for ODS in steel-faced panels. However, the potential of an incentive-led approach, perh aps based on carbon valuation, may prove a more mutually acceptable way forward.

Moving onto more general ODS banks in building foam, the most recent study completed by the Building Research Establishment (BRE) in the United Kingdom, the assessment of cost associated with the management of ODS in bu ildings was in the order of £200 ($300) per tCO 2 - eq. saved (BRE, 2010). It should be stressed that the prime purpose of this study was not to review costs in detail, but it is interesting to note that th is assessment supports the view that average recovery costs from th e wider building sector would be proportionately higher than those associated with steel-faced panels.62 One of the other factors to consider is that waste streams are unlikely to be segregated by blowing agent type and the cost-effectiveness w ill vary according to the product mix arriving at end-of-life on an annual basis. The following gr aph illustrates how this might change with time for appliances in developing co untries. It can be seen thatthe period of greatest costeffectiveness is between now and 2020. After that time, higher carbon prices would be needed to support the cost-effectiven ess of recovery of predominantly HCFCs.

Cost Effectiveness Ranges for ODS & ODS Substitute Bank Management in Developing Countries (Appliances & Foams)

0 10 20 30 40 50 60 70 80 90 100

2010 2 0 1 1 2012 2 0 1 3 2

0 1 4 2015 2016 2 0 1 7 2018 2 0 1 9 2

0 2 0 2021 2022 2 0 2 3 2024 2 0 2 5 2

0 2 6 2027 2 0 2 8 2

0 2 9 2030

YearCosts ($ per tonne CO2saved)
Low Effort - Lower Bound

Low Effort - Upper Bound

Low/Medium Effort - Lower Bound

Low/Medium Effort - Upper Bound

RECOVERY ACTIVITIES IN THE BUILT ENVIRONMENT

Experiences to date by Region (incl. logistics)

As noted in the earlier sections of this Ch apter, the only low/medium effort recovery options for foams in the buildings sector are found in the buildin g services (e.g. pipe and duct insulation) and in certain forms of prefabricated construction (e.g. steel-faced panels).

In practice, the quantity of bl ock manufactured and used glob ally for pipe insulation and other building services pr oducts (e.g. duct insulati on) is relatively small as a proportion of the total. Where pipe section is produced from bl ock (or, indeed, extruded from thermoplastic foams), there is a potential fo r recovery during decommissioning. This may also be the case for block foam prefabricated for use in composite panels.

For steel-faced panels there is also some relevant experien ce, since these products tend to be used on buildings in Europe with shorter av erage life-times than traditional constructions (typically 30 years). Although these are only now reaching the waste stream in any number, the

63 potential to use existing refrigerator de-manuf acturing equipment or ev en direct incineration exists. In most cases, the presence of the steel facings also adds to the economic case since these can be recovered and recycled. Nevertheless, ac ross the European Union’s 27 member states (EU-27) there is a large range of demolition waste practice. Only where waste segregation is already highly advanced (e.g., Au stria) does the economics of rec overy and destru ction stack-up. This is demonstrated in the following table, although it should be noted that the final relative cost-effectiveness (in cost per tonne of CO 2 saved) between appliances and panels will depend on the blowing agent mix reaching the waste stream:



## Cost effectiveness – Panels vs. Appliances

Tonnage

Band Domestic Appliance JTCCM (Japan) Kingspan Panels (trial projects) Austria Study

Destruction Transport

Sorting Dismantling

-------

-------

€ 40-50 € 25-35 € 55-65

€ 3-4

€ 20-25 € 20-25 €65-90

€ 4-6

€ 25-35

€ 5-10 Discounted!

€ 20-30

(based on steel-faced panels @ €200/te)

Per kg of blowing agent Discounted!

Total € 65-85 € 98-119 € 99-141 € 20-30

There is therefore some reticence within some Member States to see any move towards a mandated recovery and destruction requirement for ODS in steel-faced panels. However, the potential of an incentive-led approach, perh aps based on carbon valuation, may prove a more mutually acceptable way forward.

Moving onto more general ODS banks in building foam, the most recent study completed by the Building Research Establishment (BRE) in the United Kingdom, the assessment of cost associated with the management of ODS in bu ildings was in the order of £200 ($300) per tCO 2 - eq. saved (BRE, 2010). It should be stressed that the prime purpose of this study was not to review costs in detail, but it is interesting to note that th is assessment supports the view that average recovery costs from th e wider building sector would be proportionately higher than those associated with steel-faced panels.64 FUTURE TRENDS AND DRIVERS

Financing

The future trends in carbon financing are far from settled at this time following the failure of the Copenhagen Conference of the Parties to meet a binding agreement on the way forward. Although the Cancun meeting endorsed alternative bilateral and multilateral funding options via the Nationally Appropriate Mitiga tion Actions (NAMAs), it is still not clear whether these will sit alongside existing mechanisms or actually repl ace them. Either way, ther e is expected to be wholesale reform of the current Clean Development Mechanism (CDM). In turn, this is leading to considerable uncertainty about the valuation of carbon savings in the short to medium terms. With this in mind, the valuation of carbon in th e short-term depends on intrinsic valuations placed on carbon mitigation at national level rather than a market-based carbon price per se. The only region where this is not strictly true is in Europe, where the EU Em issions Trading Scheme (EU ETS) continues to provide a direct monetary basis (around €17 per tonne of CO 2 as at May 2011). However, as noted earlier in this chapter, there is no specific leverage for ODS recovery from appliances, because the measure would not be additional to the regulatory base (WEEE and the recast Ozone Regulation).

Other Regulatory Drivers

With continuing uncertainties about the co st-effectiveness of blowing agent recovery from foams in a number of key sectors, it is unlik ely that regulation will extend significantly in the next five years, particularly because access to public or private finance is likely to be limited under the current economic constr aints. The link between proposed regulation and the cost has been heightened considerably in recent year s because of the need for Regulatory Impact Assessments in a number of jurisdictions. There is concern amongst some industry sectors that penalising the low/medium effort product base by the stigma of regulator y control, when other high effort products are likely to remain unre gulated would drive counter-productive market behaviour.

A1 - 1 

### APPENDIX 1: REVIEW OF ALTE RNATIVE BLOWING AGENTS

The major blowing agents being commercially used as substitutes for HCFCs in the foam sector, or being considered for commercial intr oduction in the short-term, are shown in the subsections that follow – each of which contains a ta ble with basic properties and supply information. These tables are supplemented by descriptive para graphs which provide technical information on the blowing agents themselves and some information on usage patterns and commercial availability. It should be noted th at there are no references to regul atory constraints in this Section. While the impact of ODS regulatio ns is probably well known to th e reading audien ce and does not require further iteration here, it might be useful to note, for example, that other environmental factors, such as classification as volatile organic compounds (VOC s) may have a bearing on local acceptance. The reader is therefore encouraged to make a full evaluation of the national and local circumstances when choosing blowing agent options.

The tables and the subsequent descriptive pa ragraphs provide technical information on the blowing agents themselves and some informati on on usage patterns and commercial availability. It should be noted that there are no references to regulatory constraints in this Appendix. While, the impact of ODS Regulations is probably we ll known to the reading audience and does not require further iteration here, it might be useful to note, for example, that all fluorocarbons in the United States are not treated as Volatile Orga nic Compounds (VOCs) fo r regulatory purposes.

The blowing agents options have been divided in seven different families: 1.1 HCFCs 1.2 Hydrocarbons 1.3 Carbon Dioxide 1.4 Oxygenated Hydrocarbons (Methyl Form ate, Methylal and Dimethyl Ether) 1.5 Chlorinated Hydrocarbons (Methylene Chlo ride, Trans-1,2 di-c hloroethylene and 2- chloropropane) 1.6 Saturated HFCs 1.7 Unsaturated HFCs (HFOs)64 FUTURE TRENDS AND DRIVERS

Financing

The future trends in carbon financing are far from settled at this time following the failure of the Copenhagen Conference of the Parties to meet a binding agreement on the way forward. Although the Cancun meeting endorsed alternative bilateral and multilateral funding options via the Nationally Appropriate Mitiga tion Actions (NAMAs), it is still not clear whether these will sit alongside existing mechanisms or actually repl ace them. Either way, ther e is expected to be wholesale reform of the current Clean Development Mechanism (CDM). In turn, this is leading to considerable uncertainty about the valuation of carbon savings in the short to medium terms. With this in mind, the valuation of carbon in th e short-term depends on intrinsic valuations placed on carbon mitigation at national level rather than a market-based carbon price per se. The only region where this is not strictly true is in Europe, where the EU Em issions Trading Scheme (EU ETS) continues to provide a direct monetary basis (around €17 per tonne of CO 2 as at May 2011). However, as noted earlier in this chapter, there is no specific leverage for ODS recovery from appliances, because the measure would not be additional to the regulatory base (WEEE and the recast Ozone Regulation).

Other Regulatory Drivers

With continuing uncertainties about the co st-effectiveness of blowing agent recovery from foams in a number of key sectors, it is unlik ely that regulation will extend significantly in the next five years, particularly because access to public or private finance is likely to be limited under the current economic constr aints. The link between proposed regulation and the cost has been heightened considerably in recent year s because of the need for Regulatory Impact Assessments in a number of jurisdictions. There is concern amongst some industry sectors that penalising the low/medium effort product base by the stigma of regulator y control, when other high effort products are likely to remain unre gulated would drive counter-productive market behaviour.

A1 - 1 

### APPENDIX 1: REVIEW OF ALTE RNATIVE BLOWING AGENTS

The major blowing agents being commercially used as substitutes for HCFCs in the foam sector, or being considered for commercial intr oduction in the short-term, are shown in the subsections that follow – each of which contains a ta ble with basic properties and supply information. These tables are supplemented by descriptive para graphs which provide technical information on the blowing agents themselves and some information on usage patterns and commercial availability. It should be noted th at there are no references to regul atory constraints in this Section. While the impact of ODS regulatio ns is probably well known to th e reading audien ce and does not require further iteration here, it might be useful to note, for example, that other environmental factors, such as classification as volatile organic compounds (VOC s) may have a bearing on local acceptance. The reader is therefore encouraged to make a full evaluation of the national and local circumstances when choosing blowing agent options.

The tables and the subsequent descriptive pa ragraphs provide technical information on the blowing agents themselves and some informati on on usage patterns and commercial availability. It should be noted that there are no references to regulatory constraints in this Appendix. While, the impact of ODS Regulations is probably we ll known to the reading audience and does not require further iteration here, it might be useful to note, for example, that all fluorocarbons in the United States are not treated as Volatile Orga nic Compounds (VOCs) fo r regulatory purposes.

The blowing agents options have been divided in seven different families: 1.1 HCFCs 1.2 Hydrocarbons 1.3 Carbon Dioxide 1.4 Oxygenated Hydrocarbons (Methyl Form ate, Methylal and Dimethyl Ether) 1.5 Chlorinated Hydrocarbons (Methylene Chlo ride, Trans-1,2 di-c hloroethylene and 2- chloropropane) 1.6 Saturated HFCs 1.7 Unsaturated HFCs (HFOs)A1 - 2 1.1 HCFCs

HCFC-141b HCFC-142b HCFC-22

Chemical Formula CH 3 CFCl 2 CH 3 CF 2 Cl CHCIF 2 Molecular Weight 116.95 100.50 86.47 Boiling Point ( 0 C ) 31.9 -9.2 -40.8 Gas Conductivity (mW/mK @ 10 0 C) 8.8 8.4 9.9 Flammable Limits in Air (vol.%) 7.6-17.7 6.2-17.9 - TLV or OEL (ppm) (USA) 500 1000 1000 GWP (100 yr time horizon) 725 2310 1810

Key Producers Arkema, Cgangsu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Quzhou Rongqiang, Shandong Dongda, Solvay, Zhejiang Lantian, Zhejiang Sanmei Arkema, Cgangsu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Shandong Dongda, Solvay, Zhejiang Sanmei Arkema, Cgangsu 3f, Daikin, DuPont, Honeywell, Produven, Quimobasicos, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Sammei, Zhejiang Quhua.

A1 -3 HCFC – 141b

Description & Usage

HCFC-141b is a liquid at r oom temperature and does not have a flash point. HCFC-141b has been used as a foam blowing agent in almo st all rigid and integral skin foam sectors.

Physical and Chemical properties 7

Chemical name: 1,1-dich loro-1-fluoroethane Formula: CH 3 CFCl 2 Molecular Weight: 116.95 EC Number (EINECS): 605-613-2 CAS Number: 1717-00-6 Density (g/cm 3 ) 1.25 (10 °C) Boiling Point (°C) 31.9 Vapour pressure (mm Hg ) 525 (25 oC) Gas Conductivity (mW/m. K) 8.8 (10 °C), 9.7 (25 °C) Vapour density (air=1) 4.1 Solubility in water 1.7 g/L

HSE properties

Toxicological data: WEEL, 8 hr. TWA, ppm 500 Autoignition temperature 550 °C Flammable limits in air (vol. %) 7.6-17.7 VOC No GWP 8 (100-yr Time Horizon) 725 ODP 0.11

Commercial status

Producers: Arkema, Changshu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Quzhou Rongqiang, Shandong Dongda, Solvay, Zhejiang Lantian, Zhejiang Sanmei.

7 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/247.html. C onsulted April 2011.
8 IPCC Fourth Assessment Report: Climate Change 2007.A1 - 2 1.1 HCFCs

HCFC-141b HCFC-142b HCFC-22

Chemical Formula CH 3 CFCl 2 CH 3 CF 2 Cl CHCIF 2 Molecular Weight 116.95 100.50 86.47 Boiling Point ( 0 C ) 31.9 -9.2 -40.8 Gas Conductivity (mW/mK @ 10 0 C) 8.8 8.4 9.9 Flammable Limits in Air (vol.%) 7.6-17.7 6.2-17.9 - TLV or OEL (ppm) (USA) 500 1000 1000 GWP (100 yr time horizon) 725 2310 1810

Key Producers Arkema, Cgangsu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Quzhou Rongqiang, Shandong Dongda, Solvay, Zhejiang Lantian, Zhejiang Sanmei Arkema, Cgangsu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Shandong Dongda, Solvay, Zhejiang Sanmei Arkema, Cgangsu 3f, Daikin, DuPont, Honeywell, Produven, Quimobasicos, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Sammei, Zhejiang Quhua.

A1 -3 HCFC – 141b

Description & Usage

HCFC-141b is a liquid at r oom temperature and does not have a flash point. HCFC-141b has been used as a foam blowing agent in almo st all rigid and integral skin foam sectors.

Physical and Chemical properties 7

Chemical name: 1,1-dich loro-1-fluoroethane Formula: CH 3 CFCl 2 Molecular Weight: 116.95 EC Number (EINECS): 605-613-2 CAS Number: 1717-00-6 Density (g/cm 3 ) 1.25 (10 °C) Boiling Point (°C) 31.9 Vapour pressure (mm Hg ) 525 (25 oC) Gas Conductivity (mW/m. K) 8.8 (10 °C), 9.7 (25 °C) Vapour density (air=1) 4.1 Solubility in water 1.7 g/L

HSE properties

Toxicological data: WEEL, 8 hr. TWA, ppm 500 Autoignition temperature 550 °C Flammable limits in air (vol. %) 7.6-17.7 VOC No GWP 8 (100-yr Time Horizon) 725 ODP 0.11

Commercial status

Producers: Arkema, Changshu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Quzhou Rongqiang, Shandong Dongda, Solvay, Zhejiang Lantian, Zhejiang Sanmei.

7 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/247.html. C onsulted April 2011.
8 IPCC Fourth Assessment Report: Climate Change 2007.A1 -4 HCFC – 142b
Description & Usage
HFC-142b is a gas at room temperature, highly flammable. It is used as a foam blowing agent for extruded polystyrene foams. It can be used alone or as a blend with HCFC-22. A blend of 60/40 HCFC-142b/HCFC-22 (60/40) is non-flammable.

Physical and Chemical properties 9

Chemical name: 1-chlo ro-1,1-difl uoroethane Formula: CH 3 CF 2 Cl Molecular Weight: 100.50 EC Number (EINECS): 200-891-8 CAS Number: 75-68-3 Density/Specific gravity 1.107 (25 oC) Boiling Point (°C) -9.2 Vapour pressure (mm Hg ) 7786 (25 oC) Gas Conductivity (mW/m. K) 8.4 (10 °C), 11.5 (25 °C) Vapour density (air=1) 3.49 Solubility in water Slightly soluble

HSE properties
Toxicological data: TLV or OEL (USA, ppm) 1000 WEEL, 8 hr. TWA, ppm 1000 Autoignition temperature 632 °C Flammable limits in air (vol. %) 6.2-17.9 Flash Point -65 oC VOC No GWP 10 (100-yr Time Horizon) 2310 ODP 0.066

Commercial status

Producers: Arkema, Changshu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Shandong Dongda, Zhejiang Lantian, Zhejiang Sanmei.

9 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/131.html. C onsulted April 2011.
10 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -5 HCFC-22
Description & Usage
HCFC-22 is a non-flammable colourless ga s liquefied under pressure. One main application is as a non-flammable mixture with HCFC-142b for PU and XPS foams. In rigid PU foam it has been used in combination with HCFC-141b.

Physical and Chemical properties 11

Chemical name: Chlorodifluoromethane Formula: CHCIF 2 Molecular Weight: 86.47 EC Number (EINECS): 200-871-9 CAS Number: 75-45-6 Density (g/cm 3 ) 1.41 (20 °C) Boiling Point (°C) -40.8 Vapour pressure (mm Hg ) 6290 (25 oC) Gas Conductivity (mW/m. K) 9.9 (10 °C), 11.0 (30 °C) Vapour density (air=1) 2.98 Solubility in water 3 g/L Soluble in most organic solvents
HSE properties
Toxicological data 12 TLV (as TWA) 1000 ppm, 3540 mg/m 3 (ACGIH 1992-1993) TWA (NIOSH REL) 1000 ppm (3500 mg/m 3 ) Decomposition temperature 480 °C VOC No GWP 13 (100-yr Time Horizon) 1810 ODP 0.055

Commercial Status

Producers: Arkema, Cha ngshu 3f, Daikin, DuPont, Honeywell, Produven, Quimobasicos, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Sammei, Zhejiang Quhua.

11 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/83.html. C onsulted April 2011.

12 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/83.html. C onsulted April 2011.
13 IPCC Fourth Assessment Report: Climate Change 2007.A1 -4 HCFC – 142b
Description & Usage
HFC-142b is a gas at room temperature, highly flammable. It is used as a foam blowing agent for extruded polystyrene foams. It can be used alone or as a blend with HCFC-22. A blend of 60/40 HCFC-142b/HCFC-22 (60/40) is non-flammable.

Physical and Chemical properties 9

Chemical name: 1-chlo ro-1,1-difl uoroethane Formula: CH 3 CF 2 Cl Molecular Weight: 100.50 EC Number (EINECS): 200-891-8 CAS Number: 75-68-3 Density/Specific gravity 1.107 (25 oC) Boiling Point (°C) -9.2 Vapour pressure (mm Hg ) 7786 (25 oC) Gas Conductivity (mW/m. K) 8.4 (10 °C), 11.5 (25 °C) Vapour density (air=1) 3.49 Solubility in water Slightly soluble

HSE properties
Toxicological data: TLV or OEL (USA, ppm) 1000 WEEL, 8 hr. TWA, ppm 1000 Autoignition temperature 632 °C Flammable limits in air (vol. %) 6.2-17.9 Flash Point -65 oC VOC No GWP 10 (100-yr Time Horizon) 2310 ODP 0.066

Commercial status

Producers: Arkema, Changshu 3f, Daikin, Hangzhou Fist, Kangtai Fluorine Chemical, Shandong Dongda, Zhejiang Lantian, Zhejiang Sanmei.

9 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/131.html. C onsulted April 2011.
10 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -5 HCFC-22
Description & Usage
HCFC-22 is a non-flammable colourless ga s liquefied under pressure. One main application is as a non-flammable mixture with HCFC-142b for PU and XPS foams. In rigid PU foam it has been used in combination with HCFC-141b.

Physical and Chemical properties 11

Chemical name: Chlorodifluoromethane Formula: CHCIF 2 Molecular Weight: 86.47 EC Number (EINECS): 200-871-9 CAS Number: 75-45-6 Density (g/cm 3 ) 1.41 (20 °C) Boiling Point (°C) -40.8 Vapour pressure (mm Hg ) 6290 (25 oC) Gas Conductivity (mW/m. K) 9.9 (10 °C), 11.0 (30 °C) Vapour density (air=1) 2.98 Solubility in water 3 g/L Soluble in most organic solvents
HSE properties
Toxicological data 12 TLV (as TWA) 1000 ppm, 3540 mg/m 3 (ACGIH 1992-1993) TWA (NIOSH REL) 1000 ppm (3500 mg/m 3 ) Decomposition temperature 480 °C VOC No GWP 13 (100-yr Time Horizon) 1810 ODP 0.055

Commercial Status

Producers: Arkema, Cha ngshu 3f, Daikin, DuPont, Honeywell, Produven, Quimobasicos, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Sammei, Zhejiang Quhua.

11 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/83.html. C onsulted April 2011.

12 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/83.html. C onsulted April 2011.
13 IPCC Fourth Assessment Report: Climate Change 2007.A1 -6 1.2 Hydrocarbons

C yc l o-P entane n-Pentane Is o -Pent a ne Iso-Butane n-Butane

Chemical Formula (CH 2 ) 5 CH 3 (CH 2 ) 3 CH 3 CH 3 CH( CH 3 )CHCH 3 CH 3 CH( CH 3 )CH CH 3 CH 2 CH 2 CH 3 Mol ecu lar We i gh t 70 .1 72 .1 72 .1 58 .1 58 .1

Bo ili ng Point ( 0 C ) 49 36 .1 28 -11.7 -0.45

Gas Co nd u ctivity (mW/mK @ 10 0 C) 11 .0 14 .0 13 .0 15 .9 13.6

Flammable Limits in Air (v ol. %) 1.5-8.7 1.4-8.0 1.4-8.3 1.8-8.4 1.8-8.5

TLV or OEL ( pp m) (US A) 600 610 1 00 0 800 800

GW P (100 yr time hor izon) <25 <25 <25 <25 <25

Key Pro d uce rs Chevron Phillips, Haltermann Pr od uct s, ExxonMob il

, Haldia Petrochemical Ltd., Maruzen Pet ro chemi ca l, Pu yan g Zh o ng w ei Fi ne Chemical Bei jing Yan shan Petrochemical Co. Ltd., Ch evro n Phillip s, Halterma nn Product s, ExxonMob il

, Ma ru ze n Pet ro chemi ca l, Shell Ch evro n Ph illi p s, Halterma nn Product s, ExxonMob il , J ili n Ji n lo ng Indu strial Co Ba ye r, Chev ro n Phillip s, ExxonMob il

, Re finery of Ji n li ng Pe troc he mi cal Ch evro n Phillips, ExxonMob il

, Shanghai Petrochemical Co. Ltd.

^ M ea s ur ed at 0 o C

A1 -7 CYCLOPENTANE Description and Usage
Cyclopentane is a colorless and flammable li quid with a gasoline-like odor. It is a blowing agent for polystyrene and polyurethane foam processes. Physical and Chemical properties 14

Chemical name: Cyclopentane Formula C 5 H 10 Molecular Weight 70.13 EC Number (EINECS) 206-016-6 CAS Number 287-92-3 Density (g/cm 3 ) 0.746 (20 °C) Boiling Point ( o C) 49 Melting point ( o C) -93.3 Vapour pressure (mmHg) 318 (20 °C) Gas Conductivity (mW/m.K) 11.0 (10 °C) Vapour density (air=1) 2.42 (20 °C) Solubility in Water Insoluble
HSE properties 15
Toxicological data TLV (as TWA) (ACGIH 1993-1994) TWA (NIOSH REL) 600 ppm, 1720 mg/m 3 600 ppm, 1720 mg/m 3 Flammable limits in air (%) 1.5 - 8.7 Autoignition Temperature 380 °C Flash Point (°C) -42 VOC Yes 16 GWP (100-yr Time Horizon) <25 17
ODP 0

Commercial Status
Producers Chevron Phillips, Haltermann Products, ExxonMobil, Haldia Petrochemicals Ltd., Maruzen Petrochemical, Puyang Zhongwei Fine Chemical Co., Ltd.

14 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/6348.html. Cons ulted April 2011.
15 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/6348.html. Cons ulted April 2011.
16 Subject to regulations that can vary from country to country and within a country even from region to region.

17 Precise figure varies according to local atmospheric conditions.A1 -6 1.2 Hydrocarbons

C yc l o-P entane n-Pentane Is o -Pent a ne Iso-Butane n-Butane

Chemical Formula (CH 2 ) 5 CH 3 (CH 2 ) 3 CH 3 CH 3 CH( CH 3 )CHCH 3 CH 3 CH( CH 3 )CH CH 3 CH 2 CH 2 CH 3 Mol ecu lar We i gh t 70 .1 72 .1 72 .1 58 .1 58 .1

Bo ili ng Point ( 0 C ) 49 36 .1 28 -11.7 -0.45

Gas Co nd u ctivity (mW/mK @ 10 0 C) 11 .0 14 .0 13 .0 15 .9 13.6

Flammable Limits in Air (v ol. %) 1.5-8.7 1.4-8.0 1.4-8.3 1.8-8.4 1.8-8.5

TLV or OEL ( pp m) (US A) 600 610 1 00 0 800 800

GW P (100 yr time hor izon) <25 <25 <25 <25 <25

Key Pro d uce rs Chevron Phillips, Haltermann Pr od uct s, ExxonMob il

, Haldia Petrochemical Ltd., Maruzen Pet ro chemi ca l, Pu yan g Zh o ng w ei Fi ne Chemical Bei jing Yan shan Petrochemical Co. Ltd., Ch evro n Phillip s, Halterma nn Product s, ExxonMob il

, Ma ru ze n Pet ro chemi ca l, Shell Ch evro n Ph illi p s, Halterma nn Product s, ExxonMob il , J ili n Ji n lo ng Indu strial Co Ba ye r, Chev ro n Phillip s, ExxonMob il

, Re finery of Ji n li ng Pe troc he mi cal Ch evro n Phillips, ExxonMob il

, Shanghai Petrochemical Co. Ltd.

^ M ea s ur ed at 0 o C

A1 -7 CYCLOPENTANE Description and Usage
Cyclopentane is a colorless and flammable li quid with a gasoline-like odor. It is a blowing agent for polystyrene and polyurethane foam processes. Physical and Chemical properties 14

Chemical name: Cyclopentane Formula C 5 H 10 Molecular Weight 70.13 EC Number (EINECS) 206-016-6 CAS Number 287-92-3 Density (g/cm 3 ) 0.746 (20 °C) Boiling Point ( o C) 49 Melting point ( o C) -93.3 Vapour pressure (mmHg) 318 (20 °C) Gas Conductivity (mW/m.K) 11.0 (10 °C) Vapour density (air=1) 2.42 (20 °C) Solubility in Water Insoluble
HSE properties 15
Toxicological data TLV (as TWA) (ACGIH 1993-1994) TWA (NIOSH REL) 600 ppm, 1720 mg/m 3 600 ppm, 1720 mg/m 3 Flammable limits in air (%) 1.5 - 8.7 Autoignition Temperature 380 °C Flash Point (°C) -42 VOC Yes 16 GWP (100-yr Time Horizon) <25 17
ODP 0

Commercial Status
Producers Chevron Phillips, Haltermann Products, ExxonMobil, Haldia Petrochemicals Ltd., Maruzen Petrochemical, Puyang Zhongwei Fine Chemical Co., Ltd.

14 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/6348.html. Cons ulted April 2011.
15 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/6348.html. Cons ulted April 2011.
16 Subject to regulations that can vary from country to country and within a country even from region to region.

17 Precise figure varies according to local atmospheric conditions.A1 -8 ISOPENTANE

Description and Usage

Isopentane is a colorless and flammable liquid with a gasoline-like odor. It is a blowing agent for polystyrene and polyurethane foam processes.

Physical and Chemical properties 18

Chemical name: 2-Methylbutane Formula C 5 H 12 Molecular Weight 72.15 EC Number (EINECS) 201-142-8 CAS Number 78-78-4 Density (g/cm 3 ) 0.620 (20°C) Boiling Point ( o C) 28 Melting point ( o C) -160 Vapour pressure (mmHg) 727 (25 °C) Gas Conductivity (mW/m.K) 13.0 (10 °C) Vapour density (air=1) 2.48 (20 °C) Solubility in Water < 0.1 g /100ml (23°C)

HSE Properties 19

Toxicological data

TWA (ACGIH) 600 ppm Odor threshold (ppm) 10 Flammable limits in air (%) 1.4 – 8.3 Autoignition Temperature (°C) 420 Flash Point (°C) -57 VOC Yes 20
ODP 0 GWP (100-yr Time Horizon) <25 21

Commercial Status

Producers Chevron Phillips, Haltermann Products, ExxonMobil, Jilin Jinlong Industrial Co.

18 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/45.html. Cons ulted April 2011.
19 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/45.html. Cons ulted April 2011.

20 Subject to regulations that can vary from country to country and within a country even from region to region

21 Precise figure varies according to local atmospheric conditions. A1 -9 n-PENTANE Description and Usage
n-Pentane is a colorless and flammable liquid with a gasolin e-like odor. It is a blowing agent for polystyrene and polyurethane foam processes.
Physical and Chemical properties 22

Chemical name: n-Pentane Formula C 5 H 12 Molecular Weight 72.1498 EC Number (EINECS) 203-693-4 CAS Number 109-66-0 Density (g/cm 3 ) 0.62 6 (20 °C) Boiling Point ( o C) 36.1 Melting point ( o C) -129.7 Vapour pressure (mmHg) 512 (25 °C) Gas Conductivity (mW/m.K) 14.0 (10 °C) Vapour density (air=1) 2.48 (20 o C) Solubility in Water 0.04 g /100ml (23 °C)
HSE Properties 23
Toxicological data

TWA (OSHA PEL) TWA (NIOSH REL) C (NIOSH REL) LEL (NIOSH IDLH) 1000 ppm, 2950 mg/m 3 120 ppm, 350 mg/m 3 610 ppm, 1800 mg/m 3 (15-minute) 1500 ppm Flammable limits in air (%) 1.4 – 8.0 Autoignition Temperature (°C) 285 Flash Point (°C) - 49 VOC Yes 24
ODP 0 GWP (100-yr Time Horizon) <25 25

Commercial Status
Producers Beijing Yanshan Petrochemical Co. Ltd., Chevron Phillips, Haltermann Products, ExxonMobil, Maruzen Petrochemical, Shell.

22 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/7301.html. Cons ulted April 2011.
23 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/7301.html. Cons ulted April 2011.

24 Subject to regulations that can vary from country to and from region to region

25 Precise figure varies according to local atmospheric conditions.A1 -8 ISOPENTANE

Description and Usage

Isopentane is a colorless and flammable liquid with a gasoline-like odor. It is a blowing agent for polystyrene and polyurethane foam processes.

Physical and Chemical properties 18

Chemical name: 2-Methylbutane Formula C 5 H 12 Molecular Weight 72.15 EC Number (EINECS) 201-142-8 CAS Number 78-78-4 Density (g/cm 3 ) 0.620 (20°C) Boiling Point ( o C) 28 Melting point ( o C) -160 Vapour pressure (mmHg) 727 (25 °C) Gas Conductivity (mW/m.K) 13.0 (10 °C) Vapour density (air=1) 2.48 (20 °C) Solubility in Water < 0.1 g /100ml (23°C)

HSE Properties 19

Toxicological data

TWA (ACGIH) 600 ppm Odor threshold (ppm) 10 Flammable limits in air (%) 1.4 – 8.3 Autoignition Temperature (°C) 420 Flash Point (°C) -57 VOC Yes 20
ODP 0 GWP (100-yr Time Horizon) <25 21

Commercial Status

Producers Chevron Phillips, Haltermann Products, ExxonMobil, Jilin Jinlong Industrial Co.

18 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/45.html. Cons ulted April 2011.
19 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/45.html. Cons ulted April 2011.

20 Subject to regulations that can vary from country to country and within a country even from region to region

21 Precise figure varies according to local atmospheric conditions. A1 -9 n-PENTANE Description and Usage
n-Pentane is a colorless and flammable liquid with a gasolin e-like odor. It is a blowing agent for polystyrene and polyurethane foam processes.
Physical and Chemical properties 22

Chemical name: n-Pentane Formula C 5 H 12 Molecular Weight 72.1498 EC Number (EINECS) 203-693-4 CAS Number 109-66-0 Density (g/cm 3 ) 0.62 6 (20 °C) Boiling Point ( o C) 36.1 Melting point ( o C) -129.7 Vapour pressure (mmHg) 512 (25 °C) Gas Conductivity (mW/m.K) 14.0 (10 °C) Vapour density (air=1) 2.48 (20 o C) Solubility in Water 0.04 g /100ml (23 °C)
HSE Properties 23
Toxicological data

TWA (OSHA PEL) TWA (NIOSH REL) C (NIOSH REL) LEL (NIOSH IDLH) 1000 ppm, 2950 mg/m 3 120 ppm, 350 mg/m 3 610 ppm, 1800 mg/m 3 (15-minute) 1500 ppm Flammable limits in air (%) 1.4 – 8.0 Autoignition Temperature (°C) 285 Flash Point (°C) - 49 VOC Yes 24
ODP 0 GWP (100-yr Time Horizon) <25 25

Commercial Status
Producers Beijing Yanshan Petrochemical Co. Ltd., Chevron Phillips, Haltermann Products, ExxonMobil, Maruzen Petrochemical, Shell.

22 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/7301.html. Cons ulted April 2011.
23 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/7301.html. Cons ulted April 2011.

24 Subject to regulations that can vary from country to and from region to region

25 Precise figure varies according to local atmospheric conditions.A1 -10 ISOBUTANE

Description and Usage

Isobutane is a colorless gas with a faint pe troleum-like odor. It is a blowing agent for polyethylene and polyurethane foam processes.

Physical and Chemical properties 26

Chemical name: Isobutane Formula C 4 H 10 Molecular Weight 58.12 EC Number (EINECS) 200-857-2 CAS Number 75-28-5 Density/Specific gravity 0.557 Boiling Point ( o C) -11.7 Melting point ( o C) -255.3 Vapour pressure (mmHg) 2580 (25 o C) Gas Conductivity (mW/m.K) 15.9 (20 o C) Vapour density (air=1) 2.01 (20 o C) Solubility in Water Slightly soluble

HSE properties 27

Toxicological data

TWA (NIOSH REL) 800 ppm, 1900 mg/m 3 Flammable limits in air (%) 1.8 – 8.4 Flash Point (°C) -107 Autoignition Temperature (°C) 460 GWP (100-yr Time Horizon) <25 28
VOC Yes 29
ODP 0

Commercial Status

Producers Bayer, Chevron Phillips, ExxonMobil, Refinery of Jinling Petrochemical

26 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/24.html. Cons ulted April 2011.

27 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/24.html. Cons ulted April 2011.

28 Precise figure varies according to local atmospheric conditions.

29 Subject to regulations that can vary from country to country and within a country even from region to region A1 -11 n-BUTANE
Description and Usage
n-Butane is a colorless gas with a faint disa greeable odor. It is used It as blowing agent for polyethylene and extruded polystyrene processes.
Physical and Chemical properties 30

Chemical name: n-butane Formula C 4 H 10 Molecular Weight 58.12 EC Number (EINECS) 203-448-7 CAS Number 106-97-8 Density (g/cm 3 ) 0.579 (20 °C) Boiling Point ( o C) -0.45 Melting point ( o C) -138.35 Vapour pressure (mmHg) 1556 (20 °C) Gas Conductivity (mW/m.K) 13.6 (0°C) Vapour density (air=1) 2.046 Solubility in Water 61mg/L (20 °C)
HSE properties 31

Toxicological data

TWA (ACGIH TLV) TWA (OSHA PEL) 800 ppm 800 ppm Odor threshold (ppm) 50000 Flammable limits in air (%) 1.8 - 8.5 Flash Point (°C) -60 Autoignition Temperature (°C) 405 GWP (100-yr Time Horizon) <25 32
VOC Yes 33
ODP 0

Commercial Status

Producers Chevron Phillips, ExxonMobil, Shanghai Petrochemical Co. Ltd.

30 http://ull.chemistry.uakron.edu/erd/Chemi cals/22000/20510.html. C onsulted April 2011.
31 http://ull.chemistry.uakron.edu/erd/Chemi cals/22000/20510.html. C onsulted April 2011.

32 Precise figure varies according to local atmospheric conditions.

33 Subject to regulations that can vary from country to country and within a country even from region to regionA1 -10 ISOBUTANE

Description and Usage

Isobutane is a colorless gas with a faint pe troleum-like odor. It is a blowing agent for polyethylene and polyurethane foam processes.

Physical and Chemical properties 26

Chemical name: Isobutane Formula C 4 H 10 Molecular Weight 58.12 EC Number (EINECS) 200-857-2 CAS Number 75-28-5 Density/Specific gravity 0.557 Boiling Point ( o C) -11.7 Melting point ( o C) -255.3 Vapour pressure (mmHg) 2580 (25 o C) Gas Conductivity (mW/m.K) 15.9 (20 o C) Vapour density (air=1) 2.01 (20 o C) Solubility in Water Slightly soluble

HSE properties 27

Toxicological data

TWA (NIOSH REL) 800 ppm, 1900 mg/m 3 Flammable limits in air (%) 1.8 – 8.4 Flash Point (°C) -107 Autoignition Temperature (°C) 460 GWP (100-yr Time Horizon) <25 28
VOC Yes 29
ODP 0

Commercial Status

Producers Bayer, Chevron Phillips, ExxonMobil, Refinery of Jinling Petrochemical

26 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/24.html. Cons ulted April 2011.

27 http://ull.chemistry.uakron.edu/erd/Chemi cals/2000/24.html. Cons ulted April 2011.

28 Precise figure varies according to local atmospheric conditions.

29 Subject to regulations that can vary from country to country and within a country even from region to region A1 -11 n-BUTANE
Description and Usage
n-Butane is a colorless gas with a faint disa greeable odor. It is used It as blowing agent for polyethylene and extruded polystyrene processes.
Physical and Chemical properties 30

Chemical name: n-butane Formula C 4 H 10 Molecular Weight 58.12 EC Number (EINECS) 203-448-7 CAS Number 106-97-8 Density (g/cm 3 ) 0.579 (20 °C) Boiling Point ( o C) -0.45 Melting point ( o C) -138.35 Vapour pressure (mmHg) 1556 (20 °C) Gas Conductivity (mW/m.K) 13.6 (0°C) Vapour density (air=1) 2.046 Solubility in Water 61mg/L (20 °C)
HSE properties 31

Toxicological data

TWA (ACGIH TLV) TWA (OSHA PEL) 800 ppm 800 ppm Odor threshold (ppm) 50000 Flammable limits in air (%) 1.8 - 8.5 Flash Point (°C) -60 Autoignition Temperature (°C) 405 GWP (100-yr Time Horizon) <25 32
VOC Yes 33
ODP 0

Commercial Status

Producers Chevron Phillips, ExxonMobil, Shanghai Petrochemical Co. Ltd.

30 http://ull.chemistry.uakron.edu/erd/Chemi cals/22000/20510.html. C onsulted April 2011.
31 http://ull.chemistry.uakron.edu/erd/Chemi cals/22000/20510.html. C onsulted April 2011.

32 Precise figure varies according to local atmospheric conditions.

33 Subject to regulations that can vary from country to country and within a country even from region to regionA1 -12 1.3 Carbon Dioxide CARBON DIOXIDE Description & Usage

Carbon Dioxide (chemical formula CO 2 ) is a gas in normal conditions and exists in the atmosphere in small concentrations. It is a colourless, odourless, non-flammable gas, with very low chemical r eactivity and toxicity.

Physical and Chemical Properties 34

Formula CO 2 Molecular weight 44.0 EC Number (EINECS): 204-696-9 CAS Number: 124-38-9 Triple point Pressure (bar) 5.11 Temperature (°C) -56.6 Critical point Pressure (bar) 75.2 Temperature (°C) 31 Specific volume (L/kg) 2.156 Density 1.56 g/cm 3 (20 °C) Vaporisation Heat (Kcal/kg) 83.20 (triple point) Sublimation Heat (Kcal/kg) 136.40 (1 atm) Heat of formation of gas (Kcal/kg) 2.137 (25 °C)

34 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/6241.html. Cons ulted April 2011.
A1 -13 Phase diagram for carbon dioxideA1 -12 1.3 Carbon Dioxide CARBON DIOXIDE Description & Usage

Carbon Dioxide (chemical formula CO 2 ) is a gas in normal conditions and exists in the atmosphere in small concentrations. It is a colourless, odourless, non-flammable gas, with very low chemical r eactivity and toxicity.

Physical and Chemical Properties 34

Formula CO 2 Molecular weight 44.0 EC Number (EINECS): 204-696-9 CAS Number: 124-38-9 Triple point Pressure (bar) 5.11 Temperature (°C) -56.6 Critical point Pressure (bar) 75.2 Temperature (°C) 31 Specific volume (L/kg) 2.156 Density 1.56 g/cm 3 (20 °C) Vaporisation Heat (Kcal/kg) 83.20 (triple point) Sublimation Heat (Kcal/kg) 136.40 (1 atm) Heat of formation of gas (Kcal/kg) 2.137 (25 °C)

34 http://ull.chemistry.uakron.edu/erd/Chemi cals/8000/6241.html. Cons ulted April 2011.
A1 -13 Phase diagram for carbon dioxideA1 -14 HSE Properties

Carbon dioxide is toxic only at very high concentrati ons (5000 ppm = 9000 mg/m3).

Commercial Data

Carbon dioxide is a generic chemical with num erous suppliers and wide availability in most countries. There are two main supply sources:

**•** From mining sources (natural CO 2 ). Carbon Dioxide exists in the underground and is produced by the decomposition of carbonate compounds in presence of steam or by the sudden cooling of magma which release CO 2 as a gas.

**•** Chemically generated as a by-product of several chemical reactions in the main industrial processes. One of the main sources is the pr ocess to produce ammonia and urea. The main impurities are sulphur ous products, inert gases and water.

Since CO 2 is normally utilized as an additive in the food industry, it is supplied at very high purity (some suppliers guarantee more than 99,9%).

CO 2 is liquefied to be stored and transporte d. There are two are systems to store carbon dioxide for industrial use: pr essurized bottles for small consumption requirements and bulk tanks for high consumptions. All mayor suppliers of liquid ga ses provide rental contracts for the mentioned storage solutions.

**•** Pressurised bottles: Bottles of liquid CO 2 are at pressures of 70 to 100 bar at normal ambient temperature. Two types of pressure bottles are used – bottom feed, with an internal bottom-feed pipe for delivering liquid CO 2 or top-feed, for delivering gaseous CO 2 . Avoid any heating of the bottles either by sun ligh t or any heating source. Bottles must be handled with care using gloves and avoiding any hard contact.

**•** Bulk tanks: CO 2 is stored in insulated, pressurised tanks of capacity from 3 up to 50

m 3 , at a pressure of about 16-18 bar and temperature abou t –30 to –24 °C. The tank is normally fitted with a CO 2 level detector and cooling sy stem to control the pressure within the required limits. It is recommended that the tank is protected from adverse weather conditions and to erect around it a guard rail, to restrict access. Any parts of the electric installation should be pl aced under a roof or indoors.

Carbon Dioxide as blowing ag ent for polyurethane foams

In polyurethane foam (flexible slab-stock, fl exible moulded, integral skin, rigid) the carbon dioxide is generated chemically by th e reaction between water and isocyanate.

A1 -15 1.4 Oxygenated Hydrocarbons

Methylal Methyl Formate Di-methyl Ether

Chemical Formula CH 3 OCH 2 OCH 3 CH 3 (HCOO) CH 3 OCH 3 Molecular Weight 76.1 60.0 46.07 Boiling Point ( 0 C ) 42 31.5 -24.8 Gas Conductivity (mW/mK @ 15 0 C) Not available 10.7 (@ 25 0 C) 15.5

Flammable Limits in Air (vol.%) 2.2-19.9 5.0-23.0 3.0-18.6

TLV or OEL (ppm) (USA) 1000 100 1000 GWP (100 yr time horizon) <25 <25* 1

Key Producers Spectrum Chemicals, Alcan International, Kimbester (China) Caldic Lambiotte & Cie BOC Foam Supplies Multiple Chinese producers Air LiquideA1 -14 HSE Properties

Carbon dioxide is toxic only at very high concentrati ons (5000 ppm = 9000 mg/m3).

Commercial Data

Carbon dioxide is a generic chemical with num erous suppliers and wide availability in most countries. There are two main supply sources:

**•** From mining sources (natural CO 2 ). Carbon Dioxide exists in the underground and is produced by the decomposition of carbonate compounds in presence of steam or by the sudden cooling of magma which release CO 2 as a gas.

**•** Chemically generated as a by-product of several chemical reactions in the main industrial processes. One of the main sources is the pr ocess to produce ammonia and urea. The main impurities are sulphur ous products, inert gases and water.

Since CO 2 is normally utilized as an additive in the food industry, it is supplied at very high purity (some suppliers guarantee more than 99,9%).

CO 2 is liquefied to be stored and transporte d. There are two are systems to store carbon dioxide for industrial use: pr essurized bottles for small consumption requirements and bulk tanks for high consumptions. All mayor suppliers of liquid ga ses provide rental contracts for the mentioned storage solutions.

**•** Pressurised bottles: Bottles of liquid CO 2 are at pressures of 70 to 100 bar at normal ambient temperature. Two types of pressure bottles are used – bottom feed, with an internal bottom-feed pipe for delivering liquid CO 2 or top-feed, for delivering gaseous CO 2 . Avoid any heating of the bottles either by sun ligh t or any heating source. Bottles must be handled with care using gloves and avoiding any hard contact.

**•** Bulk tanks: CO 2 is stored in insulated, pressurised tanks of capacity from 3 up to 50

m 3 , at a pressure of about 16-18 bar and temperature abou t –30 to –24 °C. The tank is normally fitted with a CO 2 level detector and cooling sy stem to control the pressure within the required limits. It is recommended that the tank is protected from adverse weather conditions and to erect around it a guard rail, to restrict access. Any parts of the electric installation should be pl aced under a roof or indoors.

Carbon Dioxide as blowing ag ent for polyurethane foams

In polyurethane foam (flexible slab-stock, fl exible moulded, integral skin, rigid) the carbon dioxide is generated chemically by th e reaction between water and isocyanate.

A1 -15 1.4 Oxygenated Hydrocarbons

Methylal Methyl Formate Di-methyl Ether

Chemical Formula CH 3 OCH 2 OCH 3 CH 3 (HCOO) CH 3 OCH 3 Molecular Weight 76.1 60.0 46.07 Boiling Point ( 0 C ) 42 31.5 -24.8 Gas Conductivity (mW/mK @ 15 0 C) Not available 10.7 (@ 25 0 C) 15.5

Flammable Limits in Air (vol.%) 2.2-19.9 5.0-23.0 3.0-18.6

TLV or OEL (ppm) (USA) 1000 100 1000 GWP (100 yr time horizon) <25 <25* 1

Key Producers Spectrum Chemicals, Alcan International, Kimbester (China) Caldic Lambiotte & Cie BOC Foam Supplies Multiple Chinese producers Air LiquideA1 -16 METHYL FORMATE (ECOMATE®)

Description & Usage

Ecomate ® is a colourless, flammable liquid with an ethereal odour. It is a registered trademark of Foam Supplies, Inc. protected by Patent No. 6753357. It is being promoted as blowing agent for PU rigid foams mainly but also for flexible foams and microcellular elastomers with zero ODP and GWP. Use has b een reported in commercial refrigeration.

Physical and Chemical properties 35

Chemical composition: Met hyl Formate 97.5 %, Methanol 2.5 % Molecular Weight 60 EC Number (EINECS): 203-481-7 CAS Number: 107-31-3 Density (g/cm 3 ) 0.98 (20 °C) Boiling Point (°C) 32.1 Melting Point (°C) -100 Vapour pressure (mm Hg) 476.4 (20 °C) Gas conductivity (mW/m. K) 10.7 (25 °C) Water solubility (%) 33 (20 oC)

HSE Properties 36

Toxicological data: Methyl Formate ACGIH, TWA (ppm) 100 ACGIH, TWA (ppm) 100 TWA, OSHA (ppm) 100 Flammable limits (vol. %) 5.0 - 23.0 Flash point (°C) approx. -28 Autoignition Temperature (°C) approx. 440 oC VOC No GWP (100 years) Negligible ODP 0

Commercial Status

Current Supplier: BOC, Foam Supplies

35 http://www.ecomatesystems.com. Consulted April 2011.

36 MSDS, Foam Supplies, reviewed on 12.03.2010.
A1 -17 1.5 Chlorinated Hydrocarbons

Methylene Chloride Trans-1,2- dichloroethylene 2-chloropropane

Chemical Formula CH 2 Cl 2 ClHC=CHCl CH 3 CHClCH 3 Molecular Weight 84.9 97 78.5 Boiling Point ( 0 C ) 40 48 35.7 Gas Conductivity (mW/mK @ 10 0 C) Not available Not available Not available

Flammable Limits in Air (vol.%) None 6.7-18 2.8-10.7

TLV or OEL (ppm) (USA) 35-100 200 50 GWP (100 yr time horizon) Not available <25 Not available

Key Producers Multiple Sources Arkema Alfa AesarA1 -16 METHYL FORMATE (ECOMATE®)

Description & Usage

Ecomate ® is a colourless, flammable liquid with an ethereal odour. It is a registered trademark of Foam Supplies, Inc. protected by Patent No. 6753357. It is being promoted as blowing agent for PU rigid foams mainly but also for flexible foams and microcellular elastomers with zero ODP and GWP. Use has b een reported in commercial refrigeration.

Physical and Chemical properties 35

Chemical composition: Met hyl Formate 97.5 %, Methanol 2.5 % Molecular Weight 60 EC Number (EINECS): 203-481-7 CAS Number: 107-31-3 Density (g/cm 3 ) 0.98 (20 °C) Boiling Point (°C) 32.1 Melting Point (°C) -100 Vapour pressure (mm Hg) 476.4 (20 °C) Gas conductivity (mW/m. K) 10.7 (25 °C) Water solubility (%) 33 (20 oC)

HSE Properties 36

Toxicological data: Methyl Formate ACGIH, TWA (ppm) 100 ACGIH, TWA (ppm) 100 TWA, OSHA (ppm) 100 Flammable limits (vol. %) 5.0 - 23.0 Flash point (°C) approx. -28 Autoignition Temperature (°C) approx. 440 oC VOC No GWP (100 years) Negligible ODP 0

Commercial Status

Current Supplier: BOC, Foam Supplies

35 http://www.ecomatesystems.com. Consulted April 2011.

36 MSDS, Foam Supplies, reviewed on 12.03.2010.
A1 -17 1.5 Chlorinated Hydrocarbons

Methylene Chloride Trans-1,2- dichloroethylene 2-chloropropane

Chemical Formula CH 2 Cl 2 ClHC=CHCl CH 3 CHClCH 3 Molecular Weight 84.9 97 78.5 Boiling Point ( 0 C ) 40 48 35.7 Gas Conductivity (mW/mK @ 10 0 C) Not available Not available Not available

Flammable Limits in Air (vol.%) None 6.7-18 2.8-10.7

TLV or OEL (ppm) (USA) 35-100 200 50 GWP (100 yr time horizon) Not available <25 Not available

Key Producers Multiple Sources Arkema Alfa AesarA1 -18 METHYLENE CLORIDE

Description & Usage

Methylene chloride, or dichlorometh ane, is a clear, colourless liquid w ith a penetrating ether-like odour. Pure, dry methylene chloride is very stable and will not produce corrosion in mild or galvanized steel, copper, nickel, lead or tin. In the presence of water, however, it may undergo very slow hydrolysis to produce small quantities of hydrogen chlo ride, which can lead to corrosion. This process is accelerated by elevated temperatures and the presen ce of alkaline or metals. Commerci ally available methylene chloride is normally inhibited with small quantities of stabilizer s to avoid this process. Typical stabilizers are propylene oxide and cyclohexane. The low photochemical ozone creation potential (PCOP) and lack of ozone depletion potential (ODP) made it a significant CFC-replacement in the manuf acture of polyurethane flexible foam.

Physical and Chemical properties 37

Chemical name: Dichloromethane Formula: CH 2 Cl 2 Molecular Weight: 84.93 EC Number (EINECS): 200-838-9 CAS Number: 75-09-2 Density (g/cm 3 ) 1.322 (20 °C) Boiling Point (°C) 39.8 Melting Point (°C) -95 Viscosity (cp) 0.41 (25 °C) Refractive index 1.4244 (20 °C) Vapour pressure (mmHg) 349 (20 °C) Vapour density (air=1) 2.9 Water Solubility 10-50 mg/ml

HSE properties

Toxicological data: TLV (ppm) 50 OSHA PEL (ppm) 25 Flash point -4 oC Autoignition temperature 605 oC LFL (%) 13 UFL (%) 223
GWP 38 (100-yr Time Horizon) 8.7

The potential carcinogenicity of MC is a controversial issue. There is one study, performed for the National Toxicology Program (NTP) that suggests carc inogenic effects of high lifetime doses in mice. Other bioassays with different animals (rat, hamster) and at lower concentrations did not confirm these findings, indicating that the association between MC exposure and carcinogenicity may be unique to mice

37 http://ull.chemistry.uakron.edu/erd/Chem icals/8000/6380.html. C onsulted April 2011.
38 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -19 and even then concentration related. This was supported by subsequent research, concluding that important species differences exist in metabo lism between the mouse on one side, and rats, hamsters, or humans on the other side. Evidence was provided that the GST pathway of metabolism is linked to the carcinogenic response observed in mice. Since humans show a very limited ability to metabolize MC via the GST pathway, the mouse is a poor surr ogate for assessing human hazard. The above mentioned research efforts led to the development of a physiologically based pharmacokinetic (PB-PK) model to evaluate the carcinogenic risk to man from exposure to MC. Application of this model on experimental animal data concludes to no significant risk for man under current hygiene standards.

The U.S. EPA has accepted the PB-PK model, and used in its draft Update to the Health Assessment Document (HAD) for methylene chloride. Also EP A's Science Advisory Board indicated approval. OSHA, however, indicated reservations, and has based its proposed revision of the occupational exposure standard for MC on the before mentioned NTP study. The industry has submitted critical comments to this proposal, and achieved reconsideratio n by the agency. The effected date for the new standard delayed accordingly.

Industrial mortality studies have shown no evidence of that methylene chloride, even at relatively high concentrations (100-350 ppm, with peaks of up to 10 ,000 ppm) represents a car cinogenic or cardiovascular ischemic risk to humans.

The US Occupational Safety and Health Administrati on (OSHA) in January 1997 adopted a comprehensive standard for workplace exposure to methylene chloride. The standard establishes permissible exposure limits (PELs) of 25 ppm as an 8-hour time-weighted average (TWA) and 125 ppm as a short-term exposure limit (STEL). The compliance dates vary by industry sector and size of business; all companies must be in compliance by April 2000 at the latest. The standard also requires medical surveillance and contains a number of other ancillary provisions. The ACGIH threshold limit value (TLV) is 50 ppm for an 8-hour TWA exposure. In 1987, the US Consumer Product Safety Commission (CPSC) published a Statement of Interpretation and Enforcement Policy for household products containing methylene chloride. This policy statement establishes labeling guidan ce for these products under the Fede ral Hazardous Substances Act. In addition, the use of methylene chloride in cosmetic and food products is restricted by the Food and Drug Administration (FDA).

The EU classification was established as Carc. Cat. 3 /Xn;R40 in the 23 rd ATP in 1997. This classification was implemented by member states by December 1998.

Commercial status

Methylene chloride is a generic chemical and available from numerous manufacturing and trading sources. The use of recycled material in PU foam applications is discouraged be cause of a possible catalytic effect of dissolved trace metals. Several manufacturers such as Dow Chemical and Solvay offer product versions that have been specifically stab ilized for the use in PU foam.A1 -18 METHYLENE CLORIDE

Description & Usage

Methylene chloride, or dichlorometh ane, is a clear, colourless liquid w ith a penetrating ether-like odour. Pure, dry methylene chloride is very stable and will not produce corrosion in mild or galvanized steel, copper, nickel, lead or tin. In the presence of water, however, it may undergo very slow hydrolysis to produce small quantities of hydrogen chlo ride, which can lead to corrosion. This process is accelerated by elevated temperatures and the presen ce of alkaline or metals. Commerci ally available methylene chloride is normally inhibited with small quantities of stabilizer s to avoid this process. Typical stabilizers are propylene oxide and cyclohexane. The low photochemical ozone creation potential (PCOP) and lack of ozone depletion potential (ODP) made it a significant CFC-replacement in the manuf acture of polyurethane flexible foam.

Physical and Chemical properties 37

Chemical name: Dichloromethane Formula: CH 2 Cl 2 Molecular Weight: 84.93 EC Number (EINECS): 200-838-9 CAS Number: 75-09-2 Density (g/cm 3 ) 1.322 (20 °C) Boiling Point (°C) 39.8 Melting Point (°C) -95 Viscosity (cp) 0.41 (25 °C) Refractive index 1.4244 (20 °C) Vapour pressure (mmHg) 349 (20 °C) Vapour density (air=1) 2.9 Water Solubility 10-50 mg/ml

HSE properties

Toxicological data: TLV (ppm) 50 OSHA PEL (ppm) 25 Flash point -4 oC Autoignition temperature 605 oC LFL (%) 13 UFL (%) 223
GWP 38 (100-yr Time Horizon) 8.7

The potential carcinogenicity of MC is a controversial issue. There is one study, performed for the National Toxicology Program (NTP) that suggests carc inogenic effects of high lifetime doses in mice. Other bioassays with different animals (rat, hamster) and at lower concentrations did not confirm these findings, indicating that the association between MC exposure and carcinogenicity may be unique to mice

37 http://ull.chemistry.uakron.edu/erd/Chem icals/8000/6380.html. C onsulted April 2011.
38 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -19 and even then concentration related. This was supported by subsequent research, concluding that important species differences exist in metabo lism between the mouse on one side, and rats, hamsters, or humans on the other side. Evidence was provided that the GST pathway of metabolism is linked to the carcinogenic response observed in mice. Since humans show a very limited ability to metabolize MC via the GST pathway, the mouse is a poor surr ogate for assessing human hazard. The above mentioned research efforts led to the development of a physiologically based pharmacokinetic (PB-PK) model to evaluate the carcinogenic risk to man from exposure to MC. Application of this model on experimental animal data concludes to no significant risk for man under current hygiene standards.

The U.S. EPA has accepted the PB-PK model, and used in its draft Update to the Health Assessment Document (HAD) for methylene chloride. Also EP A's Science Advisory Board indicated approval. OSHA, however, indicated reservations, and has based its proposed revision of the occupational exposure standard for MC on the before mentioned NTP study. The industry has submitted critical comments to this proposal, and achieved reconsideratio n by the agency. The effected date for the new standard delayed accordingly.

Industrial mortality studies have shown no evidence of that methylene chloride, even at relatively high concentrations (100-350 ppm, with peaks of up to 10 ,000 ppm) represents a car cinogenic or cardiovascular ischemic risk to humans.

The US Occupational Safety and Health Administrati on (OSHA) in January 1997 adopted a comprehensive standard for workplace exposure to methylene chloride. The standard establishes permissible exposure limits (PELs) of 25 ppm as an 8-hour time-weighted average (TWA) and 125 ppm as a short-term exposure limit (STEL). The compliance dates vary by industry sector and size of business; all companies must be in compliance by April 2000 at the latest. The standard also requires medical surveillance and contains a number of other ancillary provisions. The ACGIH threshold limit value (TLV) is 50 ppm for an 8-hour TWA exposure. In 1987, the US Consumer Product Safety Commission (CPSC) published a Statement of Interpretation and Enforcement Policy for household products containing methylene chloride. This policy statement establishes labeling guidan ce for these products under the Fede ral Hazardous Substances Act. In addition, the use of methylene chloride in cosmetic and food products is restricted by the Food and Drug Administration (FDA).

The EU classification was established as Carc. Cat. 3 /Xn;R40 in the 23 rd ATP in 1997. This classification was implemented by member states by December 1998.

Commercial status

Methylene chloride is a generic chemical and available from numerous manufacturing and trading sources. The use of recycled material in PU foam applications is discouraged be cause of a possible catalytic effect of dissolved trace metals. Several manufacturers such as Dow Chemical and Solvay offer product versions that have been specifically stab ilized for the use in PU foam.A1 -20 TRANS-1,2-DICHLOROETHYLENE

Description & Usage

Trans-1,2-dichloroethylene is a liquid at room temperature and is recommended for use in a variety of polyurethane foam blowing applications primarily in combination with HFC-134a and HFC-245fa. Studies have shown that trans-1,2-dichloroethylene moderates the frothing effect particularly with HFC-134a and significantly improves its blowing efficiency.

Physical and Chemical Properties 39

Chemical name: trans-1,2-dichloroethylene Formula: C 2 H 2 Cl 2 Molecular weight: 96.94 EC Number (EINECS): 205-860-2 CAS Number: 156-60-5 Specific gravity: 1.26 Boiling point (°C) 48 Vapor pressure @ 25°C (mm Hg) 333 Heat of vaporization (kJ/mol) 30.3 Vapor density (air = 1) @ 20°C 1.8 Solubility @ 25°C (g trans / 100 g water) 0.63

HSE properties 40

Toxicological data: TLV 200 ppm (ACGIH TLV ® 8-hr TWA) Flammable limits in air (volume %) 6.7 - 18 Flash point (°C) -12 Minimum ignition energy @ 25°C (mJ) 40.5 Autoignition temperature (°C) 460°C Volatile Organic Compound Yes GWP (100-yr Time Horizon) Negligible ODP 0

Commercial Status

Current Producers: Arkema

39 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/108.html. C onsulted April 2011. MSDS, Arkema, Revised 03.04.2006.
40 MSDS, Arkema, Revised 03.04.2006.
A1 -21 1.6 Saturated HFCs

HFC-134a HFC-152a HFC-245fa HFC-365mfc HFC-227ea

Chemical Formula CH 2 FCF 3 CHF 2 CH 3 CF 3 CH 2 CHF 2 CF 3 CH 2 CF 2 CH 3 CF 3 CHF CF 3
Molecular Weight 102 66 134 148 170
Boiling Point ( 0 C ) -26.2 -25 15.3 40.2 -16.5
Gas Conductivity (mW/mK @ 10 0 C) 12.4 14.3* 12.5* 10.6* 11.6
Flammable Limits in Air (vol.%) N one 3.9-16.9 None 3.8-13.3 None
TLV or OEL (ppm) (USA) 1000 1000 N/A N/A 1000
GWP (100 yr time horizon)^ 1430 124 1030 794 3220

Key Producers Arkema, Daikin, DuPont, Honeywell, Kangtai Fluorine Chemical, Produven, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Guomao, Zhejiang Lantian, Zhejiang Sammei, Zhejiang Quhua Changshu 3f, Daikin, DuPont, Hangzhou Fist, Solvay, Shandong Dongyue, Zhejiang Lantian, Zhejiang Sammei. Honeywell, Central Glass, Zhejiang Lantian Solvay Solvay

* Measured at 24-25 0 CA1 -20 TRANS-1,2-DICHLOROETHYLENE

Description & Usage

Trans-1,2-dichloroethylene is a liquid at room temperature and is recommended for use in a variety of polyurethane foam blowing applications primarily in combination with HFC-134a and HFC-245fa. Studies have shown that trans-1,2-dichloroethylene moderates the frothing effect particularly with HFC-134a and significantly improves its blowing efficiency.

Physical and Chemical Properties 39

Chemical name: trans-1,2-dichloroethylene Formula: C 2 H 2 Cl 2 Molecular weight: 96.94 EC Number (EINECS): 205-860-2 CAS Number: 156-60-5 Specific gravity: 1.26 Boiling point (°C) 48 Vapor pressure @ 25°C (mm Hg) 333 Heat of vaporization (kJ/mol) 30.3 Vapor density (air = 1) @ 20°C 1.8 Solubility @ 25°C (g trans / 100 g water) 0.63

HSE properties 40

Toxicological data: TLV 200 ppm (ACGIH TLV ® 8-hr TWA) Flammable limits in air (volume %) 6.7 - 18 Flash point (°C) -12 Minimum ignition energy @ 25°C (mJ) 40.5 Autoignition temperature (°C) 460°C Volatile Organic Compound Yes GWP (100-yr Time Horizon) Negligible ODP 0

Commercial Status

Current Producers: Arkema

39 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/108.html. C onsulted April 2011. MSDS, Arkema, Revised 03.04.2006.
40 MSDS, Arkema, Revised 03.04.2006.
A1 -21 1.6 Saturated HFCs

HFC-134a HFC-152a HFC-245fa HFC-365mfc HFC-227ea

Chemical Formula CH 2 FCF 3 CHF 2 CH 3 CF 3 CH 2 CHF 2 CF 3 CH 2 CF 2 CH 3 CF 3 CHF CF 3
Molecular Weight 102 66 134 148 170
Boiling Point ( 0 C ) -26.2 -25 15.3 40.2 -16.5
Gas Conductivity (mW/mK @ 10 0 C) 12.4 14.3* 12.5* 10.6* 11.6
Flammable Limits in Air (vol.%) N one 3.9-16.9 None 3.8-13.3 None
TLV or OEL (ppm) (USA) 1000 1000 N/A N/A 1000
GWP (100 yr time horizon)^ 1430 124 1030 794 3220

Key Producers Arkema, Daikin, DuPont, Honeywell, Kangtai Fluorine Chemical, Produven, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Guomao, Zhejiang Lantian, Zhejiang Sammei, Zhejiang Quhua Changshu 3f, Daikin, DuPont, Hangzhou Fist, Solvay, Shandong Dongyue, Zhejiang Lantian, Zhejiang Sammei. Honeywell, Central Glass, Zhejiang Lantian Solvay Solvay

* Measured at 24-25 0 CA1 -22 HFC-134a
Description & Usage HFC-134a is a non-flammable gas at room temper ature. It is the most widely used zero ODP fluorochemical and is an established re frigerant. HFC-134a has been used as a blowing agent in almost all foam sectors, partic ularly rigid and integral skin foam. It is also being used for extruded polystyrene foam in Europe and North America.
Physical and Chemical properties 41

Chemical name: 1,1,1,2-Tetrafluoroethane Formula: CF 3 CH 2 F Molecular Weight: 102.03 EC Number (EINECS): 212-377-0 CAS Number: 811-97-2 Density (g/cm 3 ) 1.2076 (25 °C) Boiling Point (°C) - 26.2 Vapour pressure (mm Hg ) 4730 Gas conductivity (mW/m. K) 12.4 (10 °C), 13.7 (25 °C) Vapour density (air=1) 3.18 Solubility in water 1.5 g/L
HSE properties Toxicological data 42 : TLV or OEL (USA) (ppm) 1000 WEEL, 8 hr. TWA, ppm 1000 Flash Point -79 oC Flammable limits in air (vol. %) None VOC No GWP 43 (100-yr Time Horizon) 1430 ODP 0

Commercial status
Producers: Arkema, Daikin, DuPont, Honeywell, Kangtai Fluorine Chemical, Produven, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Guomao, Zhejiang Lantian, Zhejiang Sammei, Zhejiang Quhua.

41 http://ull.chemistry.uakron.edu/erd/Chem icals/6000/5730.html. C onsulted April 2011.

42 MSDS, DuPont, Revised 18.04.2007.

43 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -23 HFC-152a
Description & Usage
HFC-152a is a flammable gas at room temper ature. It has limited use in polyurethane foam because it is flammable, and it diffuses out of the foam quickly, preventing it from offering additional long term thermal insulation value. Yet, HFC-152a is widely used as a blowing agent for one component PU foam syst em where the foam is mostly used to fill a cavity and thermal insulation value is not the most critical parameter.

HFC-152a is used with HFC-134a in XPS boa rdstock. Although it does not offer long term thermal insulation value for the product, it is mainly used to reduce the foam density of HFC-134a foam, and improve processing cond itions. It is also used as blowing agent for extruded polystyrene sheets, mostly used in food packaging applications. It is the only HFC that is approved by US food and drug ad ministration (FDA) for this application.

Physical and Chemical properties 44

Chemical name: 1,1-Difluoroethane Formula: CH 3 CHF 2 Molecular Weight: 66.05 EC Number (EINECS): 200-866-1 CAS Number: 75-37-6 Density (g/cm 3 ) 0.886 (30 °C) Boiling Point (°C) - 25 Vapour pressure (mmHg) 4100 (25 °C) Gas conductivity (mW/m. K) 14.3 (25 °C)

HSE properties

Toxicological data: AIHA recommended TWA (ppm) 1000 Flammable limits in air (vol. %) 3.7 - 10 Flash Point -81 oC VOC No GWP 45 (100-yr Time Horizon) 124 ODP 0

Commercial status

Current Producers: Changshu 3f , Daikin, DuPont, Hangzhou Fist, Solvay, Shandong Dongyue, Zhejiang Lantian, Zhejiang Sammei.

44 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/32.html. C onsulted April 2011.
45 IPCC Fourth Assessment Report: Climate Change 2007.A1 -22 HFC-134a
Description & Usage HFC-134a is a non-flammable gas at room temper ature. It is the most widely used zero ODP fluorochemical and is an established re frigerant. HFC-134a has been used as a blowing agent in almost all foam sectors, partic ularly rigid and integral skin foam. It is also being used for extruded polystyrene foam in Europe and North America.
Physical and Chemical properties 41

Chemical name: 1,1,1,2-Tetrafluoroethane Formula: CF 3 CH 2 F Molecular Weight: 102.03 EC Number (EINECS): 212-377-0 CAS Number: 811-97-2 Density (g/cm 3 ) 1.2076 (25 °C) Boiling Point (°C) - 26.2 Vapour pressure (mm Hg ) 4730 Gas conductivity (mW/m. K) 12.4 (10 °C), 13.7 (25 °C) Vapour density (air=1) 3.18 Solubility in water 1.5 g/L
HSE properties Toxicological data 42 : TLV or OEL (USA) (ppm) 1000 WEEL, 8 hr. TWA, ppm 1000 Flash Point -79 oC Flammable limits in air (vol. %) None VOC No GWP 43 (100-yr Time Horizon) 1430 ODP 0

Commercial status
Producers: Arkema, Daikin, DuPont, Honeywell, Kangtai Fluorine Chemical, Produven, Quzhou Rongqiang, Shandong Dongyue, Solvay, Zhejiang Guomao, Zhejiang Lantian, Zhejiang Sammei, Zhejiang Quhua.

41 http://ull.chemistry.uakron.edu/erd/Chem icals/6000/5730.html. C onsulted April 2011.

42 MSDS, DuPont, Revised 18.04.2007.

43 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -23 HFC-152a
Description & Usage
HFC-152a is a flammable gas at room temper ature. It has limited use in polyurethane foam because it is flammable, and it diffuses out of the foam quickly, preventing it from offering additional long term thermal insulation value. Yet, HFC-152a is widely used as a blowing agent for one component PU foam syst em where the foam is mostly used to fill a cavity and thermal insulation value is not the most critical parameter.

HFC-152a is used with HFC-134a in XPS boa rdstock. Although it does not offer long term thermal insulation value for the product, it is mainly used to reduce the foam density of HFC-134a foam, and improve processing cond itions. It is also used as blowing agent for extruded polystyrene sheets, mostly used in food packaging applications. It is the only HFC that is approved by US food and drug ad ministration (FDA) for this application.

Physical and Chemical properties 44

Chemical name: 1,1-Difluoroethane Formula: CH 3 CHF 2 Molecular Weight: 66.05 EC Number (EINECS): 200-866-1 CAS Number: 75-37-6 Density (g/cm 3 ) 0.886 (30 °C) Boiling Point (°C) - 25 Vapour pressure (mmHg) 4100 (25 °C) Gas conductivity (mW/m. K) 14.3 (25 °C)

HSE properties

Toxicological data: AIHA recommended TWA (ppm) 1000 Flammable limits in air (vol. %) 3.7 - 10 Flash Point -81 oC VOC No GWP 45 (100-yr Time Horizon) 124 ODP 0

Commercial status

Current Producers: Changshu 3f , Daikin, DuPont, Hangzhou Fist, Solvay, Shandong Dongyue, Zhejiang Lantian, Zhejiang Sammei.

44 http://ull.chemistry.uakron.edu/erd/Chem icals/2000/32.html. C onsulted April 2011.
45 IPCC Fourth Assessment Report: Climate Change 2007.A1 -24 HFC-245fa

Description & Usage

HFC-245fa is a non-flammable liquid having a boiling point slightly below room temperature. It is used for a wide va riety of foam blowi ng applications.

Physical and Chemical properties 46

Chemical name: 1,1,1,3,3-Pentafluoropropane Formula: CF 3 CH 2 CHF 2 Molecular Weight: 134.05 EC Number (EINECS): 610-280-1 CAS Number: 460-73-1 Density (g/cm 3 ) 1.106 (97 °C) Boiling Point 47 (°C) 15.3 Freezing Point (°C) -103 Vapour Pressure (KPa) 123 (20 °C) Gas Conductivity (mW/m. K) 12.05 (20 °C) Water Solubility 0.13 g/L

HSE properties

Toxicological data: WEEL, 8 hr. TWA (ppm) 300 Flammable limits in air 48 (vol. %) None Flash Point 49 (°C) None VOC No GWP 50 (100-yr Time Horizon) 1030 ODP 0

Commercial status

Current Producers: Honeywell, Central Glass, Zhejiang Lantian.

46 http://ull.chemistry.uakron.edu/erd/Chemi cals/24000/22949.html. C onsulted April 2011.

47 MSDS, Honeywell, Revised 28.08.2007.

48 Measured at ambient temperature and pressu re using ASTM E681-85 with electrically heated match ignition, spark ignition and fused wire ignition; ambient air.

49 ASTM D 3828-87; ASTM D1310-86.
50 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -25 HFC - 365mfc
Description & Usage HFC - 365mfc is a liquid at room temperatur e with low gas phase thermal conductivity. It is being used for a wide variety of foam blowing applications.
Physical and Chemical properties 51

Chemical name: 1,1,1,3,3-Pentafluorobutane Formula: CF 3 CH 2 CF 2 CH 3 Molecular Weight: 148.09 EC Number (EINECS): 430-250-1 CAS Number: 406-58-6 Density/Specific gravity 1.26 (25 oC) Boiling Point (°C) 40.2 Vapour pressure (kPa) 53 (25 °C) Heat of vaporization (kJ/kg.K) 177 Gas conductivity (mW/m. K) 10.6 (25 °C) Vapour density (air = 1) 5.11 Solubility in Water 52 (mg/L) 26.1 (25 °C)

HSE Properties Toxicological data: SAEL (Solvay Acceptable Exposure Limit) 2007 53 (ppm) 1000 Flammable limits in air (vol. %) 3.6-13.3 Minimum Ignition Energy (mJ) 10.8 (25 °C) Flash point (°C) < –27 Autoignition Temperature (°C) 594 GWP 54 (100-yr Time Horizon) 794 ODP 0

Commercial Status
Current Producers: Solvay

Geographic Constraints The use of HFC-365mfc might fall within th e scope of European Patent 381 986 and its counterparts, all held by Bayer. Solvay has acquired from Baye r the right to sublicense its customers under these patents in all count ries except in the USA and in Canada.

51 http://www.solvaychemicals.co.uk/product/datasheet/0,0,-_EN-1000798,00.html. Consulted April 2011.

52 http://esc.syrres.com/interkow/webprop.exe?CAS=406-58-6. Consulted April 2011.
53 MSDS, Solvay, Issued 16.09.2008.

54 IPCC Fourth Assessment Report: Climate Change 2007.A1 -24 HFC-245fa

Description & Usage

HFC-245fa is a non-flammable liquid having a boiling point slightly below room temperature. It is used for a wide va riety of foam blowi ng applications.

Physical and Chemical properties 46

Chemical name: 1,1,1,3,3-Pentafluoropropane Formula: CF 3 CH 2 CHF 2 Molecular Weight: 134.05 EC Number (EINECS): 610-280-1 CAS Number: 460-73-1 Density (g/cm 3 ) 1.106 (97 °C) Boiling Point 47 (°C) 15.3 Freezing Point (°C) -103 Vapour Pressure (KPa) 123 (20 °C) Gas Conductivity (mW/m. K) 12.05 (20 °C) Water Solubility 0.13 g/L

HSE properties

Toxicological data: WEEL, 8 hr. TWA (ppm) 300 Flammable limits in air 48 (vol. %) None Flash Point 49 (°C) None VOC No GWP 50 (100-yr Time Horizon) 1030 ODP 0

Commercial status

Current Producers: Honeywell, Central Glass, Zhejiang Lantian.

46 http://ull.chemistry.uakron.edu/erd/Chemi cals/24000/22949.html. C onsulted April 2011.

47 MSDS, Honeywell, Revised 28.08.2007.

48 Measured at ambient temperature and pressu re using ASTM E681-85 with electrically heated match ignition, spark ignition and fused wire ignition; ambient air.

49 ASTM D 3828-87; ASTM D1310-86.
50 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -25 HFC - 365mfc
Description & Usage HFC - 365mfc is a liquid at room temperatur e with low gas phase thermal conductivity. It is being used for a wide variety of foam blowing applications.
Physical and Chemical properties 51

Chemical name: 1,1,1,3,3-Pentafluorobutane Formula: CF 3 CH 2 CF 2 CH 3 Molecular Weight: 148.09 EC Number (EINECS): 430-250-1 CAS Number: 406-58-6 Density/Specific gravity 1.26 (25 oC) Boiling Point (°C) 40.2 Vapour pressure (kPa) 53 (25 °C) Heat of vaporization (kJ/kg.K) 177 Gas conductivity (mW/m. K) 10.6 (25 °C) Vapour density (air = 1) 5.11 Solubility in Water 52 (mg/L) 26.1 (25 °C)

HSE Properties Toxicological data: SAEL (Solvay Acceptable Exposure Limit) 2007 53 (ppm) 1000 Flammable limits in air (vol. %) 3.6-13.3 Minimum Ignition Energy (mJ) 10.8 (25 °C) Flash point (°C) < –27 Autoignition Temperature (°C) 594 GWP 54 (100-yr Time Horizon) 794 ODP 0

Commercial Status
Current Producers: Solvay

Geographic Constraints The use of HFC-365mfc might fall within th e scope of European Patent 381 986 and its counterparts, all held by Bayer. Solvay has acquired from Baye r the right to sublicense its customers under these patents in all count ries except in the USA and in Canada.

51 http://www.solvaychemicals.co.uk/product/datasheet/0,0,-_EN-1000798,00.html. Consulted April 2011.

52 http://esc.syrres.com/interkow/webprop.exe?CAS=406-58-6. Consulted April 2011.
53 MSDS, Solvay, Issued 16.09.2008.

54 IPCC Fourth Assessment Report: Climate Change 2007.A1 -26 HFC 227ea

Description & Usage
HFC-227ea is used as a component in non-flammable HFC-365 mfc blowing agent blends. Its prime purpose is to suppress flamma bility (flash-point) of the blowing agent and/or of the polyol system. Commercially av ailable are blends with HFC-227ea ratios of 7% and 13% by wt.

Physical and Chemical properties 55

Chemical name: 1,1,1,2,3,3,3 Heptafluoropropane Formula: CF 3 CHFCF 3 Molecular Weight: 170 EC Number (EINECS): 207-079-2 CAS Number: 431-89-0 Density/Specific gravity 1.54 Boiling Point (°C) -16.5 Vapour pressure @ 25 °C (bar) 4.6 Gas Conductivity (mW/m.K at 10 °C) 11.6 Gas Conductivity (mW/m.K at 25 °C) 12.7 Vapour density (air=1) 30.2 (25°C) Solubility in Water ≈ 0.4 g/l (20°C) Decomposition temperature 425 °C Flammable limits in air (vol. %) none

HSE properties

Toxicological data: AEL TWA 1000 ppm 56
VOC No GWP 57 (100-yr Time Horizon) 3220 ODP 0

Commercial Status

Current Producers: Solvay

55 Manufacturer ́s information, Solvay Fluor GmbH, Germany. http://www.solvaychemicals.com/EN/products/Fluor/Hydrofluorocarbons_HFC/Solk ane227technicalgrade.aspx. Consulted April 2011.

56 Manufacturer ́s Information, Solvay Fluor GmbH, Germany. MSDS, Rem Tec International, Revised 30.11.2009.
57 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -27 1.7 Unsaturated HFCs (HFOs)

HFO-1234ze FEA-1100 HBA-2 AFA-L1

Chemical Formula Trans- CF 3 CH=CHF Cis- CF 3 -CH=CH-CF 3 Undisclosed Undisclosed Molecular Weight 114 164 Undisclosed Undisclosed Boiling Point ( 0 C ) -19 32 15.3<T<32.1 10.0<T<30.0 Gas Conductivity (mW/mK @ 10 0 C) 13.0 10.7 Not Reported 15.9

Flammable Limits in Air (vol.%) None to 28 o C^ None None None TLV or OEL (ppm) (USA) Unpublished 9.7 Undisc losed Undisclosed GWP (100 yr time horizon) 6 5 <15 <15

Key Producers Honeywell DuPont Honeywell Arkema

^ Flame limits of 7.0-9.5 at 30 o C are quotedA1 -26 HFC 227ea

Description & Usage
HFC-227ea is used as a component in non-flammable HFC-365 mfc blowing agent blends. Its prime purpose is to suppress flamma bility (flash-point) of the blowing agent and/or of the polyol system. Commercially av ailable are blends with HFC-227ea ratios of 7% and 13% by wt.

Physical and Chemical properties 55

Chemical name: 1,1,1,2,3,3,3 Heptafluoropropane Formula: CF 3 CHFCF 3 Molecular Weight: 170 EC Number (EINECS): 207-079-2 CAS Number: 431-89-0 Density/Specific gravity 1.54 Boiling Point (°C) -16.5 Vapour pressure @ 25 °C (bar) 4.6 Gas Conductivity (mW/m.K at 10 °C) 11.6 Gas Conductivity (mW/m.K at 25 °C) 12.7 Vapour density (air=1) 30.2 (25°C) Solubility in Water ≈ 0.4 g/l (20°C) Decomposition temperature 425 °C Flammable limits in air (vol. %) none

HSE properties

Toxicological data: AEL TWA 1000 ppm 56
VOC No GWP 57 (100-yr Time Horizon) 3220 ODP 0

Commercial Status

Current Producers: Solvay

55 Manufacturer ́s information, Solvay Fluor GmbH, Germany. http://www.solvaychemicals.com/EN/products/Fluor/Hydrofluorocarbons_HFC/Solk ane227technicalgrade.aspx. Consulted April 2011.

56 Manufacturer ́s Information, Solvay Fluor GmbH, Germany. MSDS, Rem Tec International, Revised 30.11.2009.
57 IPCC Fourth Assessment Report: Climate Change 2007.
A1 -27 1.7 Unsaturated HFCs (HFOs)

HFO-1234ze FEA-1100 HBA-2 AFA-L1

Chemical Formula Trans- CF 3 CH=CHF Cis- CF 3 -CH=CH-CF 3 Undisclosed Undisclosed Molecular Weight 114 164 Undisclosed Undisclosed Boiling Point ( 0 C ) -19 32 15.3<T<32.1 10.0<T<30.0 Gas Conductivity (mW/mK @ 10 0 C) 13.0 10.7 Not Reported 15.9

Flammable Limits in Air (vol.%) None to 28 o C^ None None None TLV or OEL (ppm) (USA) Unpublished 9.7 Undisc losed Undisclosed GWP (100 yr time horizon) 6 5 <15 <15

Key Producers Honeywell DuPont Honeywell Arkema

^ Flame limits of 7.0-9.5 at 30 o C are quotedA2 - 1 

### APPENDIX 2: ALLOCATION OF COUNTRIES TO REGIONS

Latin America and the Caribbean (LAC) Antigua and Barbuda Argentina
Bahamas
Barbados
Belize
Bolivia
Brazil
Chile
Colombia
Costa Rica
Cuba
Dominica Dominican Republic
Ecuador
El Salvador
Grenada
Guatemala Guyana
Haiti
Honduras
Jamaica
Mexico Nicaragua
Panama Paraguay
Peru
Saint Kitts and Nevis
Saint Lucia
Saint Vincent and The Grenadines
Suriname Trinidad and Tobago Uruguay
Venezuela Middle East/North Africa (MENA) Algeria
Bahrain Egypt Iran, Islamic Republic of Iraq

A2 - 2 Israel
Jordan
Kuwait
Lebanon Libyan Arab Jamahiriya
Mauritania
Morocco
Oman
Palestine Qatar
Saudi Arabia Syrian Arab Republic
Tunisia Turkey
United Arab Emirates
Yemen Sub-Saharan Africa (SSA) Angola
Benin
Botswana
Burkina Faso
Burundi
Cameroon Cape Verde Central African Republic
Chad
Comoros Congo Congo, Democratic Republic of
Cote d'Ivoire Djibouti Equatorial Guinea
Eritrea Ethiopia
Gabon
Gambia
Ghana
Guinea
Guinea-Bissau Kenya
Lesotho
LiberiaA2 - 1 

### APPENDIX 2: ALLOCATION OF COUNTRIES TO REGIONS

Latin America and the Caribbean (LAC) Antigua and Barbuda Argentina
Bahamas
Barbados
Belize
Bolivia
Brazil
Chile
Colombia
Costa Rica
Cuba
Dominica Dominican Republic
Ecuador
El Salvador
Grenada
Guatemala Guyana
Haiti
Honduras
Jamaica
Mexico Nicaragua
Panama Paraguay
Peru
Saint Kitts and Nevis
Saint Lucia
Saint Vincent and The Grenadines
Suriname Trinidad and Tobago Uruguay
Venezuela Middle East/North Africa (MENA) Algeria
Bahrain Egypt Iran, Islamic Republic of Iraq

A2 - 2 Israel
Jordan
Kuwait
Lebanon Libyan Arab Jamahiriya
Mauritania
Morocco
Oman
Palestine Qatar
Saudi Arabia Syrian Arab Republic
Tunisia Turkey
United Arab Emirates
Yemen Sub-Saharan Africa (SSA) Angola
Benin
Botswana
Burkina Faso
Burundi
Cameroon Cape Verde Central African Republic
Chad
Comoros Congo Congo, Democratic Republic of
Cote d'Ivoire Djibouti Equatorial Guinea
Eritrea Ethiopia
Gabon
Gambia
Ghana
Guinea
Guinea-Bissau Kenya
Lesotho
LiberiaA2 - 3 Madagascar
Malawi
Mali
Mauritius Mozambique
Namibia Niger Nigeria
Rwanda Sao Tome and Principe Senegal Seychelles
Sierra Leone
Somalia
South Africa
Sudan
Swaziland Tanzania, United Republic of Togo Uganda
Zambia
Zimbabwe South/Central Asia (SCA) Afghanistan Bangladesh
Bhutan
India
Maldives Nepal
Pakistan
Sri Lanka South-East Asia (SEA) Brunei Darussalam
Cambodia
Indonesia Lao People's Democratic Republic Malaysia Myanmar Philippines Singapore
Thailand
Viet Nam

A2 - 4 North-East Asia (NEA) China (incl. Taiwan) Mongolia
North Korea
South Korea

Japan Japan

Europe Albania
Andorra
Austria Bosnia and Herzegovina Belgium Bulgaria
Croatia Cyprus Czech Republic
Denmark
Estonia
Finland
France Germany
Greece Holy See Hungary
Latvia
Iceland
Ireland Italy
Liechtenstein
Lithuania Luxembourg
Macedonia
Malta
Moldova
Monaco
Netherlands Norway
Poland Portugal
RomaniaA2 - 3 Madagascar
Malawi
Mali
Mauritius Mozambique
Namibia Niger Nigeria
Rwanda Sao Tome and Principe Senegal Seychelles
Sierra Leone
Somalia
South Africa
Sudan
Swaziland Tanzania, United Republic of Togo Uganda
Zambia
Zimbabwe South/Central Asia (SCA) Afghanistan Bangladesh
Bhutan
India
Maldives Nepal
Pakistan
Sri Lanka South-East Asia (SEA) Brunei Darussalam
Cambodia
Indonesia Lao People's Democratic Republic Malaysia Myanmar Philippines Singapore
Thailand
Viet Nam

A2 - 4 North-East Asia (NEA) China (incl. Taiwan) Mongolia
North Korea
South Korea

Japan Japan

Europe Albania
Andorra
Austria Bosnia and Herzegovina Belgium Bulgaria
Croatia Cyprus Czech Republic
Denmark
Estonia
Finland
France Germany
Greece Holy See Hungary
Latvia
Iceland
Ireland Italy
Liechtenstein
Lithuania Luxembourg
Macedonia
Malta
Moldova
Monaco
Netherlands Norway
Poland Portugal
RomaniaA2 - 5 San Marino
Slovakia
Slovenia Spain
Sweden
Switzerland United Kingdom Yugoslavia

North America

Canada
USA Australia, New Zealand & The Pacific (ANZP) Australia
Cook islands Fiji
Kiribati
Marshall Islands
Micronesia
Nauru
New Zealand
Niue
Palau Papua New Guinea
Samoa
Solomon Islands Tonga
Tuvalu
Vanuatu Russia & Former Soviet Countries

Armenia Azerbaijan
Belarus Georgia
Kazakhstan Kyrgyzstan
Russian Federation Tajikistan
Turkmenistan
Ukraine
Uzbekistan

A3 - 1 

### APPENDIX 3: UNEP FOAMS TEC HNICAL OPTIONS COMMITTEE

Committee Member Affiliation Country

Mr. Terry Armitt Hennecke United Kingdom Mr. Paul Ashford, Co-chair Caleb Manage ment Services Limited United Kingdom Mr. Chris Bloom Dow United States Mr. Roy Chowdhury Australian Urethane Systems Australia Mr. Kiyoshi Hara Japanese Uret hane Manufacturers Assoc Japan Mr. Mike Hayslett Maytag/AHAM United States Dr. Mike Jeffs Consultant Belgium Mr. Candido Lomba ABRIPUR Brazil Mr. Yehia Lotfi Technocom Egypt Mr. Christoph Meurer Solvay Germany Ms. Francesca Pignagnoli Dow Italy Mr. Miguel Quintero, Co-chair Consultant Colombia Mr. Ulrich Schmidt Haltermann Products Germany Mr. Enshang Sheng Huntsman Polyurethanes China Ms. Helen Walter-Terrinoni Du Pont United States Mr. Tom Werkema Arkema United States Mr. Dave Williams Honeywell United States Mr. Allen Zhang Owens Corning China

{ PRIVATE }A2 - 5 San Marino
Slovakia
Slovenia Spain
Sweden
Switzerland United Kingdom Yugoslavia

North America

Canada
USA Australia, New Zealand & The Pacific (ANZP) Australia
Cook islands Fiji
Kiribati
Marshall Islands
Micronesia
Nauru
New Zealand
Niue
Palau Papua New Guinea
Samoa
Solomon Islands Tonga
Tuvalu
Vanuatu Russia & Former Soviet Countries

Armenia Azerbaijan
Belarus Georgia
Kazakhstan Kyrgyzstan
Russian Federation Tajikistan
Turkmenistan
Ukraine
Uzbekistan

A3 - 1 

### APPENDIX 3: UNEP FOAMS TEC HNICAL OPTIONS COMMITTEE

Committee Member Affiliation Country

Mr. Terry Armitt Hennecke United Kingdom Mr. Paul Ashford, Co-chair Caleb Manage ment Services Limited United Kingdom Mr. Chris Bloom Dow United States Mr. Roy Chowdhury Australian Urethane Systems Australia Mr. Kiyoshi Hara Japanese Uret hane Manufacturers Assoc Japan Mr. Mike Hayslett Maytag/AHAM United States Dr. Mike Jeffs Consultant Belgium Mr. Candido Lomba ABRIPUR Brazil Mr. Yehia Lotfi Technocom Egypt Mr. Christoph Meurer Solvay Germany Ms. Francesca Pignagnoli Dow Italy Mr. Miguel Quintero, Co-chair Consultant Colombia Mr. Ulrich Schmidt Haltermann Products Germany Mr. Enshang Sheng Huntsman Polyurethanes China Ms. Helen Walter-Terrinoni Du Pont United States Mr. Tom Werkema Arkema United States Mr. Dave Williams Honeywell United States Mr. Allen Zhang Owens Corning China

{ PRIVATE }

## Ozone Secretariat
United Nations Environment Programme (UNEP) P.O. Box 30552-00100, Nairobi, Kenya Tel. No.: +254 (0) 20 762 3611 Website: http://ozone.unep.org http://ozone.unmfs.org E-mail: ozoneinfo@unep.org United Nations Environment Programme P.O. Box 30552, Nairobi 00100, Kenya Tel: +254-(0)20-762 1234 Fax: +254-(0)20-762 3927 Email: uneppub@unep.org

web: www.unep.org 

### www.unep.org