# Clayton Corporation 

# Meeting with EPA Stratospheric Protection Division

December 8, 2015 1

# Introduction Clayton Corporation Personnel

• Barry Baker, President and Chief Executive Officer BS Finance (CPA), MBA
• Larry Timberlake, Director of Research and Development BS Chemistry, PhD Organic Chemistry
• Jay Zhang, Director R&D - Foam, Sealant, & Adhesives BS, MS Chemistry
• Tim Niemeyer, Senior Chemist - Spray Foam Products BS Chemical Engineering 2

# Clayton Corporation Mission Statement

• Clayton Corporation is environmentally conscious and fully supports the EPA in its Clean Air Act initiatives .


### • Clayton Corporation provides high quality products that promote energy conservation and indoor air quality.



### • Clayton Corporation supplies safe products and engineers its formulas and any formula changes to prevent unintended consequences. 3

# Agenda

• Introductions • Clayton Corporation • Low Pressure Spray Foam • New Alternative Propellants • Technical Challenges • Current Work Progress • Timeline for Commercialization • Clayton’s Petition for HFC phase out date • Summary 4

# Clayton Corporation History

• Aerosol Valve Manufacturing 1945 • One Component Low Pressure SPF 1978 • (Convenience Products) • Two Component Low Pressure SPF 1988 • Seal Krete Concrete Coatings 2001 5 Clayton Corporation and its Convenience Products division employ over 250 people in 3 facilities around the U.S., manufacturing aerosol valves, concrete coatings and polyurethane foam.6 

# CONFIDENTIAL BUSINESS 

# INFORMATION

# Clayton Regulatory Participation

• Memberships: • CPI – Center for Polyurethanes Industry • SPFA – Spray Polyurethane Foam Alliance • ASTM – American Society for Testing and Materials • SFC – Spray Foam Coalition • ICC – International Code Council • CAN/ULC – Underwriter’s Laboratory of Canada • CUFCA - Canadian Urethane Foam Contractors Association • WAIB - Western Aerosol Information Bureau • Regulatory Efforts: • EPA SNAP • California DTSC • Environment Canada / Health Canada • California South Coast Air Quality Management District (SCAQMD) 7

# Spray Foam Technologies

8 One - Component Foam Sealant Low - Pressure Two - Component Products: • Insulation • Sealant High - Pressure Two - Component Spray Foam Insulation

• A and B side in separate pressurized cylinders (one - time use kits and refillable) • Low pressure, <250 psi at start then reduce to around 50 psi • No heating of chemicals for spray • Static mixing inside nozzle • Froth - spray, No atomization • Typically applied at 5 - 7 lbs./min. • Chemicals cures in <1 min • A and B side in separate unpressurized drums or totes • Chemicals are preheated (~130F) and pressurized (~1200 psi) using special spray equipment • Impingement mix, Atomized chemicals • Typically applied at 30 lbs./min. • Chemical cure <15 seconds • Professional use only

• A & B side pre - mixed in single container • Pre - polymerized during manufacture • Moisture cure 3 - 20 min • Bead application only 1) Liquid Blowing Agents Only 2) Gas and Liquid Blowing Agents
3) Gas Blowing Agents Only

# Low Pressure Spray Foam

9 

### • LP SPF products are applied at Job Site • 1 -time use kits or refillable containers 

### • Require Gas Blowing Agent (HFC- 134a) • HP foam uses only Liquid Blowing Agent (such as HFC- 245fa) • Some LP kits may use both Gas and Liquid ( 134a and 245fa ) 

### • Cannot use flammable blowing agents • Cannot be modified after these pressurized products are 

### manufactured. (It’s common to add more catalysts to HP SPF systems for correction – by contractors/installers) • Due to distribution channels, LP Foam must be shelf-stable for 

### 12 - 18 months • HP SPF systems typically need 3 months shelf- life

# New Alternative Propellants

• Our HFO evaluation work started in 2011 • HFO- 1233zd, - 1234ze, and - 1336mzz were introduced as next generation blowing agents • Clayton set HFO -foam R&D project for the top priority in response to proposed SNAP Rule 20 

### • Lab Results: All two-component products we produce were adversely affected. 

### • When blowing agents are replaced by HFOs: • Shelf- life dropped from 15- 18 months to about 10 days • Foam density doubled or more (loss in yield and properties) • Foam cell structure collapsed, became large bubbles • Foam did not cure in time or not cured at all • Solubility was negatively impacted 10

# Challenges- Chemical Stability

• Liquid Blowing Agent: >30 patent applications related to HFO blowing agents are published (Honeywell, Arkema, and others.) • Mostly focused on liquid HFO blowing agent (HFO - 1233zd or HFO1336mzz) • Confirmed HFO deactivates/deteriorates catalysts and surfactants • Majority dealt with extending the chemical stability of LBA by screening all available catalyst candidates • Some dealt with solubility of blowing agent in foam system 

### • Gas Blowing Agent: Only 5 patent applications published • Manufacturing of HFO - 1234ze • Blends of HFO - 1234ze/HFC- 245fa • Use of 1234ze in specific 1K foam products 11 

### No solutions for GBA stability in 2K foam applications

### • Arkema and Honeywell clearly stated that Gas HFO (1234ze) is 7x less stable than liquid (1233zd) • HFO degrades forming HF (super strong acid) which attacks catalysts /surfactants, affecting foam reactivity and cell structure • HFO stability is the key obstacle for foam industry


### • Current research shows promising results. However, further 

### validation is needed to prevent unintended consequences . • Earlier formulas appeared stable for a time, but then suddenly and unexpectedly failed. 12 

# Challenges- Chemical Stability

Tough challenges to overcome, but we believe solutions are possible given adequate research time

# Challenges - Solubility

• Only small size LP Foam Packages can be shaken/remixed prior to use by installer



### • Larger packages such as 50lb and 17, 60, 120 gallon containers cannot be remixed by installer • It’s common for HP SPF installer to remix prior to spray


### • Solubility: HFO << HFC • Additives that improve HFC solubility do not work as well for HFO • Some also cause issues with worsening shelf- life chemical stability 1314 

# CONFIDENTIAL BUSINESS 

# INFORMATION15 

# CONFIDENTIAL BUSINESS 

# INFORMATION16 

# CONFIDENTIAL BUSINESS 

# INFORMATION

# Clayton’s Petition for HFC phase out date

• Historical conversion process: CFC  HCFC  HFC • Reformulation, testing, approvals, etc.


### • Currently, industry has very limited options • Gas Blowing Agent, HFO 1234ze • Single chemical, single manufacturer, single plant • Catalyst manufacturers are still developing new chemicals for HFO- based systems


### • New formulations must be validated in field trials to prevent unintended consequences during use. 17

# Industry Progress

• One LP Foam producer* • Reported an experimental product with 12 month shelf life (estimated from accelerated aging data only) • Announced that 25% of all of its low pressure spray polyurethane foam formulations will be converted from HFCs to HFOs by summer 2016.


### • We feel this shows that additional development is needed...
• Missing ....

*“The Use of Solstice® Gas Blowing Agent (GBA) in Low Pressure Spray Polyurethane Foam Applications”; Cline, Mojee and Bogdan, Mary; CPI 2015 18

# Summary
• Clayton Corporation fully supports the EPA in its Clean Air Act initiatives. • Low Pressure Spray Foam requires the use of gas blowing agent (HFO- 1234ze) 

### • The changeover from HFC- 134a requires more work than HFC245fa to overcome the known stability issues • There are many challenges that need to be addressed – not a simple drop- in • Work shows progress and we believe changeover is possible with adequate research time • Need appropriate time for testing and approval processes 

### • We recommend a 2021 conversion date to ensure all markets/all products are switched over safely 19

# Thank you

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