Presentation on theme: "In Flexible Slabstock Foams PFA – Pt Clear AL 2007."— Presentation transcript:
In Flexible Slabstock Foams PFA – Pt Clear AL 2007
ecomate ® advantages A LIQUID Physical Blowing Agent Patented: US 6,753,357 w others [WP] Pending To Replace Acetone ENVIRONMENTALLY BENIGN ZERO ODP, Negligible GWP, VOC Exempt [US EPA] Excellent Solubility Less Hazardous to Use
ecomate ® Blowing Agent Properties Clear, Colorless, Flammable Liquid Boiling Pt Flash Point LEL \ UEL LAMBDA, gas ( 25 °C) Vapor Pressure ( 25 °C) Auto Ignition Temp Specific Gravity Molecular Weight 88.7 F31,5 C -26 F-32 C 5 - 23% 0.07410,7 11.4 psig586 mm >840 F>450 C 0.9820,982 60
ecomate ® Blowing Agent - Environmental Characteristics ecomate blowing agent is an attractive long term environmental option ODPGWP VOC CFC 1114000NO CFC 1218500NO HCFC 141b0.1630NO HCFC 220.051700NO HCFC 1240.02480NO HCFC 142b0.062000NO HFC 134a01300NO HFC 245fa0790 -1040NO Cyclopentane011YES ecomate0negNO
Toxicity U.S.EPA HPV Chemical Challenge Program Revised Test Plan for the Formates Category Formic Acid* CAS#: 64-18-6 Sodium Formate CAS#: 141-53-7 Calcium Formate CAS#: 544-17-2 Methyl Formate CAS#: 107-31-3 Submitted by: American Chemistry Council Formic Acid and Formates Panel Submitted to: U.S. Environmental Protection Agency Prepared by: Elmer Rauckman, PhD, DABT Toxicology and Regulatory Affairs Freeburg IL 62243 May 27, 2003 * Formic Acid is being reviewed as an ICCA chemical and is not formally a HPV chemical. http://www.epa.gov/chemrtk/formates/c13438rt.pdf#search='methyl%20formate'
Toxicity The acute toxicity of all Formate materials is low with NO special hazards Methyl Formate [MF] is transformed very rapidly into formic acid and methanol in the body with a half-life on the order of several seconds. Formic Acid is present in many foods (18) fruit juices (30 -100 ppm), honey (20 -2000 ppm), wines (1 -340 ppm), coffee, roasted (1350 -2200 ppm), coffee, extracts (2000 -7700 ppm), evaporated milk (30 -400 ppm), and cheese (20 -200 ppm) (19). (20). (page 14) The 4-hour inhalation LC50 of methyl formate was > 21 mg/L All found negative in the Ames test No further testing is recommended.
Toxicity The acute toxicity of all Formate materials is low with NO special hazards Methyl Formate [MF] is transformed very rapidly into formic acid & methanol in the body with a half-life of several seconds. Formic Acid is present in many foods (18) fruit juices (30 -100 ppm), honey (20 -2000 ppm), wines (1 -340 ppm), coffee, roasted (1350 -2200 ppm), coffee, extracts (2000 -7700 ppm), evaporated milk (30 -400 ppm), and cheese (20 -200 ppm) (19). (20). (page 14) The 4-hour inhalation LC50 of MF was > 21 mg/L All found negative in the Ames test No further testing is recommended.
Effects of Acetone Long Term Animal Studies Kidney Damage Liver Damage Nerve Damage Increased Birth Defects Lowed Reproduction [Males]
Use in Foams Rigid Pour & Spray Integral Skinned Foams Flexible
ecomate – best alternative to 141b Solvates all Raws currently used BPt. just above ambient [like 141b] Permits good skin formation Allows fast demold times Environmentally Benign Economical – Mol Wt HALF of 141b US EPA SNAP Approved
Flexible Foams Molded & Slab Good Solubility Fine Cells Less Flammable than Hydrocarbons Non-VOC Excellent Hand
Flexible Foams Molded & Slab EcomateAcetone Mol Wt6058 B Pt, °C32.156.3 LEL, vol% 52.5 UEL, vol% 2312.8 Heat of Vaporization, BTU/Lb 202.3234 PEL, ppm 50001000 TLV, ppm 100 500 Same MW = Same Density Lower BPt = More Efficient Lower HtVap = Lower Density Higher LEL = Lower Hazard Higher PEL = Lower Hazard Lower GWP NO Baggage – Now or Future !
Full Scale Trials 2 Seamless Trials One MDI, one TDI Both Successes MDI Trial Slabstock and Visco-elastic Foam As Soft or Softer Reaches ALL density ranges More Economical
TDI SLAB TRIAL Pre-Trial Methodology Visitation Determine Current BA Handling & Exhaust Consultation - Storage, Transfer, Use Safely w/o significant changes or expense Calculation – Max Emissions = 0.27vol% Set Up - Fully Engineered, work with local Fire Marshall Inspection - line monitored during run
TDI Trials Two Systems System X High Ecomate loading ~ 4.8% of system Low Density = 0.90 pcf System Y Lower Ecomate Loading ~ 1% of system Higher Thru-put Low density = 0.95 pcf
Ecomate Monitoring TDI Flex SlabstockSYSTEM X SYSTEM Y Foam Thruput, lbs/min 434467 Ecomate Thruput, lbs/min 229.5 Run Time, min 5.85.3 Density, pcf 0.890.96 Trough [% of LEL] 2%1% Blow-off [% of LEL] 1% Side rollers [% of LEL] 1%0% Cut-off saw [% of LEL] 2%0%