Danish conference surveys the PU scene

The “cost of energy as a as a focus of industry” attention was among issues raised at the Symposium Polyurethanes – Processes – Materials conference in Denmark. Jane Denny attended.

Polyurethane’s many uses in energy generation, for comfort and its use in construction markets as well as how to preserve PU articles was explored in Nyborg, Denmark in May 2016.

From the benefits that PU brings to the wind turbine industry outlined by Covestro through the regulations that govern methods of PU production to the viscoelasticity of Tempur Sealy mattresses, representatives from key global PU players shared their thoughts.

A new thinner insulation product from BASF and the necessity to preserve polyurethane-based artistic works for future generations were among a number of key issues also raised during the one day event.

Wind competence

Covestro Nordic ceo Kim Klausen, who is also head of the German chemical supplier’s global wind project, gave the first presentation at the Technical Conference. He told delegates that the global wind industry is enjoying a period of rapid growth.

“Wind is one of the fastest growing industries in the world today. In recent years and coming years its growth rate is estimated at 9% per year.” Klausen said that up to 45% of new installations are in China.

“Not many industries are growing at that fast,” he added.

The firm – which provides a mix of epoxy and PU materials into the wind turbine manufacturing sector - has a global wind competence centre in Denmark. The centre coordinates activity all over the world with R&D remaining in the company’s Leverkusen, Germany HQ.

The main cost associated with wind turbines comes from the manufacturing process, said Klausen adding that Covestro’s attention is focused mainly on the rotor blades of the turbines.

In wind turbine production, he said polyurethanes offer a number of benefits compared with other materials: “We can infuse much faster because the starting viscosity is lower. The use of one third of an epoxy system makes it possible to infuse much faster. PU is also slightly cheaper than epoxy.”

“We can infuse much faster because the starting viscosity is lower,”

Covestro Nordic ceo Kim Klausen

Covestro’s rotor blades are fabricated using a polyurethane resin and a glass fibre fabric and the resin received the DNV GL certification in March 2016. DNV GL is an international industry standard for the safety, reliability and performance of wind turbines and, according to Covestro it was the first company to be certified.

“The pinpoint of industry at the moment is the cost of energy. After that, it’s all about cost versus input. The time has come to establish the high performance and cost advantages of polyurethane in wind power generation,” he added.

New generation insulation

Continuing the energy efficiency theme, project manager Marc Fricke’s presentation outlined what his company, BASF is claiming will be the “next generation of insulation materials.”

While Fricke won’t reveal whether the new Slentite material is MDI or TDI-based PU, he did say the company spent over 10 years developing it.

Fricke said: “It is a special type of PU, the world’s first PU aerogel," he added.  "Usually aerogel is made from silica, which is very brittle but this is cuttable and handle-able.”

“The challenge for society will be retrofitting original buildings. There is also a challenge in new buildings as we face new challenges like lack of space.”

“It is the world’s first PU aerogel.”

BASF project manager Marc Fricke

He said the firm’s Lemforde, Germany-based pilot plant for production of Slentite panels, which opened last year, is running smoothly. Samples are 40cm by 60cm.

In terms of cost, he said Slentite will be “much more expensive than standard PU. This will be a special material for applications where other materials fail. We are not saying that this will be a replacement for an insulation board but it will fill the gap between that and vacuum insulation," he added.

Tempur absorbs energy

Meanwhile, a Tempur Sealy senior research chemist Simon Simonsen, gave an overview of his firm’s flexible PU technology.

Tempur Sealy’s experience with viscoelastic foam mattresses started in 1983 and today it claims to be the world’s biggest viscoelastic foam producer with a global turnover of $4bn.

“One of the most important things in our formulation strategy is that the glass transition temperature should be around room temperature,” he said.

“In our formulation strategy the glass transition temperature should be around room temperature.”

Tempur Sealy senior research chemist Simon Simonson

He also told delegates that Tempur Sealy research suggested that a sleeper would [toss and] turn around 80 times per night when sleeping on a sprung mattresses. On a Tempur Sealy mattress, this figure is reduced to an average of less than 20 times. He added that Tempur Sealy carried out 57 kinds of testing on its foam, including pressure mapping.

“When you are turning around, you are doing it because of the pressure point and you want to compensate that in order to not hurt yourself,” he said.

Diisocyanate regulation time frames

Huntsman Polyurethanes’ strategic issue management leader Erik Vangronsveld warned delegates of impending changes to diisocyanate a handling regulations in the EU.

He told the meeting that in terms of REACH regulation, mandatory training will be needed for employees working with diisocyanates. The proposals, which are at an early stage of development, look likely to apply to anyone who handles products containing more than 0.1% by weight diisocyanate.

He told delegates to “expect direction around 2018, with implementation expected in 2018 too. This whole sector needs to organise itself to develop this training.”

According to Vangronsveld, asthma cases in the industry are on the decline. “We are talking about 500 cases in Europe per year. It’s extremely important for the industry to educate people working with isocyanates and epoxies.”

“It’s extremely important for the industry to educate people working with isocyanates and epoxies.”

Huntsman Polyurethanes’ strategic issue management leader Eric Vangronsveld

The Siemens diisocyanates occupational exposure case compounds the importance of good stewardship in manufacturing processes that involve diisocyanates, added Vangronsveld.

Polyurethane preservation

Louise Cone, conservator contemporary art and sculpture at the National Gallery of Denmark, said the museum faces critical issues around preserving objects made with polyurethane.

Cone said artists and designers have been tapping into the creative potential of polyurethanes since the 1960s.

“Many of these works enter into collections, private and public, where the expectations for lasting value are high. As conservators it is our duty to find ways to extend the life expectancy for the works in our care.

“Polyurethanes present a real challenge, which we are working feverishly to meet, to safeguard the future of irreplaceable art artefacts and objects of cultural heritage."

The association event was organised by the Danish Plastics Federation and was held in Nyborg, Denmark at the end of May, 2016. It was a one day event attended by around 20 delegates.