Francesca Pignagnoli Luigi Pellacani Rodnei Massamiti Abe

Apresentação em tema: "Francesca Pignagnoli Luigi Pellacani Rodnei Massamiti Abe"— Transcrição da apresentação:

1 Francesca Pignagnoli Luigi Pellacani Rodnei Massamiti Abe
Soluções PUR & PIR como Isolante Térmico com Alta Economia de Energia para Painéis com Faces Metálicas Tipo Sanduíche, de Acordo com as Regulamentações Européias Francesca Pignagnoli Luigi Pellacani Rodnei Massamiti Abe Bom dia meu nome é Rodnei Abe e trabalho na Dow Brasil SA no negócio de Sistemas de Poliuretano; Este trabalho (ler título) é bastante recente e foi apresentado pela Dow na UTECH 2009 ocorrido na Holanda; Não sei se todos sabem mas o mercado de Construção Civil na União Européia esta vivendo uma fase de transição muito importante e, porque não dizer de muitas oportunidades, apesar das fortes restrições em termos de regulamentações principalmente as ambientais que estão sendo propostas. A Europa esta em fase de implamentação de um código da Construção Civil comum a todos os países membros através de umas Diretivas para produtos da Construção (CPD), que falarei mais à frente, e também a implantação de Diretivas para Performance Energética em Edifícos (EPBD). Estas novas Diretivas tem levado os produtores de painéis isolantes a se desdobrarem em atender estas regulamentações através de testes e qualificações e a exigirem produtos isolantes cada vez mais eficientes; Este trabalho dá uma visão geral destas regulamentações na Europa e seu potencial impacto no mercado da Construção Civil e também o empenho da Dow no desenvolvimento de soluções em PU e PIR que possam ajudar e alavancar os produtores de painéis sandwiches com faces metálicas a atenderem estes requisitos efetivamente, seja através dos sistemas VORACOR PUR ou com a nova linha de sistemas estratificada VORATHERM PIR; Pretendo mostrar também o que vem ocorrendo no mercado brasileiro em relação às regulamentações na Construção Civil relativo aos paneis isolantes tipo sandwiches;

2 A Necessidade da Conservação de Energia
CONSUMO GLOBAL DE ENERGIA POR TIPO DE COMBUSTÍVEL Protocolo de Kyoto (Nível Global) Energy Performance of Building Directive (EPBD) (Europa) Custos Emissão CO2 MMT oil equiv PROCEL EDIFICA (Brasil) “Regulamentação para Etiquetagem Voluntária do Nível de Eficiência Energética de Edifícios Comerciais, de Serviços e Públicos” “A necessidade da conservação de energia”. Neste gráfico podemos ver que o constante crescimento do consumo de energia globalmente representa uma preocupação por um número de razões, não somente devido à escalada dos custos destas energias, mas também devido ao problema da poluição, em particular, o aumento da emissão de CO2 impactando diretamente no aquecimento Global. Estes fatos tem levado a um movimento global no controle e regulamentações no uso destas energias. Exemplo a nível global é o Protocolo de Kyoto e a nível Europa a implementação da Diretiva para Performance Energética em Edifícios (EPBD). Na Europa, em particular, o problema energético é bastante crítico uma vez que a Comunidade Europeia importa mais de 50% de sua energia tornando-a bastante vulnerável, não somente no fornecimento, mas nas estratégias política e economica de seus fornecedores. E esta situação tende a piorar se nehuma ação corretiva for feita rapidamente. Uma das soluções de impacto imediato é, de fato, a redução da demanda atual de energia. O Brasil não esta muito longe desta realidade também. Pensando nisso o Governo Brasileiro está lançando o programa ProcelEdifica..etc... From: BP STATISTICAL REVIEW , JUNE 2008

3 A Necessidade da Conservação de Energia DIVISÃO DO CONSUMO TOTAL
DE ENERGIA NA EUROPA CONSTRUÇÃO (40%) TRANSPORTE (32%) INDÚSTRIA (28%) MATERIAIS ISOLANTES DE ALTA PERFORMANCE - Impacto direto na redução de energia Voltando ao modelo Europeu. Quando se olha a divisão do consumo total de energia na Europa, entre Construção Civil, transporte e Industria, verifica-se claramente que para se atingir uma significativa redução na demanda energética é necessário focar no setor de Construção Civil que representa a maior fatia com 40% da energia total consumida na Europa; E, específicamente no íten isolamento térmico, o uso de materiais isolantes de alte performance podem reduzir diretamente a quantidade de energia nas edificações, tanta para aquecimento como para resfriamento; Esta é razão porque o uso de materiais como painéis de sandwiches de poliuretano e poliisocianurato tem crescido consideravelmente no segmento de construção civil nos últimos anos; Fonte: Directorate General for Energy and Transportation. European Comission

4 Características chaves dos painéis PUR & PIR
Impacto Isolação Térmica Conservação de Energia Resistência Mecânica Propriedades Estruturais Leveza Baixo Custo Facilidade de Produção Alto grau de pré-fabricado e facilidade de instalação Além disso, soma-se ao sucesso destes painéis algumas características chaves como excepcional isolamento térmico….

5 Conservação de Energia é Possível com Painéis de PU
ISOLANTES TÉRMICOS EM PAINÉIS: Materiais Fibrosos Inorgânicos => Lã de vidro e Lã de rocha; Materiais Orgânicos Espumados => Poliuretano, Poliisocianurato e Poliestireno; Espessura requerida para se atingir uma transmitância térmica U= 0.35 W/m2°K (source: ANPE) Em termos de isolantes térmicos mais utilizados no mercado de construção, há basicamente dois grupos dominantes: os materiais fibrosos inorganicos (lã de vidro e lã mineral) e os materias espumados orgânicos (PS, PU, PIR e fenólicos). Todos eles trabalham com o mesmo princípio de reduzir a mobilidade da fase gasosa dentro de suas estruturas. However, in the case of polyurethane and polyisocyanurate foam, the gas phase mobility is strongly reduced because it is enclosed inside the foam cells allowing to achieve an excellent thermal insulation performance. The latter can be measured as thermal conductivity or lambda-value, which is an intrinsic property of the material. For building elements we rather use the thermal transmittance, which is the thermal conductivity divided by the thickness of the building element. In the slide you see the indicative thickness of insulating panel required to achieve a thermal transmittance value of 0.35 W/(m2.°K). The better the insulating performance of the core material, the lower is the required thickness. For instance, replacing rigid faced PUR insulating sandwich panels with mineral wool means that the thickness of the insulating element may have to be increased by at least about 50 % in order to maintain the thermal transmittance performance.

6 Europa - Cenário da Regulamentação
Diretivas para Produtos de Construção (CPD) Harmonizar e criar um mercado Europeu único para produtos da construção. Pré-requisito para obter a marca CE; Atestado de conformidade de órgãos certificadores; 6 exigências essenciais (ER) No. 1 Resistência Mecânica e Estabilidade No. 2 Segurança em caso de Fogo No. 3 Higiene, Saúde e Meio Ambiente No. 4 Segurança no uso No. 5 Proteção contra Barulho No. 6 Conservação de Energia e Retenção de Calor EN 14509 NBR 15366 One of the Essential Requirements is “safety in case of fire” which is the basis for the development and introduction of uniform classes (Euro-classes) for reaction to fire throughout Europe . According to this new classification the construction products are rated from A to F. Euro-class A will cover products that do not contribute, or contribute only very slightly, to the development of a fire. Euro-class E will cover products that can resist ignition by a small flame for a short period . Euro-class D, C and B are determined primarily based on heat release parameters in the Single Burning Item test, which is an intermediate scale fire propagation test characterized by corner configuration and a rather high thermal attack. Euroclass F is for products with no performance determined. Additional classification are obtained for smoke development (s1,s2,s3) and dripping (d0,d1,d2), where s1 is best class corresponding to lowest level of smoke production and d0 best class corresponding to no falling flaming debris and/or droplets.

7 NORMA BRASILEIRA NBR 15366

8 Exemplos da Última Geração de Sistemas PUR da Dow expandido com HC para Linha Contínua (RF DBL)
System 1 S y stem 2 stem 3 Tipo de Painel Wall 80mm FR performance B3 B2 Agente Expansor N ormal pentano Ciclo Reatividade na linha de produção: Tempo de crème (s) 8 9 Tempo deGel (s) 34 35 Tempo de pega livre (s) 68 65 67 Contact time (s) 27 28 Densidade global (g/l) 4 1 3 Tensão compressão a 10% deformação (KPa) - Com substrato 145 110 127 - Sem substrato 144 105 123 Estabilidade Dimensional a -25oC, 20 hs , - Espessura Dl% 0,0 - 0,2 0,1 0, 2 Tensão adesão da espuma ao substrato (KPa) 102 112 125 Condutividade térmica inicial a 10°C (mW/m °K) 19,9 19,8 19,2 - Largura, Dl% - Comprimento, Dl% Let’s now review some examples of the Dow PU Sys offering for rigid faced sandwich panels, starting with the PUR HC blown technology. For the systems reported in the table, all test data are related to sandwich panels produced on a metal faced continuous lamination line. As each of the three systems was designed to address the specific customer requirements, direct comparison between them is not possible. Nevertheless, it can still be underlined that the overall level of performance was good, in particular excellent thermal insulation performance levels were achieved, with lambda values below 20 mW/m°K. System 3 gave the best thermal insulation, not only because it used cyclo pentane as the physical blowing agent, but also because the physical blowing agent level was 50 % higher vs. the level used in systems 1 and 2. Because of this difference in the physical blowing agent level, the overall density associated with system 3 is lower than for system 1 and 2.

9 value for 100 mm thick panel
Exemplos da Última Geração de Sistema PUR da Dow Expandido com HFC para Processo Descontínuo (DCP) System 4 System 5 System 6 Relação Iso/Pol 12 0/100 120/100 120/100 Agente expansor HFC HFC HFC FR performance B3 B3 B3 Dados de reatividade (Máquina da alta pressão): Tempo de Gel (s) 150 160 125 Densidade livre(g/l) 29.9 28.7 33.0 Propriedades da Espuma, Brett mold: Flow index 1.118 1.172 1.451 Densidade global (g/l) 40 40 46 Performance do isolamento térmico: Initial l at overpack 10% (mW/m°K, at 10°C) 22.8 22 20.3 U value for 100 mm thick panel W/(m - 2 .K) 0.23 0.22 0.20 While HCs dominate the DBL market, the use of HFCs in Europe is mainly limited to the discontinuous panel (DCP) productions, where the conversion to the less expensive HCs can be economically disadvantaged due to the high upfront costs required for the handling of the flammable blowing agent. In this table we see some properties obtained with a PUR B3 type system for discontinuous production in which the physical blowing package was based on HFCs. In spite of both the slow reactivity profile required by the discontinuous application, and of the relatively low use level of physical blowing agent, which was only about 3 % in the foam, it was possible to achieve a measurable improvement in thermal insulation performance through formulation optimization. This is demonstrated by comparing the lambda values associated with the systems 4 and 5. System 6 is also designed for DCP applications, and for a level of HFC around 3 % in the foam: unlike systems 4 and 5 though, it is designed for higher applied densities. The formulation optimization helped to achieve a further improvement in insulation performance, with the lambda value getting close to 20. Table 4 also reports the corresponding thermal transmittance values. The change in the lambda value from 22.8 mW/m°K down to about 20.3 mW/m°K is reflected by a corresponding change in the thermal transmittance from 0.23 W/(m2.K) down to 0.20 W/(m2.K). A similar improvement in the thermal transmittance can be achieved by increasing the thickness by about 10 %.

10 PIR Stratification: VORATHERM TM Product Family
Alto Índice Médio Índice Baixo Índice Iso-Polyol NCO Index > 3.0 2.2 – 3.0 1.8 – 2.2 Certificações Reação ao Fogo LPS 1181 FM 4880, EMPA 5 Euroclass BS2d0, DIN 4102 Resistência ao Fogo LPS 1208 EN1364 Processabilidade Temperature of Conveyor 60 – 65 °C 50 – 60 °C 40 – 50 °C Camada adesiva Disponível sob encomenda Disponível sob encomenda It is generally acknowledged that PIR foam is a foam prepared at an NCO index, expressed as NCO/OH ratio, that is higher than 1.8. The high isocyanate content, the high aromaticity, and the presence of the thermally robust isocyanurate rings, explain the improved flammability. Indeed, improved FR performance is the main driver for the PIR technology, and it is possible to segment the PIR formulation technology range in three levels, differentiated on the basis of the FR performance level than can be achieved. The lower level of this range corresponds to formulations that have NCO indexes just above 1.8: these formulations can be tailored to meet mild fire test requirements, while offering at the same time processability features that are in line with the capabilities of the typical DBL production process. Moving to a higher NCO index range, from about 2.2 up to about 3.0, it is possible to formulate according to different performance objectives. In particular, through proper formulation optimization it becomes possible to meet tougher fire test requirements, such as the FM 4880. Moving to very high NCO index values, higher than 3.0 NCO/OH, the isocyanurate content is so high that it delivers an excellent intrinsic flammability performance, hence the system may be tailored to meet difficult test such as the LPC 1181 or the LPS 1208. This is all summarized in this slide, reporting the key features of the polyisocyanurate systems from Dow, now commercialized under the trademark VORATHERM.

11 Initial l at 10°C (mW/m°K)
Exemplos da VORATHERMTM expandido com HC para Linha Contínua (RF DBL) System 7 System 8 System 9 PIR NCO index Baixo Médio Alto Agente Expansor normal pentane Espessura do Painel (mm) 80 - Tempo Gel (s) 33 31 30 - Densidade global (g/l) 38 39 41 Tensão Compressão (kPa) 160 150 140 Tensão adesão (kPa) 136 120 110 Initial l at 10°C (mW/m°K) 21.1 20.2 20.1 Dados de Processo da Linha Contínua: In this slide, you see some example of the VORATHERM offering from Dow. For each of the three different isocyanurate NCO index segments described above, data are from metal faced panels produced on a DBL line, with a level of normal pentane of about 3 % in the foam. The PIR panels using pentane blowing agent as described above, are examples of materials that can achieve excellent lambda values, as well as very good overall mechanical properties. When looking at fire resistance, the use of a flammable blowing agent such as pentane could have been considered as a possible obstacle towards the achievement of a high level of performance. It was possible, however, to demonstrate that this is not the case, and that a pentane blown PIR system can achieve high-level performance in terms of fire resistance. In particular 200 mm rigid faced panels prepared with a pentane blown PIR system, met IE60 fire resistance test according to the British LPS 1208 standard. É possível reduzir a 19.0 mW/mk adicionando-se uma quantidade maior de c-pentano

12 Conclusões Foi demonstrado através da otimização das formulações que é possível melhorar o desempenho da isolação térmica dos painéis PUR ou PIR de forma a atender, sem muitas dificuldades, as exigências das Diretivas de Desempenho Energético de Edificações (EPBD) na Europa e do Programa PROCELEDIFICA no Brasil. A tecnologia VORATHERMTM PIR da Dow oferece uma rota efetiva para se atingir um desempenho “high class” ao fogo além de uma excelente performance energética dos painéis. O sistema VORATHERMTM PIR da Dow atende plenamente as novas Diretivas para Produtos da Construção(CPD) na Europa referente aos painéis isolantes tipo sanduiches, EN Da mesma forma atende plenamente a norma Brasileira para Painéis e Telhas, NBR In conclusion, in the complex regulatory landscape around PUR or PIR cored metal faced sandwich panels & construction segment , the Energy Performance of Buildings Directive describes improvement targets for the energy performance of buildings, where a strategy based on the use of higher performing insulation materials, such as PUR or PIR rigid foam, would therefore have the advantage of minimizing the thicknesses and/or weight required to meet the EPBD. We have reviewed some examples of PUR and PIR foam systems suitable for DCP and/or DBL applications. The data shows that in spite of the evolution of blowing agent technology and the need to formulate to fit the various performance elements like flammability, through formulation optimization excellent lambda values have been achieved and more recent results show possibility to further improve the already excellent insulation performance. In perspective of the increasing emphasis on energy saving, customer demand and strategies to serve the construction market, Dow will continue to develop more performing insulating solutions. In the specific PIR technology area, which can offer an effective route to help achieving an overall hig-class performance in terms of fire performance, Dow offers a stratified technology to meet the various levels of fire resistance. The PIR offering from Dow is commercialized under the brand name VORATHERM.

13 OBRIGADO PELA ATENÇÃO ! RODNEI MASSAMITI ABE DOW BRASIL S.A.
FONE:

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15 Factors for Long-Term Thermal Insulation Performance
The initial termal insulation The speed and impact of the ageing according Annex C of EN13165 If ordinary ageing = fixed increments procedure is applied to calculate aged value If non-ordinary ageing = direct measurement via accelerated ageing is performed Air lgas 25°C = 26.5 mW/m.K Slow inward diffusion rate PU foam cell CO2 lgas 25°C = 16.3 mW/m.K Rapid outward diffusion rate Aging of PUR/PIR foam (closed cell structure) Pint < Pest A recent development in DOW formulation technology for a PUR HC blown foam, has shown the possibility of drastically reduce the increase of thermal conductivity during ageing The two mail factors determining the long term insulation performance of PUR or PIR foam are: the initial thermal insulation performance, which is very good in the case of PUR/PIR and depends in large amount on the type of blowing agent and the speed of the ageing, which for PUR/PIR is slow & is linked with the migration of the blowing agent and its partial replacement by air, but also to the type of facing material (permeable/impermeable) It follows that a strategy to maximize the long term thermal insulation performance should either optimize the initial thermal insulation value, or it should delay the speed of ageing. If the material is ageing in an ordinary way, then its thermal insulation performance can be determined according to the ‘fixed increments’ in accordance with EN If the material ages in a non-ordinary way, then thermal insulation should be measured via accelerated ageing. A recent development by Dow Europe in the formulation technology for a PUR hydrocarbon blown foam, has shown the possibility of drastically reduce the increase of thermal conductivity during foam ageing. The tests are still in progress, but initial results are indicating that the foam, after one month ageing, has substantially maintained it initial lambda value of about 19 mW/mK.

16 Energy saving through Thermal Insulation
The CE marking = European manufacturer's declaration that the product complies with the essential requirements of the relevant European health, safety and environmental protection legislations. For rigid faced sandwich panels, the relevant harmonized EU standard is the norm EN Thermal conductivity of core material is measured in accordance with product standard EN Both EN and the EN were published by the European Commission in the Official Journal of the European Union, which triggered the period of coexistence, from until At the end of the coexistence period, national regulations will be phased out and replaced by the harmonised EU standard. Conformity of a building product with a harmonized EU standard or a EU Technical Approval is confirmed by the CE marking, which is like a passport in the sense that it enables a product to be sold within the european market. For rigid faced sandwich panels, the relevant harmonized EU standard to be used in order to verify conformity is the norm EN The thermal conductivity of the core material is measured in accordance with the product standard EN 13165, referring to long term (25y) thermal conductivity values. Both the EN and the EN were recently published by the European Commission in the Official Journal of the European Union, which triggered the period of coexistence. This period, during which both the national regulations as well as the harmonized European standard can be applied, will last from until At the end of the period of coexsistence the national regulations will be phased out and replaced by the harmonised European standard.

17 Conservação de Energia é Possível com Painéis de PU
Espessura requerida para se atingir uma transmitância térmica U= 0.35 W/m2°K (source: ANPE) Exemplo de balanço energético (source : BING) Energia requerida para produzir um painel PU/PIR com 80 mm de espessura = 100 kWh/m2 (U= 0.30W/m2°K) Economia de Energia vs uma edificação não isolada pelo uso de painéis PU/PIR = 160kWh/m2 ano Balanço Total com 50 anos de uso = 7900 kWh de economia de energia

18 The regulatory framework
EN (harmonized standard for RF sandwich panels Answers the question: how should the panel be tested ? Council Directive 89/106/EEC Energy Performance of Buildings Directive Directive 2002/91/EC of the European Parliament and Council on energy efficiency of buildings Answers the question: how good should the insulation of the building be ? The Energy Performance of Buildings Directive sets minimum requirements of energy performance and describes improvement targets of the energy performance of buildings, and as such it is an important legislative element towards meeting the Kyoto commitments. In the Energy Performance of Buildings Directive, the term "energy performance of a building" means the calculated or measured amount of energy needed to meet the energy demand associated with a typical use of the building, which includes inter alia, energy used for heating, hot water, cooling, ventilation and lighting. The directive also includes the development of appropriate calculation procedures to be used by the European Member States. It also includes the energy performance inspections and certifications. The implementation of the Energy Performance of building directive is clearly a complex task, which is why a recast of the directive has been recently proposed , underlining the leading role of the public sector, , & new timeline for transposition & full implementation have been set.

19 NBR ( EN )