Dow Inc. · NYSE:DOW
Dow — Technical Presentation (May 2017)
40 slides from Dow's technical presentation, May 18, 2017
Slide 1: The K-12 Project Mid-term event
LIFE13 ENV/IT/001238 The K-12 Project Mid-term event Pont Canavese, 18th May 2017 K-12 CONFIDENTIAL 0
Slide 2: K12: A Real Life Project
K12- PU Disruptive technology to dramatically improve Energy Efficiency of Household Appliances LIFE13 ENV IT 1238 18/05/2017 MID TERM CONFERENCE K12: A REAL LIFE PROJECT V. Parenti, A. Gasparoni, M. Corti With the contribution of the LIFE financial instrument of the European Community K-12 CONFIDE
Slide 3: The LIFE+ K12 Project
THE LIFE+ K12 PROJECT The LIFE+ K-12 project aims to demonstrate the feasibility and effectiveness of an innovative Polyurethane (PU) technology offering significantly improved thermal insulation and, thus, energy efficiency of households cold appliances, contributing to the European Community’s goa
Slide 4: The Home Appliance Industry Challenges
The Home Appliance Industry Challenges Innovation Cost Market Policies Needs Environment K-12 CONFIDENTIAL 3
Slide 5: Background: EU climate & energy package
Background: EU climate & energy package Set of binding legislation to ensure the EU meets its climate and energy targets: 2020: 2030 : Reduction target •20% cut in greenhouse •40% cuts in greenhouse gas for Emissions gas emissions (from 1990 emissions (from 1990 levels) – trading system levels) at l
Slide 6: Background: GHG emission forecast in 2030
Background: GHG emission forecast in 2030 The European Union, United States and China collectively produced 45% of global annual emissions of GHG in 2010 Source: ESRC Centre for Climate Change Economics and Policy - Grantham Research Institute on Climate Change and the Environment (May 2015) K-12 C
Slide 7: Background: Energy Consumption
Background: Energy Consumption Residential sector account for 30% of total energy supply, distributed over 140M households Cold appliances account for 14,5% of total household energy consumption Between MDA ,cold appliances account for 37% of total household energy consumption Water Heaters 8,6%
Slide 8: Background: Energy Efficiency
Background: Energy Efficiency Energy Label New Technologies Average energy consumption trends by product groups in Western EU (2010- 2014). Source: GfK Retail and Technology Panel Draft for Energy labels rescaling (Source CECED) Energy efficiency classes of refrigerators-freezers in the EU (21 count
Slide 9: Background: The Market
BACKGROUND: THE MARKET •The cold appliances market is characterised by a high level of substitution of old appliances rather than by an increase of the existing stock. •Refrigerator stock reached the saturation level with penetration rates of around 100% in almost all EU-28 countries. •Market trends
Slide 10: The K12 projects objectives and expected results
The K12 projects objectives and expected results • Refrigerator manufacturing process demonstrated at pilot scale with optimized foaming parameters and new injection equipment • A 25-30% improvement in foam thermal conductivity performance of the new PU foam, compared to the best in class solutions
Slide 11: Domestic Refrigerators: insulation material
Domestic Refrigerators: insulation material Why Polyurethane? Comparison of thermal efficiency: 2.5 cm rigid PU foam 4.0 cm poli-styrene 4.5 cm fiber-glass 5 cm cork 12 cm wood 40 cm bricks K-12 CONFIDENTIAL 10
Slide 12: EU Energy Labeling for domestic refrigerators
EU Energy Labeling for domestic refrigerators EEI EN - supplementing Directive 2010/30/EU of 28 Sept 2010 Energy Efficiency Index – EEI = AEc / SAEc x 100 A+++ A+++ 22 AEc=Annual Energy Consumption SAEc=Standard Annul l Energy Consumption (average A++ A++ of the specific category) Only class A+ (42)
Slide 13: Why K12 Project?
Why K12 Project? K12 project objective: Demonstrate the feasibility of a novel PU insulation technology for the domestic appliance industry able to improve the refrigerators energy efficiency up to 20% By Developing a microcellular PU foam with cell size ≤ 10 μm blown with CO2 as sole Blowing Agent
Slide 14: K12 would allow one step change in Energy Efficiency
K12 would allow one step change in Energy Efficiency -21% -40% -25% K-12 CONFIDENTIAL 13
Slide 15: How a refrigerator is injected with PU foam?
How a refrigerator is injected with PU foam? Most conventional injection technology: Injection from the compressor side–door up K-12 CONFIDENTIAL 14
Slide 16: Available PU technology solutions with various Blowing Agents
Available PU technology solution in the market with various Blowing Agents 220-250 μm 150-180 μm Gel k-factor time ? TM TM ≤10 μm PASCALTM is a Tradename of The Dow Chemical Company K-12 CONFIDENTIAL 15
Slide 17: Non-PU available alternate solutions in the market
Non-PU available alternate solutions in the market with CO2 or No-Blowing Agents technologies Dow XenergyTM K12 K12 XenergyTM is a Tradename of The Dow Chemical Company K-12 CONFIDENTIAL 16
Slide 18: Thermal insulation by VIPs + PU foam
Therml insulation by VIPs + PU foam Fumed silica typical VIP physical properties Value Density (kg/m³) 170-210 Thermal Conductivity at mean temperature of 22.5°C (72.5°F) (W/m.K) @ 1 mbar ≤0.005 @ ambient pressure ≤0.019 Rated Value (W/m.K) 0.008 Source: Porextherm web site lWall = f (lVIP, lPU foam
Slide 19: PU Foam Thermal Conductivity
PU Foam Thermal Conductivity lFoam = lgas + lsolid + lradiative K-12 CONFIDENTIAL 18
Slide 20: How can we reduce the PU foam Thermal Conductivity?
How can we reduce the PU foam Thermal Conductivity? • Smaller cell size → reduce the radiation contribution • Lower foam density → reduce the solid contribution • Low gas thermal conductivity (k) → reduce the gas/blowing agent contribution however, combination of all these options must be considered
Slide 21: Energy Efficiency Impact of PU insulation
Energy Efficiency Impact of PU insulation 150-180 μm • Microcellular foam 220-250 μm • CO2 blowing agent • Lowest GWP • Long term • Fast reactivity sustainable solution • Modified fixture • Foaming under vacuum • Blowing Agent • Current process • PU injected into ≤10 μm the refrigerator PASCALTM • B
Slide 22: Towards K12: Microcellular foam upscale
Towards K12: Microcellular foam upscale ←Low Magnification - High magnification→ ←30-60 μm→ Process Optimization T, P and Output effect ↓ PU R&D Cannon Whirlpool Lab Pilot Plant prototype K-12 CONFIDENTIAL 21
Slide 23: K12 Gantt Chart and action program
K12 Gantt Chart and action program Project start date: 2014 June Project end date: 2017 November → Extension 2018 November A. Preparatory Actions B. Implementation Actions C. Monitoring of the Impact D. Comm. & Dissemination E. Project Management 1. Lab Development and 2. Pilot plant runs 3. Project
Slide 24: Scaling up from Lab scale to Semi-industrial application
Scaling up from Lab scale to Semi-industrial application First phase activities: CO2 dispersed in vein of the polyol stream Design and production of a special mold for testing the expansion of the foam with CO2 dispersed into the polyol stream A special flat mould has been studied, designed and cons
Slide 25: Specific mixing head provided with a CO2 injection valve
Specific mixing head provided with a CO2 injection valve First phase activities: CO2 dispersed in vein of the polyol stream Preparation of a specific mixing head provided with a CO2 injection valve. The test was performed by using an FPL 10 mix-head provided with a special valve to inject liquid CO2
Slide 26: Metering units
Metering units First phase activities: CO2 dispersed in vein of the polyol stream Liquid CO2 metering unit Metering unit: to handle the new types of formulation with direct injection of CO2 K-12 CONFIDENTIAL 25
Slide 27: First in-mold studies
First in-mold studies First phase activities: CO2 dispersed in vein of the polyol stream 4 different campaigns were performed c/o Afros R&D Lab with the aims to: - Test the PU chemicals and their expansion behaviour - Measure the foam cell sizes obtained and the foam performance including the percen
Slide 28: Pilot Plant to realize fine and stabilized CO2 dispersion
Pilot Plant to realize fine and stabilized CO2 dispersion Folllowing the indications derived from the first series of tests in very small scale by DOW and the Naples Engineering University, we decided to realize a special pilot plant able to repeat in full size the expansion situation Polyol meterin
Slide 29: K12 Pilot Plant in operation
K12 Pilot Plant in operation Test and trials with the Pilot plant assembled and fully operative K-12 CONFIDENTIAL 28
Slide 30: Pilot plant: Polyol and Isocyanate metering module
Pilot plant: Polyol and Isocyanate metering module The module for metering the polyol and the isocyanate in high pressure installed and properly working. K-12 CONFIDENTIAL 29
Slide 31: Pilot plant control: New operator interface and software
Pilot plant control: New operator interface and software The control of the whole pilot plant has been developed with a new software and logic. It controls the different functions by blocks, particularly the new operator-interface is based on the visual schematization of the functioning of the diffe
Slide 32: Components of the new K12 Pilot Plant
Components of the new K12 Pilot Plant Module to efficiently store and disperse polyol and CO2 with high efficiency mixing + Module to meter the dispersed fluid to the high pressure mixing head K-12 CONFIDENTIAL 31
Slide 33: K12 Pilot plant: sealing of the mix heads
K12 Pilot plant: sealing of the mix heads The LN 10 mix head has been specifically designed and set to maintain a delta pressure of around 70 bar between the POLYOL and ISO grooves. Any leaking from the grooves can block completely the mix head. This achievement is the result of several months of te
Slide 34: K12 Pilot Plant: Transfer module
K12 Pilot Plant: Transfer module The transfer module is composed of a special cylinder and its ancillaries. It can accumulate the reactive mixture during its reaction, maintain the mixture under pressure and release it at a certain phase of the reaction. It can expel the complete mixture before it b
Slide 35: Flat mold and press for expansion under pressure
K12 Pilot plant: Flat mold and press for expansion under pressure . Upon the completion of the first part of tests into the brett mold, the tests have been transferred to the flat mold. It can maintain the mixture under pressure and then upon release of the pressure to complete the foam expansion. T
Slide 36: Conclusions
Conclusions A new and important milestone has been achieved through the pilot plant modules in terms of fine dispersion of CO2 and polyol and in term of capability to meter it to the mixing head in any pressure conditions. The use of the system showed that it is possible to disperse the CO2 up to 40
Slide 37: K12 trials continue with a new device
K12 trials continue with a new device Actually we are running tests of the expansion in high pressure conditions (up to 160 bar) We use a special spherical container adapted from an hydraulic accumulator. Test and trials are ongoing with increasing quantities of CO2 K-12 CONFIDENTIAL 36
Slide 38: Conclusions
Conclusions Today the by Pilot Plant it is possible to produce dispersion of polyol and CO2 in any pressure conditions up to 160 bar and To dose and mix them into an high pressure mixing head properly sealed To test the expansion in pressure conditions up to 160 bar by means of a special spherical c
Slide 39: Next action: begin the prototyping phase
Next action: begin the prototyping phase The K12 project will continue with the application to a prototype refrigerator. In the mean time we will set up the type of chemicals and the type of expansion conditions that can further improve the reduction of the cells size and the control of the filling
Slide 40: Thank You
K12- PU Disruptive technology to dramatically improve Energy Efficiency of Household Appliances Thank You With the contribution of the LIFE financial instrument of the European Community Form 830-044-0717 K-12 CONFIDENTIAL