Flammability of fridge insulation foam produced … - HC flamability tests.pdfFlammability of fridge...

Flammability of fridge insulation foam produced with a hydrocarbon blowing agent LIT 7627 1

Flammability of fridge insulation foam produced with a hydrocarbon blowing agent

Version 1.0

December 2012


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We operate at the place where environmental change has its greatest impact on people’s lives. We reduce the risks to people and properties from flooding; make sure there is enough water for people and wildlife; protect and improve air, land and water quality and apply the environmental standards within which industry can operate.

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Published by: Environment Agency Horizon house, Deanery Road, Bristol BS1 5AH Email: [email protected] www.environment-agency.gov.uk © Environment Agency 2011 All rights reserved. This document may be reproduced with prior permission of the Environment Agency.

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Contents

1 Summary ............................................................................................................. 4

2 Introduction .......................................................................................................... 4

3 Methodology ........................................................................................................ 5

3.1 Collection of samples .................................................................................... 5

3.2 Laboratory tests ............................................................................................ 7

4 Summary of Results ............................................................................................ 9

5 Conclusions ....................................................................................................... 10

5.1 Coding, classification and consignment of waste ........................................ 10

5.2 Safe handling, storage and treatment ......................................................... 11

5.3 Other wastes ............................................................................................... 12

6 Acknowledgments .............................................................................................. 12

Appendix 1 – Information recorded from sampled cooling appliancse ..................... 13

Appendix 2 – Results of burn rate tests for fridge foam samples ............................. 14


1 Summary

The aim of this study was to test the flammability of fridge1 insulation foam produced

using a hydrocarbon blowing agent in order to assess potential implications for the

prevention of accidents and incidents from the storage and treatment of waste

fridges. This report would also be used to clarify and review appropriate classification

and coding under the Duty of Care and Hazardous Waste Regulations2.

The study found that all tested foam samples should be considered “highly

flammable” under European Test Method A.10 Flammability (Solids)3 and concludes

that all fridge insulation foam produced using a hydrocarbon blowing agent should be

classified as hazardous waste, unless tested and demonstrated otherwise.

The results of the study will be used to:

- Identify options for minimising or preventing accidents and incidents

- Ensure that fridges containing hydrocarbon blown foams are sent to

appropriate permitted treatment facilities for storage and further treatment

- Inform the classification/consignment of waste foam produced by fridge

treatment activities; ensuring that a consistent approach is taken

2 Introduction

Modern fridges often contain insulating foam that is blown with hydrocarbon (HC)

blowing agents, usually cyclopentane but may also include n-pentane and i-pentane,

collectively referred to in this report as “pentane”. These hydrocarbon blowing agents

have replaced the use of chlorofluorocarbon (CFC) and Hydrochlorofluorocarbon

(HCFC) blowing agents (ozone depleting substances (ODS)) and

Hydrofluorocarbons (HFC) blowing agents (gases with high global warming potential

(GWP)). HC blowing agents are not ODS and do not have a high GWP but pose

greater fire risk due to their high flammability.

Permitted fridge treatment facilities accept fridges (those containing

CFC/HCFC/HFC/HC refrigerants and blowing agents) and process them to remove

the oil and capture the refrigerant from the cooling circuit. Once this is done, in

1 The term “fridge” is used in this report to refer to cooling appliances that contain insulating foam;

including fridges, fridge-freezers, freezers, chest-freezers and refrigerated displays.

2 See http://www.environment-agency.gov.uk/business/topics/waste/40047.aspx and

http://www.environment-agency.gov.uk/business/topics/waste/32180.aspx for further information.

3 Test method specified in Annex V of Directive 67/548/EEC and Appendix C of Environment Agency

Technical Guidance WM2 for the assessment of the flammability of a solid substance.

http://www.environment-agency.gov.uk/business/topics/waste/40047.aspx



accordance with the WEEE Directive and associated Defra BATRRT guidance4, the

degassed CFC, HCFC and HFC fridge carcasses must be treated in dedicated plant,

which will ensure that the blowing agent is collected and sent for destruction (e.g.

incineration).

The WEEE Directive and Defra BATRRT guidance do not explicitly require the

collection and destruction of hydrocarbon blowing agents; however appliances

containing foam produced with these blowing agents must be treated in “intrinsically

safe” plant. In addition to being processed in dedicated fridge plants, a number of

operators currently co-process degassed hydrocarbon fridges in scrap metal

shredders, whilst others process them in generic waste shredders.

There has been uncertainty regarding the correct classification of degassed

hydrocarbon fridges (containing foam with a hydrocarbon blowing agent) under Duty

of Care/Hazardous Waste Regulations and they have often been classified and

transferred as non-hazardous wastes (e.g. under European Waste Codes 16 02 14

(discarded equipment other than those mentioned in 16 02 09 to 16 02 13) or 20 01

36 (discarded electrical and electronic equipment other than those mentioned in 20

01 21, 20 01 23 and 20 01 35)).

Pentane blowing agents that are used in the insulating foam of fridges have the R11

(highly flammable) risk phrase (note: term not to be confused with “R11” CFC

refrigerant). The pentane is entrained within the foam and therefore the material

should be assessed for flammability as a solid in accordance with Test Method A.10

Flammability (Solids). If the foam is assessed as being hazardous (i.e. under the

R11 risk phrase) then it would be assigned the H3A (highly flammable) hazardous

property and appliances that contain it as a component would be classified

hazardous waste under European Waste Code 16 02 13* (discarded equipment

containing hazardous components other than those mentioned in 16 02 09 to 16 02

12) or 20 01 35* (discarded electrical and electronic equipment other than those

mentioned in 20 01 21 and 20 01 23 containing hazardous components).

3 Methodology

3.1 Collection of samples

The fridge appliances used to obtain the samples of insulation foam were provided

by European Metal Recycling Ltd at their Darlaston facility. A sample of fridge foam

was taken from 20 fridge appliances that had been identified as containing a

hydrocarbon (pentane) blowing agent. Each foam sample was cut from the side

panel of the appliance using a reciprocating saw and cut to the following

approximate dimensions: 200mm x 400mm (Figure 1). The height/depth of the

4 http://archive.defra.gov.uk/environment/waste/producer/electrical/documents/weee-batrrt-

guidance.pdf


sample depended upon the thickness of the foam panel, which was generally

between 40-100mm. Once cut, each sample was numbered, recorded and double-

bagged. For each sample, the following information was also obtained from the

corresponding appliance, where available:

Blowing agent type

Manufacturer and model

Fridge type and capacity/volume

Refrigerant type and charge

The information obtained from each appliance is summarised in Appendix 1.

The blowing agent type was recorded from markings stamped on the exterior of the

appliance and the other information (fridge type, refrigerant charge etc) was taken

from the appliance name plate (e.g. as shown in Figure 2).

Figure 1 Cutting of foam panel and collection of fridge information

Figure 2 Blowing agent marking and appliance name plate


3.2 Laboratory tests

The samples of fridge insulation foam were tested by the Environment Agency

National Laboratory Service (NLS), Nottingham, following Test Method A.10

Flammability (Solids). The blowing agent contained in each of the samples was

analysed and confirmed using gas chromatography mass-spectrometry (GC MS).

Following the test method, test samples were cut as unbroken strips from the foam

panels to the following dimensions: 250mm long, 20mm wide by 10mm high. The

test samples were cut to the required shape using a hacksaw blade and an

aluminium cutting guide (shown in Figure 4).

Test method A.10 requires all substances to be subjected to a preliminary screening

test, prior to the burning rate test. All samples satisfied the requirements of the

Figure 3 Double-bagged samples of foam in laboratory

Figure 4 Cutting of test sample from foam panel


preliminary screening test (in terms of substance ignition and propagation of

combustion) and were therefore passed on to the burning rate test.

For the burning rate tests, the samples of foam were placed on non-combustible

plates inside a fume cupboard and lit at one end using a gas burner. The

propagation of the flame along the length of the sample was recorded using a digital

stopwatch.

Test method A.10 states that a substance should be considered highly flammable

when the burning rate over 100mm of any test sample is less than 45 seconds. The

method requires the rate of burning over 100mm of the sample to be measured after

the flame has burned an initial distance of 80mm. These two distances were marked

out on the non-combustible plates positioned below the test samples so that the

burning rate of the flame over the required 100mm could be timed using the

stopwatch (as shown in Figure 5).

1) Ignition of test sample

2) Flame propagation reaches

80mm marker, stopwatch started

3) Flame propagation reaches

180mm marker, stopwatch stopped

The test method requires that the test is performed six times unless a positive result

is observed earlier. All test samples provided a positive result, however the burn rate

test was repeated on three test samples cut from each panel (i.e. 60 tests were

carried out in total, with 3 test samples taken from each of the 20 foam panels).

Figure 5 Trial run of burning rate test

80mm

Markers

180mm


4 Summary of Results

The results of the burn rate tests and GC MS analysis carried out on the samples cut

from the fridge insulation panels are tabulated in Appendix 2.

Blowing agent type

The GC MS analysis of the blowing agent(s) contained in the foam panels confirmed

that each panel contained a hydrocarbon blowing agent, as had been marked on the

exterior of the appliances (see Appendix 1). The results also confirmed that

cyclopentane was the principal hydrocarbon blowing agent used in the foam panels.

However, 9 foam panels also contained iso-pentane as a minor constituent (with

cyclopentane identified as the main constituent), and 2 panels contained iso-pentane

as the main constituent.

Burning rates

All foam samples burned the required distance (100mm) in a time under 20 seconds.

The slowest burn rate recorded was 19.3 seconds (test sample 3, fridge 1) and the

fastest recorded was 2.8 seconds (test sample 1, fridge 8). The average burning rate

time across all 60 samples was 9.4 seconds.

The fastest and slowest burning samples both contained cyclopentane blowing

agent. The type of hydrocarbon blowing agent did not appear to have a significant

effect on the burning rate of the foam samples, with the average burning rate

between the 3 types (i.e. those containing a) cyclopentane, b) cyclopentane and iso-

pentane (as minor constituent) and c) iso-pentane (as main constituent)) being 9.7,

9.3 and 9.2 seconds respectively. Therefore, variability in burning rate between

samples was possibly due to variability in hydrocarbon blowing agent content

(quantity), rather than type.

Test method A.10 states that a substance should be considered as highly flammable

when the time of burning in any tests carried out according to the test procedure is

less than 45 seconds. As illustrated in Figure 6, the burning times recorded for all 60

test samples were significantly less than 45 seconds (all were below 20 seconds)

and therefore all tested material were considered “highly flammable” in accordance

with the test procedure.

Flammability of fridge insulation foam produced with a hydrocarbon blowing agent LIT 7627

10

Figure 6 Average burn times of foam panel samples taken from each fridge

5 Conclusions

As stated in section 4, based upon the test data obtained from this investigation, it

was concluded that all fridge panels tested should be considered as highly

flammable solid materials. As a result of this, we believe that all fridge insulation

foam produced using a hydrocarbon blowing agent should be considered highly

flammable, unless tested and demonstrated otherwise.

This conclusion has the following potential implications:

5.1 Coding, classification and consignment of waste

When assessing waste electrical equipment, such as fridges, it is the presence or

absence of hazardous components that determines if they are classed as hazardous

waste or not. Insulation foam that has been blown with a hydrocarbon blowing agent

(pentane) has been demonstrated to posses the hazardous property H3A (highly

flammable). This means it is a hazardous component and would, amongst other

components, make a fridge a hazardous waste.

On the basis of this, degassed fridges (appliances that have had the

refrigerant/compressor removed) that contain insulation foam produced with a

hydrocarbon blowing agent should be classified and consigned under one of the

following hazardous waste codes: 16 02 13* or 20 01 35*. Similarly, foam panels

0.0

10.0

20.0

30.0

40.0

50.0

60.0 B

urn

rat

e (

seco

nd

s)

Fridge number

45 second threshold specified by test method A.10


11

mechanically cut and removed from fridges that contain a hydrocarbon blowing

agent should be classified and consigned under the 19 12 11* waste code.

Waste residues resulting from waste shredding or fragmentising activities that co-

process degassed fridge carcasses that contain insulation foam produced with a

hydrocarbon blowing agent should be classified as hazardous waste under code 19

02 04* (premixed wastes composed of at least one hazardous waste), unless it can

be demonstrated that the hydrocarbon blowing agent has been removed from the

foam by the shredding process5.

The requirements of the revised Waste Framework Directive (2008/98/EC),

specifically regarding the ban on the mixing of hazardous wastes (Article 18), will

apply to the management of these hazardous wastes.

5.2 Safe handling, storage and treatment

In Defra’s WEEE BATRRT guidance, it is stated that appliances containing

hydrocarbons must be processed in intrinsically safe equipment. Many pentane

blown fridges are currently processed in dedicated fridge plant where the foam is

separated, milled and heated to release and collect the blowing agent. Typically, this

is done under a nitrogen inerted atmosphere to meet the BATRRT criteria. However,

not all dedicated treatment plant are currently inerted and it is unclear how these

plants will operate with the changing proportions of ODS to pentane fridges (i.e. as

the proportion of fridges that contain pentane increases).

A small number of other operators currently co-process pentane blown fridges in

light iron shredders, which could potentially pose a risk if the shredding process

releases the pentane (although we understand that the air dilution provided might be

adequate to keep gas concentration below the explosive limit) or if a spark ignites

the foam material. We also understand that some operators are using general waste

shredders to process pentane fridges, which may cause greater safety concerns.

We are currently in discussions with the HSE to confirm the definition of “intrinsically

safe equipment”.

It must be ensured that at sites accepting or producing wastes consisting of or

containing hydrocarbon-blown fridge foam appropriate measures are provided for

their safe storage and handling to prevent fire initiation and escalation/propagation

(i.e. appropriate measures for waste separation/segregation (e.g. fire breaks/walls)

and the prevention of flammable atmospheres).

5 See Environment Agency guidance Classifying and coding wastes from physico-chemical treatment

facilities HWR06 for further information on the principles of treating and classifying hazardous wastes,

available from http://www.environment-agency.gov.uk/business/topics/waste/104765.aspx



12

5.3 Other wastes

This investigation has focussed on the flammability of hydrocarbon-blown fridge

insulation foams. However, the same potential issues/implications may apply to the

classification/consignment, storage and treatment of other similar waste foam

materials that contain a hydrocarbon blowing agent (e.g. building insulation foam,

insulation foam contained in other types of appliances, furniture foam and packaging

materials).

Under the requirements of the Duty of Care and Hazardous Waste Regulations, it is

the responsibility of the waste producer to ensure that all wastes are described and

classified correctly, taking into account any relevant hazardous properties.

6 Acknowledgments

We wish to acknowledge the help provided by:

European Metal Recycling, Darlaston - for providing and assisting with the

collection of the fridge foam samples.

The National Laboratory Service, Nottingham - for assisting in the design and

implementation of the testing methodology.

For further information, please contact National Operations, Waste Technical

Services.


Appendix 1 – Information recorded from sampled cooling appliancse

Fridge Manufacturer/model Description Type/capacity Blowing agent mark on appliance

Refrigerant type & charge

1 Electrolux / ERN2821 Fridge freezer Type 2 / 283l Pentane R600A 80g

2 BEKO / TLDA5215 Fridge (large) Type 2 / 260l C-Pentane/ I-pentane R600A 28g

3 Bosch / KSV24214B/02 Fridge freezer Type 2 / 222l n-Pentane R600A 56g

4 LEC / EL550BW Fridge Type 1 / 13l Pentane R600A 20g

5 Unidentified Fridge Type 1 Pentane Unidentified *

6 Bosch / unidentified Fridge freezer Type 2 / 315l Pentane R600A *

7 Hotpoint / RLA18G Fridge freezer Type 2 / 353l Pentane R600A 30g

8 LEC / T350CW Fridge freezer Type 2 / 190l Pentane R134A 70g

9 Electrolux / ER6641T Fridge Type 1 / 159l Pentane R134A 55g

10 Whirpool / RPT531-1/H Fridge freezer Type 2 / 189l C-Pentane R600A 52g

11 Scandinova Fridge Type 2 Cyclopentane R134A *

12 Indesit / RGV1142UK Fridge Type 1 / 91l Cyclo / Iso pentane R134A 60g

13 Unidentified Freezer Type 1 Cyclopentane R600A *

14 Whirlpool / RE128 Fridge Type 1 / 118l Cyclopentane R600A 30g

15 Proline PLF140W Fridge Type 1 / 110l Cyclopentane R600A 25g

16 Hotpoint Freezer Type 2 Pentane R600A *

17 Kyoto KU96FF Freezer Type 2 / 260l Pentane R600A 60g

18 Hotpoint / FFA71P Fridge freezer Type 2 / 292l Pentane R600A 43g

19 BEKO / T3DA524FW Freezer Type 2 / 197l C-pentane I-Pentane R600A 44g

20 Hotpoint / FZA50P Freezer Type 2 175l Pentane R600A 37g * Charge (quantity of refrigerant in cooling circuit) not stated on appliance


Appendix 2 – Results of burn rate tests for fridge foam samples

Fridge

Burn times (100mm in secs) Average burn time Identified blowing agent(s) from GC analysis Sample 1 Sample 2 Sample 3

1 7.5 12.8 19.3 13.2 Cyclopentane

2 10.7 9.8 9.7 10.1 Major constituent cyclopentane, minor iso-pentane


4 7.1 11.7 8.9 9.2 Cyclopentane

5 15.7 7.9 8.0 10.5 Major constituent iso-pentane, minor pentane

6 6.2 11.7 5.8 7.9 Major constituent iso-pentane, minor pentane


8 2.8 5.5 6.7 5.0 Cyclopentane

9 10.9 4.8 10.7 8.8 Cyclopentane


11 10.1 5.0 9.1 8.1 Cyclopentane


13 5 13.5 10.4 9.6 Cyclopentane

14 9.8 15.9 12.8 12.8 Cyclopentane

15 5 8.4 3.9 5.8 Cyclopentane


17 11.3 16.1 15.8 14.4 Cyclopentane



20 8 9.2 7.7 8.3 Major constituent cyclopentane, minor iso-pentane

Average 9.4

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