r Wiseman Ceramic Composite - Fly Ash · Composite Insulation Anne Oberlink, Tom Robl, Bob Jewell,...

Fly Ash De

rived

Ceram

ic‐

Polyurethane

Foam Com

posite

Insulatio

n

Anne

Obe

rlink, Tom

Rob

l, Bo

b Jewell, Brock Marrs, Joh

n Wise

man

University

of K

entucky Ce

nter fo

r App

lied Energy Research –Lexington, Kentucky

NuForm

Materials –Sadieville, Kentucky

2015

Wo

rld

of

Co

al A

sh (

WO

CA

) C

on

fere

nce

in N

asvh

ille,

TN

- M

ay 5

-7, 2

015

htt

p:/

/ww

w.f

lyas

h.in

fo/

‐Polyurethane Foam

Insulatio

n

•One

of the

best insulating

materials on

the market

•For rigid foam

panels, different

thicknesses a

re available to su

it diffe

rent app

lications

•Spray fo

am polyurethane

provides both insulatio

n and air

sealing, as it e

xpands to

fill gaps

and cracks

•Easy to install

2

Polyurethane

Foam Insulatio

n

•Has a high oxygen

index

•Manufactured from

petroleum

de

rivatives

•Untreated

and

exposed

to high

temps or flame, th

e foam

s will

burn vigorou

sly and

spread

•Burning

characteristics req

uire

manufacture with

fire re

tardant

for o

ptim

ally sa

fe app

lication

3

Polyurethane

Foam Insulatio

n Fire Retardants

•Halogen

ated

fire re

tardants fo

rm

a slo

w burning

char o

n the foam

•No longer con

sidered

desira

ble

due to enviro

nmental

considerations –

•Po

ssible leaching

into th

e environm

ent

•Accumulating in bird

s, m

ammals,

and fish

•Accumulating in so

il and sediment

4

Alternatives to

Che

mical Fire

Retardants

•Add

ition

of u

ltrafine fly

ash‐

deriv

ed ceram

ic particles to

polyurethane

foam

allows for

multip

le ben

efits, including:

•Lower flam

mability of the

PU fo

am•Higher strength and

toughn

ess

•Re

duced overall cost

•Fine particles a

lso fo

rm an

inorganic crust o

n the foam

SEM im

age of ultrafine fly

ash‐derived

ceram

ic particles recovered

from

coal com

bustion ash.

5

‐Materials/Techniqu

es Used

•Ultrafine ceramics (D 5

0= 5 microns) recycled from

disc

arde

d coal com

bustion ash

from

:•Kingston

Fossil Plant (Ten

nessee

Valley Au

thority

; Kingston, Ten

nessee)

•Kyger C

reek Pow

er Plant (O

hio Valley Electric Corpo

ratio

n; Che

shire

, Ohio)

•Ghe

nt Pow

er Plant (K

entucky Utilities; C

arroll Co

unty, Kentucky)

•To fabricate compo

site foam

s, fly‐ash de

rived

ceram

ics w

ere blen

ded into

commercially available po

lyurethane

foam

resin

s:•3‐lb den

sity; U.S. C

ompo

sites, W

est P

alm Beach, Florid

a

•Low den

sity, low strength, high insulatin

g capacity

6

‐ASTM C303 –Standard Test M

etho

d for D

imen

sions and

De

nsity

of P

reform

ed Block and

Board‐Type Thermal Insulatio

n

•Den

sity of 5 blocks w

ere

measured at th

e same tim

e:•Width and

length of e

ach block

were measured to nearest m

m in

2+ locatio

ns•Thickness o

f each block measured

4+ times

•Blocks were weighed

•De

nsities were calculated

7

‐ASTM C303 –Standard Test M

etho

d for D

imen

sions and

De

nsity

of P

reform

ed Block and

Board‐Type Thermal Insulatio

n

•De

nsity

calculatio

n were also used to

compare com

posite foam

s:“Ben

ch‐top

Mold vs. “Pilot‐scale Mold”

•Re

sults:

•AD

C increased weight o

f PU fo

ams

whe

n compared to Con

trol fo

am•Re

gardless of sou

rce, iron

, or cou

pling

agent, AD

C adde

d sim

ilar w

eight

•Exception is Kingston

with

Iron

for

“pilot‐scale”, due

to large am

ount of

iron‐rich material

8

‐ASTM D16

21 –Standard Test M

etho

d for C

ompressiv

e Prop

ertie

s of Rigid Cellular P

lastics

•Co

mpressiv

e Strength was te

sted

:•Test sp

ecim

ens (2 in. x 2 in. x 2 in.)

were cut

•Samples te

sted

in dire

ction of

expansion (lo

ngitu

dinal) and

perpen

dicular to expansion (traverse)

–aniso

trop

y

9

‐ASTM D16


etho

d for C

ompressiv

e Prop

ertie


lastics

•Results:

•Ad

ditio

n of 30%

(by weight) ADC

improved

strength of P

U fo

am•Im

provem

ent w

as dep

ende

nt on ash source

•Ghe

nt and

Kingston are pred

ominately Class F

(high alum

inum

/low calcium

)•Kyger C

reek closely re

sembles Class C (h

igh calcium)

10

ASTM

D16


etho

d for C

ompressiv

e Prop

ertie


lastics

•Results:

•Foam

s with

ceram

ic produ

cts w

ith iron

‐rich particles w

ere also produ

ced and

tested

•Iro

n‐rich particles d

id not adversely affe

ct PU fo

ams, but strengthen

ed th

em

more than

ceram

ics a

lone

11

‐ASTM D16


etho

d for C

ompressiv

e Prop

ertie


lastics

•Silane

(SiH

4) cou

pling agen

ts are

used

to promote adhe

sion

betw

een additives and

matrix

materials du

ring compo

site

prod

uctio

n•Silane

, in solutio

n form

, was

blen

ded with

the AD

C•Silano

l (Si‐O‐H) w

as fixed on

to th

e surface of ADC

via hydrogen bo

nding

with

surface hydroxyl group

s (‐OH) on

the ceramics

12

‐ASTM D16


etho

d for C

ompressiv

e Prop

ertie


lastics

•Results:

•Ad

ditio

n of silane

strengthen

ed th

e compo

site foam

s beyon

d the be

nefit of

adding

untreated

ceram

ics

•It was anticipated

that ADC

with

out iron particle wou

ld perform

better

13

ASTM

C272 –Standard Test M

etho

d for W

ater Absorption of

Core M

aterials for S

andw

ich Co

nstructio

ns

•Water absorption is an

impo

rtant a

spect o

f insulation, especially if it’s

installed be

low groun

d level, or can

com

e into con

tact with

moisture

•Water absorption can lead

to:

•Mildew

•Mold grow

th•Ro

t•Diminish

ed perform

ance

•Closed cell foam

s (PU

) usually provide

a vapor barrie

r, bu

t impo

rtant

to te

st th

e additio

n of ADC

14

ASTM


etho

d for W

ater Absorption of

Core M

aterials for S

andw

ich Co

nstructio

ns

•Spe

cimen

s were cut (3 in. x 3 in.

x 0.5 in.) and weighed

•5 sp

ecim

ens p

er fo

rmulation

were completely im

mersed in

water (7

3 ±5°F)

•After 24 ho

urs:

•Specim

ens rem

oved

from

water

•Shaken

to re

move surface water

•Weighed

•Percent w

eight increase calculated

15

ASTM


etho

d for W

ater Absorption of

Core M

aterials for S

andw

ich Co

nstructio

ns

•Decrease in amou

nt of w

ater

absorbed

during 24

hou

r im

mersio

n was gen

erally

observed

•Iron‐rich materials were show

n to

perform worse

•Silane

detracted

slightly overall

•With

the exception of Kingston

with

Fe, ADC

’s pe

rformed

as g

ood

or better than Co

ntrol

16

‐FMVSS 30

2 –Flam

mability of M

aterials Used in th

e Interio

r of

Motor Veh

icle Occup

ant C

ompartments Test

•Prim

ary Objective –de

term

ine the feasibility of u

se ADC

’s as a flam

e retardant in PU

foam

for insulation

•Re

ctangular p

anels (4 in. x 12 in. x 1 in.) were cut from larger com

posite

foam

panels (0%

, 15%

, 30%

, and

45%

(by weight) ADC

)•Govmarktest:

•Mou

nted

specim

ens v

ertically

•38

mm flam

e from

a Bun

sen bu

rner was placed 19

mm below

center o

f bottom edge

of sp

ecim

en fo

r 15 second

s•Distance th

e flame traveled

and

burn tim

e were recorded

•Bu

rn ra

te was calculated if flames traveled

at least 38 mm from

edge

17

‐FMVSS 30

2 –Flam

mability of M

aterials Used in th

e Interio

r of

Motor Veh

icle Occup

ant C

ompartments Test

•Con

trol (0

wt%

ADC

):•All 8 sp

ecim

ens ignite

d and

flames traveled

beyon

d the

38mm th

reshold

•On average, con

trols b

urne

d at

a rate of 7

9.8 mm/m

in•All 8 = B grade

•Specim

en ignites, burning

progress m

ore than

51 mm

beyond

the 38mm timing start

line

18

FMVSS 30

2 –Flam

mability of M

aterials Used in th

e Interio

r of

Motor Veh

icle Occup

ant C

ompartments Test

•15

wt%

ADC

:•All 8 sp

ecim

ens ignite

d•Only 6 remaine

d lit past tim

e line

•Bu

rn ra

te was calculated for o

nly 5

of 8 sp

ecim

ens

•Average bu

rn ra

te was 57.6

mm/m

in•5 specim

ens =

B grade

•2 specim

ens =

SE grade

•Self‐extin

guish

ing –specim

en

ignites, but doe

s not burn to th

e tim

ing zone

•1 specim

en = SE/NBR

grade

•Specim

en ignites, burning

progresses to

timing line,

extin

guish

es with

in 51 mm beyon

d start line

19

‐FMVSS 30

2 –Flam

mability of M

aterials Used in th

e Interio

r of

Motor Veh

icle Occup

ant C

ompartments Test

•30w

t% and

45w

t% ADC

:•All spe

cimen

s = SE grade

•If the specim

en ignited at all, th

e fla

mes extinguish

ed before

reaching

the 38

mm line

•Results su

ggest A

DC’s have

potential as flame retardants,

or at least have the po

tential

to be able to

slow

the bu

rn

rate

20

NFPA 28

6 –Standard M

etho

ds of Fire

Tests fo

r Evaluation

Contrib

ution of W

all and

Ceiling Interio

r Finish

to Roo

m Fire

Growth Test

•Kn

own as th

e Full Ro

om Te

st•Used to determine the contrib

ution of interio

r finish

materials to ro

om fire growth

durin

g specific fire expo

sure con

ditio

ns•Measures:

•Extent of fire

growth

•Rate of h

eat release

•Total heat release

•Time to flasho

ver

•Time to flam

e extension

•Total heat flux incide

nt to

the flo

or•Upp

er level gas te

mpe

rature

•Sm

oke ob

scuration

•Prod

uctio

n of carbo

n mon

oxide

•Em

issions of o

ther com

bustion gases

21

‐NFPA 28

6 –Standard M

etho

ds of Fire

Tests fo

r Evaluation

Contrib

ution of W

all and

Ceiling Interio

r Finish

to Roo

m Fire

Growth Test

•Full Roo

m te

st has tw

o ph

ases:

•First –

prelim

inary test of two pane

ls pu

t togethe

r to form

a “room

corne

r”•Second

–consists o

f six fu

ll‐sized

panels forming tw

o walls and a ceiling

•Prelim

inary “roo

m corne

r” te

st is necessary to

ensure that a sm

aller

amou

nt of m

aterial can

with

stand the intensity

of th

e flame with

out:

•Dripping

flam

ing material

•Da

maging the test app

aratus

•Creatin

g a fire that risks spreading

beyon

d

containm

ent

22

‐NFPA 28

6 –Standard M

etho

ds of Fire

Tests fo

r Evaluation

Contrib

ution of W

all and

Ceiling Interio

r Finish

to Roo

m Fire

Growth Test

•Trim

med

panels w

ere mou

nted

vertically at jun

cture of tw

o 8 ft.

x 12

ft. test w

alls

•Panels received full test

expo

sure of 4

0 kW

flam

e for 5

minutes, followed

by 160 kW

flame for 1

0 minutes

•Panels a

re observed du

ring the

test –if fla

mes sp

read

to edges

of panels o

r ceiling, or if m

aterial

drippe

d fla

mes, test is stopp

ed

23

‐NFPA 28

6 –Standard M

etho

ds of Fire

Tests fo

r Evaluation

Contrib

ution of W

all and

Ceiling Interio

r Finish

to Roo

m Fire

Growth Test

•First a

ttem

pt:

•Tw

o pane

ls were sent

bare, leaving

PU fo

am

fully exposed

to th

e fla

me

•These pane

ls survived

for

1 minute, 20 second

s of

the lesser flam

e intensity

(40 kW

) before the fla

mes

reache

d the ceiling

of the

testing apparatus

24

‐NFPA 28

6 –Standard M

etho

ds of Fire

Tests fo

r Evaluation

Contrib

ution of W

all and

Ceiling Interio

r Finish

to Roo

m Fire

Growth Test

•It w

as determined

that PU fo

ams

shou

ld be tested

with

a gypsum

wallboard covering

•Test req

uires m

aterials of

interest be installed in te

st

apparatus as th

ey wou

ld be in

building application

•Secon

d attempt:

•45

wt%

com

posite foam

blend

ed

and spread

on back of a

4 ft. x 8 ft.

pane

l of ½

in. gypsum wallboard

25

‐NFPA 28

6 –Standard M

etho

ds of Fire

Tests fo

r Evaluation

Contrib

ution of W

all and

Ceiling Interio

r Finish

to Roo

m Fire

Growth Test

•Results:

•Im

proved

from

first a

ttem

pt•Pane

ls faced with

gypsum wallboard su

rvived

first 5

minutes of the

40 kW

flam

e expo

sure

•Flam

e intensity

was increased to 160

kW, panels survived

an add

ition

al 4 m

inutes, 58 second

s•Althou

gh panels d

id not re

ceive a passing grade, th

e results were very promising

26

‐ASTM Stand

ard C1


etho

d for S

teady‐State

Heat F

lux Measurements and

The

rmal Transmission Prop

ertie

s by M

eans of the

Guarded

‐Hot‐Plate App

aratus

•Prim

ary ob

jective of te

st was to

dire

ctly m

easure th

e thermal con

ductivity

of A

DC PU fo

am com

posites

•Services o

f Precisio

n Measurements and

Instruments

Corporation (PMIC; C

orvallis, OR) were used

•Specialize in m

easurin

g:•Co

efficient of the

rmal expansio

n•Co

efficient of m

oisture expansion

•Thermal Con

ductivity

27

‐ASTM Stand

ard C1


etho

d for S

teady‐State

Heat F

lux Measurements and

The

rmal Transmission Prop

ertie

s by M

eans of the

Guarded

‐Hot‐Plate App

aratus

•Results:

•Erratic

tempe

ratures w

ere

observed

while te

sting at highe

st

temps

•Thermal con

ductivity

value

s at

‐18°C and 23°C were typical of

closed

‐cell PU fo

am m

aterials

•Calculated

R‐value

s are goo

d indicator A

DC PU fo

ams w

ould

compe

te very well w

ith current

insulatin

g materials

•2 square sp

ecim

ens (6 in. x 6 in. x 1 in.)

were cut –

30wt%

28

‐Con

clusions

•ADC

PU fo

am have show

n a marked increase in

efficien

cy and

pe

rformance whe

n compared to current PU fo

am•A

DC’s:

•Show

potentia

l as flame retardant

•Increase com

pressiv

e strength

•De

crease water absorption

•Overall, ADC

’s are a very promising

material, with

great potentia

l for ADC

PU

foam

com

posites

29

Thank you!

30

r Wiseman Ceramic Composite - Fly Ash · Composite Insulation Anne Oberlink, Tom Robl, Bob Jewell,...

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Transcript of r Wiseman Ceramic Composite - Fly Ash · Composite Insulation Anne Oberlink, Tom Robl, Bob Jewell,...