POLYSTYRENE FOAM INSULATION: IMPLEMENTATION OF ALTERNATE SUSTAINABLE FLAME RETARDANT

摘要

Sustainable solutions are being increasingly demanded in the construction product market place. Polystyrene insulation is an increasingly important component of green construction. The benefits of insulation in residential and commercial buildings include lower energy consumptions, improved thermal comfort, reductions in the first costs of the heating and cooling equipment and reductions in CO2 emissions from the burning of fossil fuels across the United States. As with all foam insulations, polystyrene foam insulation is combustible and must comply with stringent building and fire codes, which have been in place since 1976. The basic requirement in codes is a flame spread index of 75 or less and a smoke developed index of 450 or less when tested in accordance with ASTM E84, in addition to separation of the foam insulation from building occupants through use of a thermal barrier, typically 1/2" gypsum board. Additional requirements are in place depending upon the particular application. Like many other building products - from electrical wires to structural and decorative wood products to paint - foam insulation uses flame retardants to protect people and property from the hazards of fire. Flame retardants used in foam insulation meet current regulations and their history of safe use is supported by scientific research. Manufacturers are committed to product safety and the effectiveness of flame retardants, and support research and development efforts to continually advance and improve these materials. A recent announcement by the Design for the Environment program of the U.S. EPA detailed a suitable polymeric flame retardant for use in polystyrene foam insulation. The chemistry is a brominated polymeric flame retardant to replace Hexabromocyclododecane (HBCD). HBCD has recently been listed as a persistent organic pollutant (POP) under the UNEP Stockholm convention and is on the Authorisation List (Annex XIV) under the European Union REACH (Registration, Evaluation, Authorization and Restriction of Chemicals) Regulation and will be phased out. Response to these actions has led to phase out schedules in various geographies. While earlier conference papers have given an overview of the environmental, health and safety performance of this new polymeric flame retardant, this paper will focus more on the transition process required for an industry sector to incorporate a new additive. Thus it will give an indication of the degree of complexity involved in implementing such developed solutions through the approval of raw materials, plant qualification, product certification in different geographies and markets while throughout seeking to maintain the quality of the final product in terms of technical and environmental performance and meeting critical regulatory milestones, such as building and fire code requirements. If we use the Polymeric FR as an example, assuming that all goes to plan from conception, registration to implementation with full certification for 1 country, an estimate for the development and introduction of PS foam insulation containing the new flame retardant additive is in the range of 7-11 years. An update on the status of the transition to the new polymeric flame retardant alternative by the polystyrene foam insulation industry will also be provided as HBCD is phased out globally.