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Innovation & Technologie Angebot

Production technology of insulating foaming material - eco-expanded polystyrene

Country of Origin: Ukraine
Reference Number: TOUA20200317001
Publication Date: 20 March 2020

Summary

This Ukrainian R&D company has developed a technology for the production of a new type of heat and sound insulating and fire-resistant material, which is a complete replacement for expanded polystyrene and has undeniable advantages, both of the material itself and the technology of its production and use. The company is looking for partners in a joint venture agreement or license agreement.

Description

The Ukrainian R&D company established in 2016 is engaged in developing new technologies in the field of ecology, waste management, create materials for construction, generate green energy. The company has developed a new heat-insulating material, which allows to completely replace expanded polystyrene, previously used in construction for insulation of building facades and sound insulation. Due to a large number of shortcomings, in particular, the emission of toxic phenolic fumes during combustion, the difficulty of disposing of waste, damage by rodents, and also the fragility, the foam has been banned for use in the EU since 2016. Existing analogs do not meet the modern requirements of consumers. Analogs (basalt slabs, polyurethane foam, etc.) are either more expensive, or heavy, and have limitations on their use, or are toxic when burned, or have poor fire protection.



  The eco-expanded polystyrene is produced locally at plants of various capacities, from individual to industrial, and looks like a safe, eco-friendly foam that hardens within 10-15 minutes. It's poured into the formwork, can be applied to the surface, having high adhesion. The density of the foam is adjustable, which makes it possible to have a different texture and physical properties (thermal conductivity, hardness \ surface hardness, noise and fire resistance, fire protection, etc.), which makes foam universal and very effective for use.



  The company's product can be a material for the production of a new type of building materials, including eco sandwich panels. It does not contain phenol and formaldehyde. Material for external use contains only a concentration of bound formaldehyde of 0.01% of the total volume of foam, which is absolutely safe for humans when burning.



  When installing the company's product, there are practically no scraps or other types of waste, i.e. almost all 100% of the material is used.



  No need to use a large number of related mounting materials when installing insulation on the facades compared to polystyrene (wall mounts). This gives significant cost savings during installation - there is no need to drill walls, use a variety of fasteners, nets, a sharp reduction in hours, and other overhead costs. The foam is poured into the formwork or inside the facade material.



  Composition of the installation: pumps, dispensers, air compressor, control, and monitoring unit, tanks with components and water, process reactor (foam generator-mixer), hoses and supply hoses, a system of valves and taps. 



  The technology is easily scalable and installations can be produced at the request of the end-user.



  The industrial pilot plant, proposed for implementation at the initial stage, has a foam capacity of 5 to 10 m3 per hour. The installation was performed in a mobile version, it has an approximate size of 1x1x1 meter and a total weight with loading o of 400 kg. It is mounted on a pickup truck to the car.



  The Ukrainian R&D company is interested in creating a joint venture in the EU, the purpose of which is:

  - manufacture of work units and mechanisms in the EU;

  - large-knot assembly and production of finished plants for the production of eco-polystyrene (and their modifications) in the EU with the partial manufacture of some components in Ukraine (know-how);

  - warranty and post-warranty service of the supplied equipment and warranty and post-warranty repair;

  - supply of consumables and components. 

  There is an option to sell patents, technology and the entire range of intellectual property to an interested buyer under a license agreement.

Advantages and Innovations

The advantages of the eco-expanded polystyrene  include its following properties:

- Does not support combustion;

- When exposed to an open flame and the high temperature does not emit toxic substances and gases;

- Does not shrink and is not subject to cracking;

- Has pronounced antibacterial and fungicidal properties (not subject to damage by rodents, insects, mold);

- High level of sound insulation (equal to or higher than polystyrene);

- High heat resistance;

- Lack of vapor permeability - no cold bridges are created, etc.

- The volume cost in terms of 1 m3 is commensurate with the price of polystyrene, but with significant savings in materials and labor costs during installation;

- Undemanding to the qualifications of workers (simple filling cavities from the sleeve);

- Significantly reduced timelines for finishing facades compared to polystyrene.

- Availability of raw materials in the local market.

- Low power consumption of installations, small size.

- The absence of the need to deliver the material to the installation site is made locally in any quantities. No need for warehouses.

- Ability to produce foam of any color using pigments;

- High speed of hardening - 10-15 minutes.

- Lack of smell, noise, waste during installation.

- Ecological safety for people and the environment;

- It is easily and environmentally friendly disposed of; when it enters the soil it turns into nitrogen fertilizer;

- Warranty period - up to 50 years.

Stage Of Development

Prototype available for demonstration

Requested partner

1. Ukrainian R&D company is interested in cooperation and creation of a joint venture with companies that can help with:

- product certification and patenting in the EU,

- conducting marketing and promotion actions,

- manufacture of work units and mechanisms in the EU,

- large-knot assembly and production of finished plants (and their modifications) in the EU with the partial manufacture of some components in Ukraine (know-how);

- conducting tests;

- service of the supplied equipment and warranty and post-warranty repair;

- supply of consumables and components;

2. Ukrainian R&D company is looking for companies that work in the field of construction, and which would be interested in acquiring the technology.