FINEfoam140 (Poylsocyanurate y Foam) 보냉팀 DONGSUNG FINETEC Co.Ltd.
CONTENTS A 1. PIR 소개 A2. 2 FINEfoam 140 Production Process A 3. PIR 적용사진 4. Certificate & 시험성적서 5. 생산방식비교 ( 연속식과단속식 ) 6. 단열재별열전도율비교 7. 단열재비교 (PIR / Cellular Glass) 8. Main Reference
1. PIR 소개 POLYURETHANE FOAM 은 분자간결합구조가우레탄 -NHCOO- 로되어있는다공성기포 (Cell) 를가지고있는고분자물질 Cell Membrane (Window) 골격 /Flame ( Foam Cell 구조 ) <Resin> <MDI> <Mixing> <Foaming> <Product>
1. PIR 소개 PUR 반응 (Polyurethane Reaction) R-N=C=O + R O H -> [ -R-N-C-O-R-] n l ll H O PIR 반응 (PolyIsocyanurate Reaction) 3 R-N=C=O Isocyanate Trimerization Catalyst / Heat R O C N R N C C N O R O Isocyanurate
1. PIR 소개 PIR(FINEfoam 140) 의특성 1. 높은난연성과탁월한열전도율값으로동일한두께적용시, 여타단열재중열효율이가장뛰어남. ( 비교표첨부 ) 2. 연소시연기발생이적고난연성탁월. 3. Trimer 반응으로우수한 Cell구조가형성되어열전도값이낮아 우수한단열성보유. 4. 적용온도가 110 부터초저온도즉, -196 까지의조건에서 탁월한보온성발휘. 5. 높은기계적강도로구조물시공에적합하여 Plant 공사에많이 사용되며유지보수가간단. 6. 뛰어난시공성으로복잡한시공구간도간단히시공.
1. PIR 소개 물성 (Properties) ITEM UNIT FINEfoam 140 (PIR) Test Method Density kg/m3 Min. 40 ASTM D 1622 Thermal Conductivity ( 열전도율 ) Fresh Max.0.019 W/mK 180 Day Aged Max.0.023 ASTM C 177 or ASTM C 518 Closed Cell % Min.90 ASTM D 2856 Water Vapor Transmission ( 투습율 ) 1.7 X 10^-3 ASTM E 96 Linear Coefficient Of Thermal Expansion ( 선팽창계수 ) 10^-6/ Max. 70 ASTM E 228 or ASTM D 696 Fire Resistance ( 난연성 ) Burning Time sec No defect ( 만족 ) (Max.120) KS M 3809 Spread Length Of Fire (Max. 60) mm No defect ( 만족 ) or BS 476 ASTM E 84 만족 Compressive Strength ( 압축강도 ) kg f / cm2 Min. 2.5 ASTM D 1621 f
1. PIR 소개 생산능력 (Production Capacities) DIV. PRODUCTS TYPE CAPA./YEAR PIR BLOCKS Ff120~280 230,000m3 INSULATION MATERIALS PIR BOARDS Fb120~220R 100,000m3 PIPE COVERS VARIABLE SIZE 42,000 m3 RAW MATERIALS PIR SYSTEM Fp100~900 10,000 ton * Based on one shift
2. FINEfoam 140 Production Process 1. LAB TEST PROPERTY TEST 4. AGING 2. BLENDING 5. CUTTING 3. FOAMING 6. PACKING
2. FINEfoam 140 Production Process 1. LAB TEST & PROPERTY TEST DEVELOPMENT OF PU RAW METERIAL
2. FINEfoam 140 Production Process 2. BLENDING BLENDING OF POLYOL, BLOWING AGENT, CATALYST etc
2. FINEfoam 140 Production Process 2. BLENDING ISOCYANATE BLOWING AGENT SILICONE POLYOL CATALYST A B BLENDING PIR
2. FINEfoam 140 Production Process 3. FOAMING CONTINUOUS FOAMING AT BUN LINE
2. FINEfoam 140 Production Process 4. AGING AGING OF PUR/PIR FOAM (Minimum 15 days)
2. FINEfoam 140 Production Process 5. CUTTING PIPE COVER CUTTING WITH CNC WIRE CUTTING MACHINE
2. FINEfoam 140 Production Process 6. PACKING PACKING WITH CARTON BOX ----------------- * Protection 1 ST :Cartonbox 2 nd : Air Bubbled Plastic film wrapping
3. PIR 적용사진 LNG Receiving Terminal Pipe Insulation
3. PIR 적용사진 LNG & LPG Receiving Terminal Pipe Insulation
4. Certificate & 시험성적서 ISO9001, ISO14001, OHSAS 18001
4. Certificate & 시험성적서 시험성적서 (KOTRIC, ASTM E 84)
5. 생산방식비교 ( 연속식과단속식 ) 연속식 (PIR-FINEfoam140) 과단속식 (PUR-Mold Type) 연속식 -PIR (FINEfoam140) 비교단속식 -PUR(Mold Type) Block 이동일생산Lot로품질이균일하고우수함. 균일성 개별생산으로균일성결여 CNC 로가공하여, 표면이깨끗하고 skin 딱딱한표면층 (ki (skin) 이있고, 이로인해 Crack 표면층이없음가능성이높음. 우수함. 모든 Block 이동일한물성 연속생산으로생산성이우수하여. 어떠한현장도적기납품준수함. 뛰어난난연성을가지며, 각종난연 Test시우수한등급을보유. 자기소화성을가져불꽃확산방지 CNC로 Programming g 하여가공 모든 Size 가공가능. 물성 생산성 난연성 Size 모든 Block 이혹은모든성형제품이 조금씩다른물성을가짐 금형의경우하루생산성이한정되어큰 Project 납품에문제많음. 자기소화성이없어, 화재에취약 금형생산의경우금형 (Mold) size 에 따라생산, 긴급생산분의경우문제있음. * PIR 은보냉단열재의가장중요한부분인일괄적인 Block 생산을가능하게함. * 일괄적이고균일한 PIR 생산으로, Ii Icing, Crack, 수증기침투등을막아줌. * 전세계모든 LNG 현장에서쓰이는 PIR 은연속식 LINE 에서생산됨.
5. 생산방식비교 ( 연속식과단속식 ) 단속식 LINE Air bubbles Hard skin * 단속식 LINE 은 Mold 하나당 1개의 Block 만생산이가능하므로 각 Block 마다불규칙적인물성을가짐. * 단속식 LINE으로 PUR 생산시 Hard Skin 을만들어, PUR 표면과 안쪽에많은 Air Bubbles 이발생함.
5. 생산방식비교 ( 연속식과단속식 ) 단속식 LINE Icing * 보냉재는민감하기때문에, 아주작은 Air Bubble 이나외부의 Icing 등으로 심각한 Damage 를입을수있다. * 단속식 LINE 에서생산된제품을사용한현장에서는 Icing 이발견되는것을 자주볼수있다. * Air Bubble은보냉단열재를취약하게만들어결국 Crack이생긴다.
6. 단열재별열전도율비교 0.0600 열전도율 (W/mK, at 20 ) 0.0550 0.0400 0.0350 0.0410 0.0325 0.0380 0.0200 0.0200 0.0000 PIR (FINEfoam 140) Mineral Wool Cellular Glass Hitlin Perlite Rubber Foam 현재, 상용되는단열재중 PIR (FINEfoam 140) 의열전도율이제일낮아단열성이매우우수하여, LNG, LPG 및플랜트용단열재로많이사용되고있음.
7. 단열재비교 (Cellular Glass) Section PIR Foam (FINEfoam 140) Cellular- Glass Description Density (kg/ m3 ) 밀도에따른기계적성질이뛰어나고, 현장작업시 Min.40 120 ( 밀도 ) 운반및설치시파손위험이적음. PIR, FINEfoam의 Cell이 Cellular Glass보다조밀하여, Thermal 열전도율이두배정도우수하여같은단열조건이면, conductivity i PIR 의두께가 Cellular l Glass보다절반의두께로동일 0.020 0.040 (W/mk) 한단열효과를낼수있음. 이효과로인해발생될 ( 열전도율 ) Support의두께, 철골구조등을감안하면, 시공비를 Save시킬수있는요인이많음. Compressive properties (kgf/ cm2 ) ( 압축강도 ) 표면거침정도 - 3.0 6.3 매우거침 PIR은 Trimer 구조로되어있어구조적안정성및계적강도가우수함. Cellular Glass 의경우, 제품의표면이매우거칠어, Anti-Abrasive sealant를바르지않을경우, Steel 의표면에 Damage를주며, 이 Sealant로인해인화성이높아짐 Flexural properties (Kgf/ cm2 ) 5.6 4.9 표면의 Rigidity가우수하여작업시파손이적음. ( 휨강도 ) Shear strength (Kgf/ cm2 ) 2.8 3.5 기계적성질이뛰어남 ( 전단강도 ) 기
7. 단열재비교 (Cellular Glass) Section Shrinking stability (-20 ) ( 수축안정성 ) Temperature range ( ) ( 사용온도범위 ) Flammability (ASTM E-84) ( 난연성 ) Absorption (vol%) ( 흡수성 ) Toxicity in fire ( 유독성 ) Linear coefficient of thermal expansion PIR Foam (FINEfoam 140) Cellular- Glass 0.6% 0.15% -200 ~ 120-238 ~ 482 UL Class 1 불연 Description PIR 분자구조내에 Ring 구조를갖는 Trimer 구조로인해극저온에서오는수축 / 팽창에대한안정성이뛰어남. LNG/LEG/LPG 등초저온 Plant 분야에널리사용되고있으며, 지역난방의축열조등고온분야에도독점적으로사용됨. PIR, FINEfoam은미국, 일본, 유럽그리고한국에서내 / 외장단열재혹은산업 Plant 용으로난연등급을승인받아일본, 동남아, 중동시장을중심으로수출되고있는우수한제품임. 1 0.2 Close cell 구조로인해, 흡수성이뛰어남. Toxicity is generated by Mastic. Toxicity is generated by Mastic. 7.0 x 10-6 / 9.0 x 10-6 / Cellular Glass는불연이지만, 함께사용되는 Joint sealer및 Mastic으로인해독성연기가발생되며, PIR보다 Cell 기공이크고, Open cell이많아독성이많이발생됨. PIR, FINFfoam 이온도변화에따른선팽창 / 수축성능이뛰어남.
7. 단열재비교 (Cellular Glass) FINFfoam 140 이아래와같은이유로 Cellular Glass 보다효과적임. 1. 낮은열전도율 : PIR, FINEfoam이 Cellular glass와비교하여거의절반수준임. 이경우단열두께와이에동반되는부자재및 Support, 철골구조까지 Cost를 Save 시킬수있음. 그리고, Maintenance 비용 ( 즉, 운전비용 ) 또한 Save시킬수있음. 2. PIR, FINEfoam은배관보온용으로 2~4 쪽으로공급되고있으며, 시공시 handling에유리하나 Cellular glass의경우는여러쪽으로납품되고있음. 3. Cellular Glass의경우표면이거칠어 Pipe에 Damage를주므로, 이를방지하기위한 Anti-Abrasive 를내부전체표면에발라줘야하며, 이로인한시공비상승과화재시유독가스가많이발생한다. 4. 짧은납기와여러공급업체를통한구매가 PIR의또다른장점인반면, Cellular glass는미국의 Pittsburgh Corning Corp. 에서만생산되고있음.
8. Main Reference CARRIER CLIENT OWNER CAPA Q TY Hyundai Heavy Industries Dynacom /FIONA/QSC /AP.M LNGC150K LPGC 35-82K 7 Ships 23 Ships Daewoo Shipbuilding & Marine Eng g Tapias/Shell/ MOL/NWS/TMT /Exmar/ AP.M LNGC 140-145K LPGC 6-78K 27 Ships /Exmar/ AP.M LPGC 6 78K 22 Ships Samsung Heavy Industries SK/BP/MISC Oman/BG/AP.M/ /BG/APM/ OSG/CTOC LNGC 138-217K LPGC 95K Off-Shore 74 Ships 1 Ships 2 Ships Hanjin, STX Korea LNGC 138K 9Shi Ships H.I.C
8. Main Reference LNG TERMINAL LNG TERMINAL CLIENT FACILITIES Q TY Incheon Samsung E&C Daewoo E&C Dae Ah E&C TK#7~20 Sub & Main Rack,Process 14 Tanks Pyeongtack Hanyang Corp. Daelim Ind. Samsung E&C TK#8~23 Tankage Process, Bog 16 Tanks Tongyoung Kwangyang POSCO Samchuk Daelim Ind. TK#1~17 17 Tanks Daewoo E&C Jetty,Berth Hyundai E&C Process,Utility Daelim Ind. TK#1~3 4 Tanks Posco E&C Jetty,Berth Process,Utility Daelim Ind. TK#1~4 4 Tanks Doosan Heavy Ind. Jetty,Berth Process,Utility 100% Market share for Domestic PIR business
8. Main Reference OVERSEAS LNG TERMINAL Japan Iran Iran CLIENT FACILITIES Q TY A&A Material POGC /w Hyundai Daelim &NICC POGC ANS&PKSK&PAC Tokyo Gas Sakai Gas South Pars#2~10 South Pars #15&16 CO2 PUR 141B PUR PIR PIR Lybia Dae Woo E&C Wafa Pjt PIR Malaysia Qatar Samsung Heavy Ind. Samsung E&C Hyundai E&C MOP LPG Tank NGL 4 PIR Board PIR Thailand & Daw Woo Eng g LPG Tank PIR Indonesia Yemen Dae Woo E&C LNG Tank PIR Export is Increasing for, especially, LNG & LPG plant