Expanded Polystyrene (EPS) beads typically use
pentane as blowing agent in its manufacture. The stricter ecological
concerns have given an incentive to scientists to develop a novel
process that is not based on Pentane. The beads are expanded and moulded
by the end product manufacturers using a blowing agent. Currently,
pentane is used, but it is an inflammable, volatile organic compound
(VOC) and upto half remains in the EPS after processing and is slowly
released into the atmosphere during storage and use.
EUREKA project E! 2683 VOC FREE EPS has addressed these concerns by
producing a VOC free alternative in the world’s first water-blown
expandable polystyrene bead. The partners may take the unusual step
of commercially launching the product in the USA. USA seems to be
the preferred first destination, with a view to take advantage of
stricter legislative controls on VOC release. The new-patented process
creates a molecular bond encapsulating starch in a shell of polystyrene.
The chemically bonded starch absorbs micro-drops of water, which becomes
a safer, more environmentally friendly blowing agent inside the beads.
The project achieved a considerable reduction in VOC emissions resulting
from polystyrene foam, an improvement in productivity for foam moulders
and improved safety during production of the foam. Increasing VOC
emission reduction targets will necessitate the installation of pentane
‘capture and destroy’ systems. These will require significant
investments and will reduce the problem, but will never solve it completely.
While Nova Chemicals developed the new expansion process for VOC free
EPS, the German partner Teubert GmbH designed and built the new EPS
expansion machine.
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