ANALYSIS OF ALTERNATIVES HBCDD USE IN EPS FOR BUILDING APPLICATIONS Analysis of Alternatives Legal name of applicant(s): INEOS Styrenics Netherlands BV INEOS Styrenics Ribecourt SAS INEOS Styrenics Wingles SAS Synthos Dwory 7 spółka z ograniczoną odpowiedzialnością spółka komandytowo-akcyjna. Synthos Kralupy a.s. StyroChem Finland Oy Monotez SA RP Compounds GmbH Synbra Technology bv 1 ANALYSIS OF ALTERNATIVES Sunpor Kunststoff GmbH Dunastyr Polystyrene Manufacturing C. Co. Ltd Versalis SpA Unipol Holland bv Submitted by: INEOS Styrenics Netherlands BV 2 ANALYSIS OF ALTERNATIVES HBCDD USE IN EPS FOR BUILDING APPLICATIONS CONTENTS LIST OF TABLES AND FIGURES............................................................................................................................. 5 A. USE 1: FORMULATION OF FLAME RETARDED EXPANDED POLYSTYRENE (EPS) TO SOLID UNEXPANDED PELLETS USING HEXABROMOCYCLODODECANE AS THE FLAME RETARDANT ADDITIVE (FOR ONWARD USE IN BUILDING APPLICATIONS). ..................................................................... 8 B. USE 2: MANUFACTURE OF FLAME RETARDED EXPANDED POLYSTYRENE (EPS) ARTICLES FORUSE IN BUILDING APPLICATIONS. ............................................................................................................................... 8 1 SUMMARY ............................................................................................................................................................ 8 2 ANALYSIS OF SUBSTANCE FUNCTION.......................................................................................................... 17 2.1 Assessing the function of Hexabromocyclododecane in Expanded Polystyrene ............................................ 17 2.1.1 Production of EPS pellets (beads) ....................................................................................................... 19 2.1.1.1 The suspension process ......................................................................................................... 19 2.1.1.2 The mass process ................................................................................................................... 20 2.1.2 Manufacture of EPS by the two-step process ...................................................................................... 20 2.1.3 Production of ‘blown’ (expanded) EPS beads and boards .................................................................. 21 2.2 Considerations for selecting flame retardants for EPS ................................................................................... 21 2.2.1 The flammability process .................................................................................................................... 22 2.2.2 Features of an ideal flame retardant .................................................................................................... 23 2.2.3 Impacts on other properties ................................................................................................................. 23 2.2.4 Thermal stability ................................................................................................................................. 24 2.2.5 Fire safety flammability standards for EPS ......................................................................................... 25 2.2.5.1 European Fire Regulations .................................................................................................... 28 2.2.5.2 The Euroclass System ........................................................................................................... 28 2.2.6 Product Standards relevant for EPS (and XPS) ................................................................................... 29 2.2.6.1 European product standard for sandwich panels EN 14509 .................................................. 29 2.2.6.2 European product standard for EPS ...................................................................................... 30 2.2.6.3 Euroclass testing of EPS (and XPS) ...................................................................................... 30 2.2.6.4 Compliance with the Construction Products Directive/Regulation and the Euroclass system 31 2.3 Consideration of obstacles or difficulties identified or expected in relation to finding an alternative fulfilling or replacing the equivalent function of HBCDD. ............................................................................................... 33 3 IDENTIFICATION OF POSSIBLE ALTERNATIVES ......................................................................................... 36 3.1 List of possible alternatives ............................................................................................................................ 37 3.2 Description of efforts made to identify possible alternatives .......................................................................... 48 3.2.1 Research and development .................................................................................................................. 48 3.2.1.1 The identification of the polymeric flame retardant alternative. ........................................... 53 3.2.1.2 Alternative production process .............................................................................................. 56 3.2.1.3 Alternative final products ...................................................................................................... 56 3.2.2 Data searches ....................................................................................................................................... 62 3.2.3 Consultations ....................................................................................................................................... 62 4 SUITABILITY AND AVAILABILITY OF POSSIBLE ALTERNATIVES ......................................................... 64 4.1 ALTERNATIVE 1 ......................................................................................................................................... 64 4.1 a Substance ID and properties .................................................................................................................. 64 4.2a Technical feasibility ............................................................................................................................ 81 4.3a Reduction of overall risk due to transition to the alternative ............................................................... 81 4.4a Economic feasibility ............................................................................................................................ 81 3 ANALYSIS OF ALTERNATIVES – HBCDD FOR USE IN EPS IN BUILDING APPLICATIONS 4.5a Availability .......................................................................................................................................... 81 4.6a Conclusion on suitability and availability for Alternative 1 ................................................................ 81 b) ALTERNATIVE 2 .............................................................................................................................................. 81 4.1b Substance ID and Properties ................................................................................................................ 81 4.2b Technical feasibility ............................................................................................................................ 82 4.3b Reduction of overall risk due to transition to the alternative ............................................................... 82 4.4b Economic feasibility ............................................................................................................................ 82 4.5b Availability .......................................................................................................................................... 82 4.6b Conclusion on suitability and availability for Alternative 2 ................................................................ 83 c) ALTERNATIVE 3 .............................................................................................................................................. 83 4.1c Substance ID and Properties ................................................................................................................ 83 4.2c Technical feasibility ............................................................................................................................ 85 4.3c Reduction of overall risk due to transition to the alternative ............................................................... 85 4.4c Economic feasibility ............................................................................................................................ 86 4.5c Availability .......................................................................................................................................... 86 4.6c Conclusion on suitability and availability for Alternative 3 ................................................................ 86 d) ALTERNATIVE 4 .............................................................................................................................................. 87 4.1d Substance ID and Properties ................................................................................................................ 87 4.2d Technical feasibility ...........................................................................................................................