Zero-VOC Industrial Maintainance Metal Coating

This page updated April 27, 2006.

Adhesive Coatings Company

Zero-VOC Industrial Maintainance Metal Coating

CARB Grant Number 95-346


The statements and conclusions in this Report are those of the grantee and not necessarily those of the California Air Resources Board. The mention of commercial products, their source, or their use in connection with material reported herein is not to be construed as actual or implied endorsement of such products.

Abstract
Hydrocarbon emissions generated from stationary sources are a significant environmental problem in California. One of the largest stationary emission sources is the evaporation of solvents used in paints, coatings, inks, and other products. Local air pollution control districts in California have passed rules to limit the volatile organic compounds (VOC) content in these products. Air emissions can be reduced through a gradual shift from high-to low-/no-VOC coatings. By phasing in low-/no-VOC coatings, industries will be able to reduce energy use and air emissions without installation of add-on controls.
Under California Air Resource Board (ARB) sponsorship, AeroVironment Environmental Services, Inc. (AVES), Adhesive Coatings Co. (ADCO), and Compliance Engineering Technology, Inc. (CET) are teamed to develop and demonstrate a metal coating, which contains no volatile organic compound (VOC) and no hazardous air pollutant (HAP). This two-part system consists, in general, of an epoxy resin emulsion and an aqueous solution of a reaction product of certain polyamines. This new technology can help the coating industry reduce emissions of VOC and HAP. At the same time, this technology has the potential of affecting a sizable reduction in energy consumption in: (1) heat curing end products coated with paint made with the new polymer and (2) thermal oxidizing VOCs from solvent-based coating operations.
The objectives of this project are to develop a new metal coating system that is sufficiently mature for demonstration and to develop a technology transfer plan to get the product into public use. The coating system was first fully tested in the laboratory. Hundreds of panels were prepared and tested, and many engineering hours were spent to develop the coating theory and fine tune the coating performance characteristics. The performance characteristics of this new coating system are excellent in terms of adhesion, drying times, hardness, and rust and chemical resistance.
Field demonstrations were conducted at two selected manufacturing facilities. The field demonstrations provide valuable information on how the coating performs in a full-scale application. In addition, the field demonstrations provide the information required for converting from conventional metal coating to the new metal coating system.
This report summarizes the research and development of this metal coating system. Topics presented in this report include: product performance data, application techniques, ease of use, and field demonstration results. A cost analysis was conducted for this new system and included costs of materials, capital outlay, and disposal expenses. An environmental impact study was also included in this project to address emissions benefits, disposal cost saving, and energy conservation based on data gathered during the in-plant, full-scale demonstrations.
Substantial progress has been made to identify market opportunities in California for new environmentally-sound products, specifically the need for a no- / low-VOC finishing coating system for metal furniture and industrial maintenance coatings. The complete absence of organic solvents means that this new coating is not only less hazardous to use but emits no volatile organic compounds; therefore, it does not contribute to air pollution. The selfcontained manufacturing process emits no significant air pollutants.
For example, it is estimated that companies in California use over 300-million liters or 10-million gallons of industrial maintenance, primer, and other architectural coatings each year in California alone. The potential to reduce emissions is very significant if all such coatings contained no solvents. Eliminating approximately three pounds per gallon of solvent by employing the no-VOC coating technology, would be equivalent to eliminating over 30-million pounds of emissions each year. Because this new water-borne metal finish coating dramatically reduces the level of VOCs, it has excellent potential for long-term emission compliance. It does not contain HAPs, which are specifically beneficial to a worker’s health.
The environmental benefits of this project and the cost-effective solution for VOC reduction in California would be achieved with the continuous VOC reduction capability of this product and thereby help the California Air Resources Board (ARB) meet clean air goals.

Funding Source

Funding Amount


ICAT

$223,002

Grantee

$223,618


Click here for the entire final report.

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