michael donkin may 13th - twi...1. performance - longer lifetime, especially offshore...
TRANSCRIPT
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Technology Developments in Protective Coatings
Michael Donkin
May 13th 2015
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• Protective coatings market
• Key technology drivers
• Examples of New technology
• The future
Agenda
2
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale.
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Protective Coatings market
3 Protective Coatings
•Thermal (Coal, Gas, Oil) power stations
•Wind, Hydro & other renewables
•Nuclear
Power Generation
•Drilling rigs,
•Platforms,
•Floating production
•Subsea
Oil and Gas Upstream
•Chemical processing plants
•Refineries
•Storage facilities
Oil, Gas and Chemical
•Extraction, Pre-treatment
•Refining (Processing)
•Smelting
•Transportation
•Metals & Minerals
Mining
•Airports,
•Stadiums
•Iconic buildings
•High-rise buildings
HVI
•Water storage
•Waste treatment
•Desalination plants
Water and Wastewater
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• Historically alkyds, Epoxies (70%) and Polyurethanes have
provided the majority of coatings in PC
– Alkyds for light duty
– Epoxies/Polyurethanes for heavy duty
• The market is mature and new technologies take time to develop
– Specification position
– Track record is essential, especially for offshore use
• Many products and technologies exist in the market for a number of
years
Technologies in PC
4 Protective Coatings
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Key new technology drivers
5 Protective Coatings
All products supplied and technical advice or recommendations given are subject to our standard conditions of sale.
1. Performance
- Longer lifetime, especially offshore (Norsok/ISO12944)
- Extended guarantees and Warranties
- Gloss and colour retention
- Third party testing
2. Productivity
- Fast cure/Fast return to service
- Power (electricity) generation
3. Environmental and legislation
- VOC (High solids/Water based)
- Product Stewardship
- Heavy metals
.
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New Technologies
6 Protective Coatings
• A number of new technologies have emerged to meet the
key drivers which include :
• Polysiloxanes
• Polyaspartics
• Fluoropolymers
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• A new technology for Protective coatings (patent protected)
• First introduced in the mid 90’s as a replacement for an epoxy
build coat and PU topcoat – 3 coat to a 2 coat system
• Key properties
Step change in durability
Low VOC (<250g/litre)
Isocyanate free
Can be formulated as one or two
component coatings
Extensive use offshore in harsh
environments
7 Protective Coatings
1. Performance - Polysiloxanes
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Polysiloxanes
8 Protective Coatings
• Polysiloxanes have the bond O-Si-O in the backbone and can be
blended into most organic polymer systems
• The higher bond strengths of the Si-O bond (108 K Cal mol-1) compared
to the C-C bond strength (83 K Cal mol-1) which confers thermal
stability and UV stability, the Si-O bond is already oxidised.
• The Polysiloxane (glass) is transparent to UV and not easily degraded if
at all
• Usually blended with organic polymers to give flexibility and good
adhesion
• Latest technology is capable of <100g/litre coatings
• The time taken for accelerated testing is more of a challenge!
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9 Protective Coatings
Accelerated Durability
0
20
40
60
80
100
120
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Glo
ss
Rete
nti
on
Hours
Quv A Exposure
Urethane Polysiloxane. Polyurethane. Epoxy Polysiloxane.
12 Months
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New technology for M+R
• Patented AN chemistry
• <275 g/litre
• Very high durability
• Designed for brush/roller
application
• Tin and heavy metal free
10 Protective Coatings
Single pack Polysiloxane
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Key properties
• Very high durability
• Thin film application
– 30-50 microns
• Buildings and bridges are
typical areas of application
12 Protective Coatings
Fluoropolymer
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• This chemistry relies on a carbon fluorine bond
• C-F (105 K Cal mol-1) bond is very high energy and very difficult to
break with sunlight. It can also strengthen the adjacent C-C (83 K Cal
mol-1) bond making the polymer much more UV durable.
• Can be the highest durable topcoat and most resistant to weathering
• Mostly specified in Asia and the US where specific durability standards
exist
• Can be supplied as liquid paint or powder
13 Protective Coatings
Fluoropolymer
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14 Protective Coatings
Accelerated artificial weathering
Exposes the coating to an
environment, which magnifies
the stresses of the natural
environment
The stresses are:
• Light. Both energy
(wavelength) and irradiance
energy
• Temperature
• Humidity
• Stresses are normally cyclical
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15 Protective Coatings
EEMMAQUA – Testing high durability EMMAQUA – New technology testing – Testing high durability topcoats
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16 Protective Coatings
Emmaqua
• Exposure is quantified in terms of the total light dose of
incident light. 300 MJ.m-2 correlates to one years Florida
exposure
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17 Protective Coatings
EMMAQUA – 8 years Florida equivalent
0
20
40
60
80
100
0 500 1000 1500 2000 2500
MJ Exposure (Emmaqua)
Gloss
1K Polysiloxane
Polyurethane Note: QUV does not have any
Direct comparison with
external exposure
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18 Protective Coatings
Ultra Emmaqua
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• Corrosion standards are required by our customers
– Norsok
– ISO12944
– NACE and others
– These tests are usually cyclic and include UV/Freezing (-15C) and salt
spray.
– Some tests require -60C and +60C cycling.
19 Protective Coatings
Third party test requirements
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• The requirements of the corrosion standards drives the choice of
technology
– Zinc based primers
– Epoxy barrier coats
• Topcoats have to be compatible with these type of products and test
regime
• Typical accelerated test times for C5M offshore environments are 6-9
months
20 Protective Coatings
Third party test requirements
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Increasing focus on improving productivity
• For example Wind blades/OEM/Pipes
–Fast cure technology is Polyaspartic
• Application methods are changing with
more acceptance of twin feed/heated twin
feed spray
–Epoxy ultra high solids
• Tidal wave farms
2. Productivity
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Key properties
• Fast cure at a range of temperatures (0 – 40°C)
• Good balance of corrosion, aesthetics and physical properties
• Suited for OEM applications
– Good gloss and early hardness
• C3 for DTM and up to C5 for 2/3 coat systems
• Tin free
22 Protective Coatings
Fast cure Polyaspartics
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23 Protective Coatings
Polyaspartics
O
O
O
O
N E t
E t
R +
R ' N C O
R '
O
O
O
O
E t
E t
N C
N H
R
O
H
Aspartic acid ester Isocyanate Polyurea
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24 Protective Coatings
Polyaspartic hardness
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• 2 Hours hard dry and moveable at 25C/60%RH
• DTM (150-200 microns)
25 Protective Coatings
Polyaspartic
Polyaspartic chemistry can give a range of dry speeds depending
on the blend used.
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26 Protective Coatings
Heated twin feed application
Temperatures of 50-90C have been used with cure times
as short as 15 minutes.
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27 Protective Coatings
Silicone elastomers and their use in PC
• Marine fouling can cause a number of problems to
occur on immersed assets
– Increase the weight of floating assets
– Increase hydrodynamic drag on tidal turbine blades
– Cause difficulties in accessing critical areas of
immersed devices for maintenance
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High performance ultra-smooth coatings and their use in marine energy
28 Protective Coatings
Amphiphilic fluoropolymer technology (None toxic antifouling)
• Generally marine life has a preference for either hydrophobic or hydrophilic
surfaces
• Advantage of amphiphilic technology is it combines characteristics of both types
of surface
• Delivers improved water flow and inhibits more marine life than other coatings
INSOLUBLE
SOLUBLE
HYDROPHOBIC HYDROPHILIC AMPHIPHILIC
Fluoropolymer
Advanced
Fluoropolymer
Silicone
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29 Protective Coatings
Silicone elastomers and their use in PC
What does this mean in practice?
• Reducing hydrodynamic drag can help in
maintaining the torque of the device and therefore
deliver designed power from the unit
• It can reduce maintenance costs by alleviating the
need to hire divers to clean the device of marine
fouling before maintenance can take place
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High performance ultra-smooth coatings and their use in PC
31 Protective Coatings
A real life example
• A 30 month trial was undertaken at a hydroelectric plant in Brazil. The
test was to compare a Fluoropolymer foul release coating with a coal tar
epoxy.
Coal tar epoxy
Fluoropolymer
foul release
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32 Protective Coatings
Wave & Tidal assets protected by AkzoNobel
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• VOC legislation
– Continued focus from all regions of the world to reduce VOC’s
– Predictions that by 2020 it will be below 250g/litre
– China tax >420g/litre, California <100g/litre
• The technology options are either water based
or high solids
– Epoxies
– Polyaspartic
– Polysiloxane
– Polyurethane
3. Environmental - VOC
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• Key properties
– Low VOC, <100g/litre
– Single or two component
– Good durability
– Easy to apply thin films
– Hybrid systems.
– Performance equivalent to solvent based
• Drawbacks
– Poor drying at low temp/high RH
34 Protective Coatings
Water based - VOC
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VOC HS Polyurethanes
Key properties
• Durability
• Flexibility of formulation
• Excellent Mechanical properties
• Adhesion to epoxies
• Track record
• Ability to formulate low VOC alternatives
– <250 g/litre new product
– Easy application at 50 microns without thinning
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– REACH, K REACH, EPA, NICNAS
– Akzonobel programme
– Materials of concern
– Isocyanates
– Tin
– Cobalt
– Chromates
– Coal tar
36 Protective Coatings
Legislation
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• A number of isocyanate free technologies
(Interfine 629, Interfine 629HS and Interfine 691)
• Polysiloxanes
• Functional acrylics
– Patented technology
– <250g/litre VOC
37 Protective Coatings
Isocyanate free
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• Uncertain!
• <100g/litre? Solvent free?
• Higher durability and lifetimes
• Lower film thickness and lower cost systems
• Functional coatings
The future
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Any questions?