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EPA-600/R-98-130 October 1998

LOW- AND NO-VOC COATING TECHNOLOGIES: 2ND BIENNIAL INTERNATIONAL CONFERENCE .

March 13-15,1995 Durham, North Carolina

Ella J. Darden and Jesse N. Baskir, Compilers RESEARCH TRIANGLE INSTITUTE

P.O. BOX 12194 RESEARCH TRIANGLE PARK, NORTH CAROLINA 27709

EPA Purchase Order No. 5DOS52NANX

EPA Project Officer: Michael Kosusko U.S. Environmental Protection Agency

National Risk Management Research Laboratory Air Pollution Prevention and Control Division

Research Triangle Park, NC 27711

Prepared for:

U.S. ENVIRONMENTAL PROTECTION AGENCY OFFICE OF RESEARCH AND DEVELOPMENT

WASHINGTON, DC 20460

Abstract The report docul technical inform technologies that those from tradil 100%-solids liqt technology to eii environmental li: to the indoor air

TABLE OF CONTENTS (Cont.)

SESSION 5 APPLICATION TECHNOLOGIES/SURFACE PREPARATIC

Advances in Aerospace Coating Technologies: Convergent Spray Techno1 Encapsulant Lead Paint Remover ................................ Utilization of Effervescent Spray Technology to Eliminate Volatile and To: SERDP, USMC Spray Booth Control and P2 Demonstration . . . . . . . . . . .

SESSION 6 POWDER COATINGS .................................

Overview of Powder Coatings Technology and EPA's Powder Coatings Re Powder Coatings: Technology of the Future, Here Today . . . . . . . . . . . . . Chlorinated Maleinized Guayule Rubber in Powder Coatings: No VOC Tb Rubbercoatings ............................................. Novel Acrylic Cure Polyester Powder Coating Resin Technology ........

SESSION 7A AUTOMOTIVE APPLICATIONS .......................

Reduction of VOC Emissions from Painting of Car Bodies -a Case Study o'

Two Swedish Car Plants ........... : ........................... New Low-VOC Fluorinated Coatings .............................. Supercritical Fluid (SCF) Adhesion Promoters for Automotive Plastic Appl

SESSION 7B WOOD mJRNITuRE TECHNOLOGIES ..................

Demonstration of No-VOC Wood Topcoat ......................... Evaluation of Supercritical Carbon Dioxide Spray Technology to Reduce SI Finishmg Process .............................................. Evaluation of Alternative Chemical Strippers on Wood Furniture Coatings

SESSION 8A MILITARY APPLICATIONS ............................

Low- and No-VOC Conformal Coatings Over No-clean Flux Residues . . , Low-VOC and No-VOC Coating Systems for Aerospace and Its Support . LowVOCMarineCoatings ......................................

, Evaluate Alternative Paint Stripping Technologies Used in Aircraft and Spi

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TABLE OF CONTENTS

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ABSTRACT .......................................................................... ii

INTRODUCTION .................................................................... vi

SESSION 1 OPENING .............................................................. 1-1 Welcome Frank Princiotta. Director. U.S. Environmental Protection Agency.

National Risk.Management Research Laboratory. Air Pollution Prevention and Control Division (Visuals) ................... 1-3

Keynote Alexander Ramig. Jr., Vice President of Research and Development.

State Perspective Gary Hunt. North Carolina Office of Waste Reduction (No Paper) University Perspective John Massingill. Coatings Research Institute (Visuals) .......... 1-8 EPA Coatings Research Michael Kosusko. U.S. Environmental Protection Agency. National

ICYGlidden (Summary) .................................. 1-6

Risk Management Research Laboratory. Air Pollution Prevention and Control Division ................................... 1-30

SESSION 2 REGULATORY UPDATE ................................................ 2-1

Regulatory Climate (No Paper) Low VOC Measurements. H A P Measurements in Paints. Questions. Questions. Questions . . . . . 2-3 Developments inEuropean VOC Emission Regulations ................................ 2-61 Coating Alternatives GuidE (CAGE) .............................................. 2-77

SESSION 3 RADIATION CURABLE COATINGS ...................................... 3-1

Barriers to the Use of W and EB Technologies ....................................... 3-3

Acrylated Lesquerella Oil in Ultraviolet-Cured Coatings ............................... 3-11 Volatile Contents of W Cationically Curable Epoxide Coatings .......................... 3-26

Environment and Technology Teamed for Economic Sustainability (Abstract) . . . . . . . . . . . . . . 3-10

SESSION 4 LIFE-CYCLE ANALYSIS ................................................. 4-1

The Use of Life Cycle Assessment in an Ecolabeling Scheme: the European Ecolabel on Paints and Varnishes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Optimizing Coating Formulations for Total Environmental and Product Performance ........ 4-17 Life Cycle Analysis of an Aqueous Low-VOC Coating ................................ 4-33

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TABLE OF CONTENTS (Cont.) - PAGE

SESSION 5 APPLICATION TECHNOLOGIES/SURF'ACE PREPARATION ............... 5-1

Advances in Aerospace Coating Technologies: Convergent Spray Technology (Abstract) ...... 5-3 Encapsulant bad Paint Remover .................................................. 5 4 Utilization of Effervescent Spray Technology to Eliminate Volatile and Toxic Diluents ....... 5-10 SERDP. USMC Spray Booth Control and P2 Demonstration ............................ 5-28

~ SESSION 6 POWDER COATINGS ................................................... 6-1

Overview of Powder Coatings Technology and EPA's Powder Coatings Research ............ 6-3

Chlorinated Maleinized Guayule Rubber in Powder Coatings: No VOC Thermosetting Chlorinated Rubbercoatings .............................................................. 6-31

. Powder Coatings: Technology of the Future. Here Today ............................... 6-7

Novel Acrylic Cure Polyester Powder Coating Resin Technology .......................... 6-40

SESSION 7A AUTOMOTIVE APPLICATIONS ......................................... 7-1

Reduction of VOC Emissions from Painting of Car Bodies -a Case Study of Two Swedish Car Plants ........... : ............................................. 7-3 New Low-VOC Fluorinated Coatings ............................................... 7-13 Supercritical Fluid (SCF) Adhesion Promoters for Automotive Plastic Applications ......... 7-23

SESSION 7B WOOD mJRNITuRE TECHNOLOGIES .................................. 7-35

Demonstration of No-VOC Wood Topcoat ......................................... 7-37 Evaluation of Supercritical Carbon Dioxide Spray Technology to Reduce Solvents in a Wood FinishingProcess .............................................................. 7 4 7 Evaluation of Alternative Chemical Strippers on Wood Furniture Coatings ................ 7-57

SESSION 8A MILITARY APPLICATIONS ............................................. 8-1

Low- and No-VOC Conformal Coatings Over Noclean Flux Residues .................... 8-3 Low-VOC and No-VOC Coating Systems for Aerospace and Its Support .................. 8-17 LowVOCMarineCoatings ...................................................... 8-23

. Evaluate Alternative Paint Stripping Technologies Used in Aircraft and Space Vehicles ....... 8-27

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TABLE OF CONTENTS (Cont.)

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SESSION 8B ARCHITECTURAL AND INDUSTRIAL MAINTENANCE COATINGS .................................................. 8-31

Evaluation of Innovative Low-Volatile Organic Compound Industrial Maintenance Coatings . . 8-33 Solventless and Low-VOC Architectural Coatings Formulated from Novel Latexes with LowMFTandHighT, ......................................................... 8-46 Evaluation of Emissions from Latex Paint ......................................... 8-58 New Polyurethane Prepolymers for Ultra-Low VOC Plural Component Coatings ............ 8-70

SESSION 9 LOW- AND NO- VOC COATINGS . PART 1 ............................... 9-1

Orgwsosilanes in Low VOC Coatings .............................................. 9-3 Polyester Oligomers of Narrowed Molecular Weight Distribution ........................ 9-14 New Epoxy/Anhydride Chemistry for Durable High Solids Coatings ..................... 9-30

SESSION 10 LOW- AND NO-VOC COATINGS . PART 2 ............................... 10-1

100% Solids Liquid Sprayable Coatings ............................................ 10-3 Alternative Dielectric Coating Medium for Electric.Motor Field Coil Manufacture . . . . . . . . . 10-16 Odour and VOC Emissions Reduction on coil-coating Lines by Using Waterborne Paints . Part II: Full Waterborne System Application ....................................... 10-26 Closing Remarks .............................................................. 10-37

Appendix A ATTENDEES LIST ..................................................... A-1

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INTRODUCTION

In 1992, surface coating operations accounted for approximately 24 percent of all volatile organic compound (VOCs) released from industrial processes’. While pollution control equipment can reduce solvent emissions from some coating operations, adoption of pollution prevention techniques such as the use of lower-emitting coatings, in many cases provides a cost-effective alternative. For many coatings applications, such as small coating operations or architectural and industrial maintenance applications, pollution prevention may be the only economically viable approach to reducing emissions. Lower-emitting coating technologies are being developed rapidly to reduce VOC and hazardous air pollutants (HAP) emissions from coating operations in a wide variety of industrial and commercial applications. These technologies include higher solids solventborne coatings, waterborne coatings, coatings containing reactive diluents, 100 percent solids liquid sprayable coatings, powder coatings, radiation curable coatings, and spray coatings that employ supercritical carbon dioxide as a solvent. In addition to new coating technologies, improvements in coating application equipment and application techniques continue to offer opportunities for substantial reductions in VOC emissions through improved application efficiency.

A conference entitled “Low- and No-VOC Coating Technologies: 2nd Biennial International Conference” was held on March 13 -15,1995, in Durham, North Carolina. The primary purpose of the confirence was to provide a forum for the exchange of technical information on lower-emitting coating technologies. Plenary presentations provided perspectives on new technology needs and developments from the coatings industry and from federal and state government representatives. Papers described some of the latest developments in new coating technology, coating application equipment, chemical agents for coating removal, and issues associated with measuring the VOC content of coatings.

Approximately 175 people participated in the conference. Of these attendees, approximately 13 percent were coating users, 12 percent were environmental consultants, 49 percent were government agency representatives, 9 percent were coating manufacturers, 3 percent were in coating marketing and sales, 3 percent were educators, and 11 percent were in other categories. There were six foreign participants: two from Canada, two from Belgium, one from Italy, and one from the United Kingdom.

Technical papers presented at the conference focused on regulations, radiation curable coatings, life-cycle analysis of coatings, surface preparation, powder coatings, automotive applications, wood furniture technologies, military applications, architectural and industrial maintenance coatings, and other low- and no- VOC coating technologies. Paper topics included a description of a 100%- solids liquid sprayable coating, solventless architectural coatings, use of effervescent spray technology to eliminate volatile diluents, the use of lifecycle assessment to develop an environmental labeling scheme for coatings, and an examination of VOC emissions to the indoor air environment from latex paints.

‘Nizich, Sharon, 1993. National Air Pollutant Emission Trends, 1900-1992. EPA- 4.54R-93-032 (NTIS PB94-152097). U.S. Environmental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, North Carolina. October.

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