surface coating operations: metal parts & products presented by terone preston 2007 california...

Surface Coating Operations:

Metal Parts & Products

presented by Terone Preston 2007

California Air Resources Board California Air Resources Board

Presents: Presents:

Metal Parts and Products Coating

Oil Field Production and RefiningOil Field Production and RefiningMotor Fuel TransferMotor Fuel TransferAutomotive TailpipesAutomotive TailpipesSolvent useSolvent use

Hydrocarbon Sources

Ozone Concentration Maps

Ozone Causes:Ozone Causes:Alveolar injury leading to pulmonary inflammation Alveolar injury leading to pulmonary inflammation and permanent lung damageand permanent lung damage

Respiratory discomfort to sensitive populationsRespiratory discomfort to sensitive populations

$330 Million in crop damage each year$330 Million in crop damage each year

Damage & failure of paints and rubber parts Damage & failure of paints and rubber parts

Who Cares?

Corrosion protectionCorrosion protection

Restore factory colorRestore factory color

Change color or make uniformChange color or make uniform

Restore protection to repaired spotRestore protection to repaired spot

Reduce wearReduce wear

Why Paint ?

Occurs between dissimilar metals

Ion Exchanges

Galvanic Corrosion

CoatingsCoatings

A thin film of organic material A thin film of organic material adhering to a mechanical device to adhering to a mechanical device to protect it from corrosion or assaultprotect it from corrosion or assaultby its environment. Consequently by its environment. Consequently the color, and texture of the the color, and texture of the surface are also altered.surface are also altered.

What is a Coating?

•Binders or Resin•Solvents, Thinners and Diluents•Pigments & Extenders•Additives

CoatingsCoatings

200-9200-9

The Four Components of any Coating

A soluble solid capable of hardening into a thin film

CoatingsCoatings

Binder

AcetatesAcetates Latex Latex

AcrylicsAcrylics Nitrocellulose Nitrocellulose

Alkyds Alkyds Polyurethanes Polyurethanes

Asphaltics SiliconeAsphaltics Silicone

Epoxies VinylsEpoxies Vinyls

TriglycidalisocyanuratesTriglycidalisocyanurates

CoatingsCoatings

Common Binders/Resins

Air dryAir dryThermoset/ ThermocureThermoset/ Thermocure

Baked cure 194Baked cure 194ooFFThermoplasticThermoplasticRadiationRadiation

CoatingsCoatings

Curing

Curing Curing

Enamels are often cured by Enamels are often cured by combining two components combining two components that release or absorb a water that release or absorb a water molecule.molecule.

Exotic curing triggers include UV, Exotic curing triggers include UV, IR and Electron beamIR and Electron beam

CoatingsCoatings

CuringCuring

LacquerLacquer - - cures by the cures by the

evaporation of the solventevaporation of the solvent

EnamelEnamel - - cures by an irreversible cures by an irreversible

chemical reaction involving various chemical reaction involving various

components or atmospheric water components or atmospheric water

or oxygenor oxygen

CoatingsCoatings

CoatingsCoatings

Liquids added to reduce Liquids added to reduce viscosity, promote flow viscosity, promote flow and permit drying by and permit drying by evaporationevaporation

Solvents, Diluents and Thinners

Organic Solvent TypesOrganic Solvent Types

CoatingsCoatings

Terpenes Terpenes pine tree extractpine tree extract

Hydrocarbons Hydrocarbons Aliphatic (mineral spirits)Aliphatic (mineral spirits)

Naphthenic, Aromatic (Toluene & Xylene)Naphthenic, Aromatic (Toluene & Xylene)

Oxygenated Oxygenated Alcohols, Esters & KetonesAlcohols, Esters & Ketones

Furans Furans Tetrahydrofuran for polyvinyl chlorideTetrahydrofuran for polyvinyl chloride

Chlorinated Chlorinated Trichloroethane, Methylene chlorideTrichloroethane, Methylene chloride

CoatingsCoatings

1) mechanical strength1) mechanical strength2) UV protection2) UV protection3) Hold out of prior color3) Hold out of prior color4) color (see additives)4) color (see additives)

Pigments are small, hard particles added for:

Some Common PigmentsSome Common Pigments

CoatingsCoatings

Titanium Dioxide Titanium Dioxide Powdered Metals Powdered Metals Zinc Oxide Zinc Oxide Stainless Steel FlakeStainless Steel Flake

Antimony Trioxide Antimony Trioxide Bronze, ZincBronze, Zinc

AluminumAluminum Para RedPara Red Carbon Black

Iron Oxide GraphiteToluidine Red Black Iron

CoatingsCoatings

Extenders are less expensive pigments with poorer hold outCalcium Carbonate

Talc (Magnesium Silicate)

China Clay (Aluminum Silicate)

Calcium Silicate

Silica Mica

Gypsum (Calcium Sulfate)

Barytes or Blanc Fixe (Barium Sulfate)

AdditivesAdditives

CoatingsCoatings

A chemical added for a specific A chemical added for a specific effect on either the wet or dry film. effect on either the wet or dry film. examples: examples: luster enhancer, drying luster enhancer, drying

speed, hardness, anti fish eyespeed, hardness, anti fish eye

Normally totals less than 5% of Normally totals less than 5% of liquid volumeliquid volume

AdditivesAdditivesCoatingsCoatings

Skinning agents Skinning agents methyl ethyl ketoximemethyl ethyl ketoxime, , Wetting agents Wetting agents (for pigment) anionic, (for pigment) anionic,

cationic and nonionic cationic and nonionic soya lecithinsoya lecithin, , Anti-foaming Anti-foaming (usually water-borne) (usually water-borne)

silicone and non-siliconesilicone and non-silicone, , Coalescing Coalescing (latex emulsion)(latex emulsion) , ,Thickening Thickening (water borne) (water borne) methyl cellulosemethyl cellulose, , Microbicides Microbicides mercurial & nonmercurialmercurial & nonmercurial others: others: luster enhancer, drying speed, hardness, anti fish eyeluster enhancer, drying speed, hardness, anti fish eye

Water as a DiluentWater as a Diluent

x grams of solids x grams of solids covers area ycovers area y

x grams of solids x grams of solids covers area ycovers area y

solidssolids

organic organic solventssolvents

solidssolids

waterwater

cosolventcosolvent

solventssolvents

CoatingsCoatings

A Coating System

Compatability Intercoat

Topcoat

Substrate: Steel, Plastic or other Primer/sealer/surfacer

1 to 5 mils eachPowder

ROG Control Strategies for CoatingsROG Control Strategies for Coatings

Use ReductionUse Reduction

• • Plating instead of coatingPlating instead of coating

• • Use of Exempt SolventsUse of Exempt Solvents

• • Use of Water-Borne ProductsUse of Water-Borne Products

• • Increased Solids ContentsIncreased Solids Contents

• • Increased Transfer EfficiencyIncreased Transfer Efficiency

Retrofit Control DevicesRetrofit Control Devices

• • Capture and ReuseCapture and Reuse

• • Capture and DestroyCapture and Destroy

ControlControl

1994 Coating Consumption by type1994 Coating Consumption by type

Type Million Gallons PercentType Million Gallons Percent

WaterWater 586 50.9 586 50.9

Hi-Sol 110 9.6Hi-Sol 110 9.6

Powder 70 6.0Powder 70 6.0

Radiation Cure 6.4 0.5Radiation Cure 6.4 0.5

Non Comp High VOC Non Comp High VOC 378 378 32.932.9

1149.6 1001149.6 100

CoatingsCoatings

Exempt SolventsExempt Solvents

Vary by DistrictVary by District

Have a Variety of Human Health Effects Have a Variety of Human Health Effects Including Anesthesia and Intoxication Including Anesthesia and Intoxication

Stratospheric Ozone DepletionStratospheric Ozone Depletion

Sometimes Incompatible with Aluminum Sometimes Incompatible with Aluminum or Water or Water

CoatingsCoatings

200-12

Waterborne Pro and ConWaterborne Pro and Con

reduced air emissions increased water and HAP reduced fire hazard emissions low cure temps pretreatment becomes more easy clean up critical drying times controlled

more by weatherthan by additives

higher viscosity & air pressure means lower TE

rust proof equipment required

CoatingsCoatings

200-11

CosolventCosolventaka coupling agentaka coupling agent

a solvent that causes two a solvent that causes two immiscible liquids to miximmiscible liquids to mix

may comprise up to 30% of the may comprise up to 30% of the liquid in a waterborne coatingliquid in a waterborne coating

CoatingsCoatings

Know your Waterborne coatingsKnow your Waterborne coatings

Dispersions- are usually transparent Dispersions- are usually transparent

like coconut milklike coconut milkPolymers- are usually translucent like Polymers- are usually translucent like

stained glassstained glass

Emulsions- are most often opaque,Emulsions- are most often opaque,

like milk or Elmer’s gluelike milk or Elmer’s glue

CoatingsCoatings

For information on For information on Waterborne solutions:Waterborne solutions:

Water on the web:Water on the web:

www.specialchem4coatings.comwww.specialchem4coatings.com

www.cage.rti.org/altern.cfm

www.paint.org

www.paintcenter.orgwww.paintcenter.org

CoatingsCoatings

http://www.cage.rti.org/altern.cfm

http://www.paint.org/

High Solids Pro and Con High Solids Pro and Con 62% solids by weight62% solids by weight

reduced air emissions increased viscosity

reduced storage reduced storage & handling stability

CoatingsCoatings

Thermoplastic or thermosetNo on-site color mixingFaraday cageElectrostatic application or fluidized bed required

200-12

Powder CoatingsPowder Coatings

Coatings

Powder CoatingsPowder Coatings

Coatings

Common MP&P CoatingsVOC Limits

Prefab Arch. 275 g/l 420Metallics 350 g/l 420 Masks &Lubs 800 g/l 800

baked air dry

RegulationRegulation

Coating steps and points ofCoating steps and points of

sanding/depaintingsanding/depainting

surface clean and prepsurface clean and prep

primer & topcoat application primer & topcoat application

flash off/drying flash off/drying

cure cure

touch uptouch up

equipment clean upequipment clean up 200-2

Process

emissionemission

Surface Preparation

DepaintingDegreasingSurface etching

These 3 may use water,

particulate or VOC

Points of VOC Emission

Storage Application Cleanup Mixing Drying & Prep.

90% of VOC Emission

25 n-Octane

34 Tertiary Butyl Acetate

49 Water

70 Methyl-isopropyl ketone

110 Ethanol

170 Benzene and Methyl ethyl ketone (MEK)

250 n-Hexane

360 Acetone

690 Methylene chloride (MC)

Selected Vapor Pressures in mm Hg at 38oC

Terone

Application Techniques

DipFlowRoll

SprayAirlessAir HVLP/Electrostatic

}

} ElectrodepositionAutodeposition

ProcessProcess

AutodepositionAutodeposition

no electrical current used; waterborne; an acid no electrical current used; waterborne; an acid bath releases iron cations from steel that react bath releases iron cations from steel that react with negatively charged latex polymer to with negatively charged latex polymer to precipitate coating solids onto surfaceprecipitate coating solids onto surface

aka autophoresisaka autophoresis

ElectrodepositionElectrodeposition aka Electrophoresisaka Electrophoresis

Coating solids and part are Coating solids and part are given opposite charges. given opposite charges. Coating particles are drawn Coating particles are drawn magnetically to part. magnetically to part.

similar to Electroplatingsimilar to Electroplating

ProcessProcess

Listed Hazardous Materials Listed Hazardous Materials found in Coatingsfound in Coatings

BenzeneBenzene Lead Lead

1,3-Butadiene1,3-Butadiene Methylene Chloride Methylene Chloride

Carbon tetrachloride Perchloroethlene Carbon tetrachloride Perchloroethlene

Chromium VIChromium VI Toluene Toluene

Ethylene dibromideEthylene dibromide Trichloroethylene Trichloroethylene

Ethylene dichlorideEthylene dichloride Vinyl chloride Vinyl chloride

Glycol ethersGlycol ethers Xylene Xylene 700-2,3

Plating

How it WorksHow it Works

A direct current is passed A direct current is passed through a Chromic acid bath through a Chromic acid bath causing positive chromium and causing positive chromium and hydrogen ions to migrate to the hydrogen ions to migrate to the cathode and negative oxygen cathode and negative oxygen ions to migrate to the anode. ions to migrate to the anode.

Plating

ROG Control Strategies for ROG Control Strategies for CoatingsCoatings









Control

Transfer Efficiency (T.E.)Transfer Efficiency (T.E.)

the ratio of the amount of solids the ratio of the amount of solids adhering, to the amount of solidsadhering, to the amount of solidsapplied applied

200-17

AirlessAir Atomized High Volume, LowElectrostatic PressureAir-Assisted Turbobell

Spray ApplicationSpray Application

Process

HVLP Alternative

Wing Port

Spray GunSpray Gun

Air path

Spray fan pattern is compressed by air from the spray cap wing ports.

00 20%20% 30%30% 40%40% 50%50% 60%60% 70%70% 80%80% 90%90% 100%100%

HVLPHVLP

Airless ElectrostaticAirless Electrostatic

Air - Assisted Airless ElectrostaticAir - Assisted Airless Electrostatic

Air ElectrostaticAir Electrostatic

Air - Assisted AirlessAir - Assisted AirlessAirless SprayAirless Spray

65% 65%

Percent TransferEfficiency

Air SprayAir Spray

High Volume/Low PressureCoatings Application

200-21

Since the early 1990’s complying equipment is manufactured with an embossed “HVLP” label (not seen here)

ControlControl

ControlControl

HVLP Primer Conventional Air

Spray Gun Caps- note wing port sizeSpray Gun Caps- note wing port size

ControlControl

Spray cap pressure gauge is specific to Spray cap pressure gauge is specific to the make and model of gunthe make and model of gun

Electrostatic spray gunnote charging electrode

Transfer Efficiency ParametersTransfer Efficiency Parameters

Spray equipmentSpray equipment

Paint pressure and air pressure at nozzlePaint pressure and air pressure at nozzle

Ambient temperature and humidityAmbient temperature and humidity

Air flow rate in spray boothAir flow rate in spray booth

Painters training and experiencePainters training and experience

Coating chemistryCoating chemistry

Shape of part Shape of part

ProcessProcess

Control Alternative:Control Alternative:

Rather than Meet Any of the ROC Limits a Rather than Meet Any of the ROC Limits a Source May:Source May:

• • Collect at Least 90 Percent by Weight Collect at Least 90 Percent by Weight of Emissions of Emissions

AndAnd

• Transport to a Central Device that Reduces • Transport to a Central Device that Reduces Emissions at Lease 95 Percent Emissions at Lease 95 Percent (Total Control = 85%) (Total Control = 85%)

ROG Control Strategies for CoatingsROG Control Strategies for Coatings


• • Plating instead of coatingPlating instead of coating








ControlControl

Booth Design Booth Design

Air FlowAir Flow Particulate CollectionParticulate Collection

DowndraftDowndraft Water WashWater Wash

SidedraftSidedraft Dry filter Dry filter

HoodHood

ControlControl

200-29200-29

Booth Design Booth Design

ControlControl

•IncinerationDirect FlameCatalytic

•Carbon Adsorption•Condensation•Absorption

Control EquipmentControl Equipment

ControlControl

ThTherermal mal OxiOxidatdationion

Destroys VOC with the three T's of Destroys VOC with the three T's of combustion:combustion:

TimeTimeTemperatureTemperatureTurbulenceTurbulence

Achieves 75-99% reduction in the Achieves 75-99% reduction in the emissions entering the deviceemissions entering the device

Control

Direct Flame vs. CatalyticDirect Flame vs. Catalytic

Capital costsCapital costsoperating cost (auxiliary fuel)operating cost (auxiliary fuel)operating temperatureoperating temperature

ControlControl

Control

Slow Catalyst PoisonsSlow Catalyst Poisons

IronTinSilicon

HalogensSulfurZinc

PhosphorousLeadArsenicAntimonyMercuryBismuth

Reversible Catalyst Inhibitors Fast Acting

Catalyst Poisons

I bought the equipment. Why does it still smell?

Catalysts are Subject to:Catalysts are Subject to:

Thermal Aging - Heat Cycles Cause the Thermal Aging - Heat Cycles Cause the Metal to Recrystallize in Metal to Recrystallize in an Ineffective Form an Ineffective Form

Burnout - Burnout - Excessive Heat "Boils" Excessive Heat "Boils" the Metal off the Substrate the Metal off the Substrate

Gumming - Surface Area is Covered by Gumming - Surface Area is Covered by Heavy Organics From Paint Heavy Organics From Paint or Fuel Oil or Fuel Oil

Control

Check Incinerators for:Check Incinerators for:

Auxiliary Fuel FlowAuxiliary Fuel Flow

Gas Flow from Booth to StackGas Flow from Booth to Stack

Outlet Temp. Higher than Inlet Temp.Outlet Temp. Higher than Inlet Temp.

Inlet VOC Concentration Higher than Inlet VOC Concentration Higher than Outlet VOC ConcentrationOutlet VOC Concentration

Bypass Stack EmissionsBypass Stack Emissions

Control

ControlControl

Carbon AdsorptionCarbon Adsorption

Electromagnetically attracts Electromagnetically attracts VOC onto activated carbonVOC onto activated carbon

Achieves 40 to 65% Achieves 40 to 65% reduction reduction

Rule, FederalRule, Federal

http://www.epa.gov/ttn/atw/misc/miscpg.html#RULE

Final in Jan 2004Final in Jan 2004

http://www.epa.gov/ttn/atw/misc/fr13aug02p.html

The text of USEPA’s Metal Parts coating NESHAP can be found here:

http://www.epa.gov/ttn/atw/misc/miscpg.html#RULE

http://www.epa.gov/ttn/atw/misc/fr13aug02p.html

RuleRule

California jurisdictions with MP & P rulesCalifornia jurisdictions with MP & P rules

Bay Area 8-19 South Coast 1107Monterey Bay 434 San Diego 67.3Mojave 1115 San Luis Obispo 411Sacramento 451 Ventura 74.12San Joaquin Unified 4603 Yolo-Solano 2.25Santa Barbara 330

InspectionInspection

The Paperwork for a VOC The Paperwork for a VOC InspectionInspection


Operator Must Maintain Daily:Operator Must Maintain Daily:

All data necessary to All data necessary to determine compliancedetermine compliance


Determine the VOC Content of Determine the VOC Content of Coatings in storage & being appliedCoatings in storage & being applied

Ask for Product specification Ask for Product specification sheet or Material Safety Data sheet or Material Safety Data SheetSheet

Take a sample for laboratory Take a sample for laboratory analysisanalysis


MP & P allowable VOC Limits MP & P allowable VOC Limits

Depending on the type of coating Depending on the type of coating the VOC limit may range from the VOC limit may range from 275-340 to 420 gram VOC 275-340 to 420 gram VOC per liter of coatingper liter of coating


The Product Label may include:The Product Label may include:

1) Id number or name1) Id number or name2) Mixing instructions2) Mixing instructions3) VOC content as applied3) VOC content as applied4) Weight percent water4) Weight percent water5) Solvent names & densities5) Solvent names & densities

Exempt CompoundsGroup I1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee)1,3-dichloro-1,1,2,2,3-pentafluoropropane (HCFC 225cb)3,3-dichloro-1,1,1,2,2-pentafluoropropane (HCFC 225ca)acetoneethanechlorodifluoromethane (HCFC-22)trifluoromethane (HFC-23)2,2-dichloro-1,1,1-trifluoroethane (HCFC-123)2-chloro-1,1,1,2-tetrafluoroethane (HCFC-124)pentafluoroethane (HFC-125)1,1,2,2-tetrafluoroethane (HFC-134)1,1,1,2-tetrafluoroethane (HFC-134a)1,1-dichloro-1-fluoroethane (HCFC-141b)1-chloro-1,1-difluoroethane (HCFC-142b)

Exempt CompoundsGroup I con’t1,1,1-trifluoroethane (HFC-143a)1,1-difluoroethane (HFC-152a)cyclic, branched, or linear, completely fluorinated alkanescyclic, branched, or linear, completely fluorinated ethers with no unsaturationscyclic, branched, or linear, completely fluorinated tertiary amines with no unsaturationssulfur-containing perfluorocarbons with no unsaturations and with sulfur bonds only to carbon and fluorine.difluoromethane (HFC-32)1,1,1,2,2,3,3,4,4-nonafluoro-4-methoxy-butane (C4F9OCH3)2-(difluoromethoxymethyl)-1,1,1,2,3,3,3-heptafluoropropane [(CF3)2CFCF2OCH3]1-ethoxy-1,1,2,2,3,3,4,4,4-nonafluorobutane (C4F9OC2H5)2-(ethoxydifluoromethyl)-1,1,1,2,3,3,3-heptafluoropropane [(CF3)2CFCF2OC2H5]parachlorobenzotrifluoride (PCBTF)methyl acetate

Exempt Compounds

Group IImethylene chloride (dichloromethane)1,1,1-trichloroethane (methyl chloroform)trichlorofluoromethane (CFC-11)dichlorodifluoromethane (CFC-12)1,1,2-trichloro-1,2,2-trifluoroethane (CFC-113)1,2-dichloro-1,1,2,2-tetrafluoroethane (CFC-114)chloropentafluoroethane (CFC-115)cyclic, branched, or linear, completely methylated siloxanes (VMS)tetrachloroethylene (perchloroethylene)

Group II (cont.)ethylfluoride (HFC-161)1,1,1,3,3,3-hexafluoropropane (HFC-236fa)1,1,2,2,3-pentafluoropropane (HFC-245ca)1,1,2,3,3-pentafluoropropane (HFC-245ea)1,1,1,2,3-pentafluoropropane (HFC-245eb)1,1,1,3,3-pentafluoropropane (HFC-245fa)1,1,1,2,3,3-hexafluoropropane (HFC-236ea)1,1,1,3,3-pentafluorobutane (HFC-365mfc)chlorofluoromethane (HCFC-31)1,2-dichloro-1,1,2-trifluoroethane (HCFC-123a)1 chloro-1-fluoroethane (HCFC-151a)

Exempt Compounds

InspectionsInspections

Ask for Mixing RecordsAsk for Mixing Records

A log should be available at A log should be available at the mixing station, spray the mixing station, spray booth or paint foreman's booth or paint foreman's deskdesk


Compare materials in the log Compare materials in the log to materials on the shelvesto materials on the shelves

Sign and date this logSign and date this log

CalculationsCalculations

To calculate excess emissions To calculate excess emissions consult Section 500 and consult Section 500 and Appendix F of your manualAppendix F of your manual


The Physical InspectionThe Physical Inspection

Applicable RulesApplicable Rules

NuisanceNuisance

Visible EmissionsVisible Emissions

General Organic SolventGeneral Organic Solvent

PermitPermit

Fugitive DustFugitive Dust


Inapplicable operationsInapplicable operations

StencilingStenciling

OSHA type markingsOSHA type markings

Solid film lubricantsSolid film lubricants

Electrical insulating and thermal Electrical insulating and thermal

conducting coatingsconducting coatings

Any operations specificallyAny operations specifically

addressed by another ruleaddressed by another rule


Points of VOC Emission

Storage Application Cleanup Mixing Drying & Prep.

90% of VOC Emission

Closed containerClosed container

For solvent laden waste materials For solvent laden waste materials


Inspection

The Seven Points of Any InspectionThe Seven Points of Any Inspection

CaptureCaptureTransportTransportAir MoverAir MoverInstrumentationInstrumentationControl EquipmentControl EquipmentSubsystemSubsystemStackStack

Permit Conditions

Mixing

Look for secondary operations.Look for secondary operations.InspectionsInspections

DegreasingDegreasingSandblastingSandblastingSpace HeatingSpace Heating

How can the inspector improve compliance rates?

Bring the right toolsBring the right attitude.

•Specify operating conditions for control equipment and installation of a measuring device•Permit should specify renegotiation of permit when the volume of coating exceeds X (to limit unreported growth)

Permit negotiations

Recommendations/EngineeringRecommendations/Engineering

•Void a particular exemption

•Specify higher than required transfer efficiency

Permit negotiation

Possible Permit Conditions:Possible Permit Conditions:

Federal Executive Order 12088 &

Prohibition of Specification

" You want me to do WHAT?!!!"

LaserTouch targeting device improves a sprayer's transfer efficiencyby reducing overspray and material consumption. mounted to a spray gun, dual lasers project an image that helps maintain optimal distance btwn gun & target Proper spray gun distance, gun angle, lead & lag, edging and overlap impact TE. Developed by Iowa Waste Reduction Center

The Final Word on Successful Inspecting

Patience, Repetition, ConsistencyPatience, Repetition, Consistency

QuestionsQuestionsQuestionsQuestions

surface coating operations: metal parts & products presented by terone preston 2007 california...

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