United States Environmental Protection Agency Air and Energy Engineering Research Laboratory Research Triangle Park, NC 27711 Research and Development EPA/600/SR-94/022 April 1994 EPA Project Summary Proceedings: Pollution Prevention Conference on Low- and No-VOC Coating Technologies Coleen M. Northeim and Ella Darden The report documents a conference that provided a forum for the exchange of technical information on coating technologies. It focused on improved and emerging technologies that result in fewer volatile organic compound (VOC) and toxic air emissions than tra- ditional coating emissions. Among the new products and improvements fo- cused on were an electrophoretic u re- thane coating, a zero-VOC house paint, and developments involving such inor- ganic polymers as zinc silicates and silicones. Coatings for such substrates as metal (aerospace), wood (furniture), plastic, foil, and concrete were also dis- cussed. This Project Summary was developed by EPA's Air and Energy Engineering Research Laboratory, Research Tri- angle Park, NC, to announce key find- ings of the research project that is fully documented in a separate report of the same title (see Project Report ordering information at back). Introduction Surface coating operations release ap- proximately 19% of stationary area source volatile organic compound (VOC) emis- sions. Many of these sources cannot be impacted by add-on controls at a reason- able cost due to their small size and/or the difficulty of capturing emissions. The reduction of solvent emissions from archi- tectural and other coatings continues to rely on prevention technologies, such as the replacement of VOC with water or nonphotochemically reactive solvents, the use of high solids coatings, or improve- ment of the efficiency of transfer of the coating to the coated surface. In current practice, reformulation with nonphoto- chemically reactive solvents may lead to other environmental problems, such as increased toxicity, greater stratospheric ozone depletion potential, and worsened multimedia effects. A conference, "Pollution Prevention Con- ference on Low- and No-VOC Coating Technologies," was held May 25-27, 1993, in San Diego, CA. The conference was sponsored by the U.S. Environmental Pro- tection Agency (EPA), Research Triangle Institute (RTI), and the American Institute for Pollution Prevention (AIPP). The con- ference provided a forum for the exchange of technical information on coating tech- nologies. Specifically, the conference fo- cused on improved and emerging tech- nologies that result in fewer VOC and toxic air emissions than traditional coating systems. Approximately 230 people attended the conference: about 50% were from indus- try, 40% from government, and 10% from consulting firms and universities. There were three registrants each from Taiwan and the United Kingdom; and one each from Sri Lanka, Norway, and the Philip- pines. Conference registrants are listed in Appendix A of the proceedings. Approximately 40 technical papers were presented at the conference, divided into 11 sessions focusing on such topical ar- eas as coating technologies, specific coat- ing applications and case studies, appli- cation equipment, and pollution preven- tion concepts. Several papers focused on new products and improvements in these areas, such as an electrophoretic urethane coating, a zero-VOC house paint, and de- ------- velopments involving inorganic polymers such as zinc silicates and silicones. Coat- ings for substrates, such as metal (aero- space), wood (furniture), plastic, foil, and concrete, were also discussed. Conference Program Portions of the conference program fol- low, including the session topics, paper titles, and authors. The project report includes copies of the presented papers that were submitted for inclusion in the proceedings. Conference Scope The purpose of this conference is to provide a forum for the exchange of tech- nical information on coating technologies. One of the primary objectives of the con- ference will be the presentation and dis- cussion of improved coating technologies that result in fewer volatile organic com- pound (VOC) and toxic air emissions. The conference is designed to benefit coating manufacturers and users and representa- tives of government, academia, environ- mental groups, and other research and development organizations. Research and case studies will be presented that are specifically applicable to the architectural and industrial maintenance (AIM), aero- space, automotive, wood furniture, and printing industries. The sessions will con- sist of technical paper presentations and are planned to allow for discussion peri- ods and active participation by all attend- ees. Tuesday, May 25 Session 1: Opening Session, Modera- tor-Coleen M. Northeim, RTI 8:15 a.m. Welcome by Richard J. Sommerville, Air Pollution Control Officer, San Diego County Air Pollution District, San Diego, CA 8:30 a.m. Keynote by Paul Eisele, Director of Health Safety & Environmental Affairs, Masco Corporation, Taylor, Ml 9:00 a.m. Coating Research in the U.S. EPA's Organics Control Branch, Michael Kosusko, U.S. Environmental Protection Agency, Air and Energy Engineering Research Laboratory, Research Triangle Park, NC 9:20 a.m. Using Life-Cycle Analytical Techniques to Assess Alternative Coating Systems, Keith A. Weitz and John Warren (Speaker), Research Triangle Institute, Research Triangle Park, NC Session 2: Technologies, Moderator- Robert McCrillis, U.S. EPA/AEERL 10:00 a.m. Radiation Curing Technology: Ultravio- let and Electron Beam Processing, Ri- chard Stowe, Fusion UV Curing Sys- tems, Rockville, MD 10:30 a.m. Environmental Compliant Thermoplas- tic Powder Coating, David F. Eliicks, Department of the Air Force, Air Force Corrosion Program Office, Robins AFB, GA 11:00 a.m. Supercritical Fluid Spray Application of Low-Pollution Coatings for Plastic Sub- strates, Wayne Miller and Kenneth Nielsen, Union Carbide Corporation, South Charleston, WV, and Tom Morrison, Red Spot Paint & Varnish, Evansville, IN 11:30 a.m. Utilizing Dispersion Resins with Inorganci Solids in a New Formulary Blending Process to Achieve Synergis- tic Results of Performance (Expanded Abstract), Philip W. Coscia, Resources Conservatory International, Gustine, CA Session 3: Powder Coatings, Moderator-Richard Sayad, Dow Chemical Company 1:15 p.m. Advantages of Powder Coating, Albert Holder, Naval Surface Warfare Center, Annapolis, MD 1:45 p.m. Aerospace Applications for Powder Coating at Hughes Aircraft Company, Larry Brown, Hughes Missile Systems Company, Tucson, AZ 2:15 p.m. Fluoropolymer Coatings for Architectural, Automotive and General Industrial Ap- plications, David M. Grafflin, Evodex Powder Coatings, Birmingham, AL Session 4: Federal Programs, Moderator-John Warren, RTI 3:00 p.m. US Navy Compliance to Shipbuilding and Ship Repair Environmental Regula- tions, Alex Kaznoff, Naval Sea Systems Command, Arlington, VA 3:30 p.m. Low-VOC Coatings Developed by DOE for Environmentally Conscious Manu- facturers, Mark D. Smith, Allied Signal, Inc., Kansas City, MO 4:00 p.m. The Precedent-Setting Use of a Pollu- tion Prevention Project in an EPA En- forcement Settlement, David Nelson, EnviroSearch International, Salt Lake City, UT, and James J. Periconi, Donovan Leisure Newton and Irvine, New York, NY 4:30 p.m. Army Pollution Prevention Success Sto- ries, Jack Hurd, Army Acquisition Pollu- tion Prevention Support Office, Alexan- dria, VA, and Mark W. Ingle, Ocean City Research Corporation, Arlington, VA Wednesday, May 26 Session 5: Encouraging Pollution Prevention, Moderator-Coleen Northeim, RTI 8:00 a.m. Pollution Prevention Opportunities in Coatings: Educating Those who are Responsible for This Task, Robert B. Pojasek, GEI Consultants, Inc., Winchester, MA 8:30 a.m. Economic Incentives to Stimulate the Development and Diffusion of Low- and No-VOC Coating Technologies, Brian Morton, Research Triangle Institute, Research Triangle Park, NC, and Bruce Madariaga, U.S. Environ- mental Protection Agency, Office of Air Quality Planning and Standards, Research Triangle Park, NC 9:00 a.m. Pollution Prevention in the Wood Refinishing Industry, Azita Yazdani, Pollution Prevention International, Inc., Brea, CA 9:30 a.m. The Importance of Product Steward- ship and its Impact on Pollution Prevention, Richard Sayad, Dow Chemical Company, Midland, Ml Session 6: Inorganic Coatings, Moderator-Vic Young, Waste Reduction Resource Center ------- 10:15 a.m. Long-Term Corrosion Protection With Single-Coat, High-Ratio Zinc Silicate, Parke Schaffer, Jr., Inorganics Coat- ings, Inc., Malvern, PA 10:45 a.m. Two Surprises From an Inorganic Zinc- Rich Silicate Coating, C. William Anderson, Marine Environmental Research, Inc., Morehead City, NC 11:15 a.m. A New Inorganic Coating for Magne- sium Alloys With Superior Corrosion Resistance, Alex J. Zozulin, Technol- ogy Applications Group, Inc., Grand Forks, ND, and Duane E. Bartak, University of Northern Iowa, Cedar Falls, IA 11:45 a.m. Inorganic Chemistry as an Option for Formulating High Solids, Low- and Zero-VOC Architectural and Industrial Maintenance Coatings, Christine L. Stanley and Raymond Foscante, Ameron, Brea, CA Session 7: High Solids & Water Based Coatings, Moderator-Wade Ponder, U.S. EPA/AEERL 1:30 p.m. The Development of Practical Zero- VOC Decorative Paints, Richard Tuckerman and David W. Maurer, Glidden Company, Cleveland, OH 2:00 p.m. New Environmentally Acceptable Metal Coating Systems, Peter C. Ryder, Hawking International Limited, United Kingdom, and Peter Hope, LVH Coatings Limited, United Kingdom 2:30 p.m. Water-Reducible Polyurethane Coatings for Aerospace Applications, Patricia B. Jacobs and David C. McClurg (Speaker), Miles, Inc., Pittsburgh, PA Concurrent Sessions Session 8: Applications 1, Moderator- Kevin Dick, Nevada Small Business Development Center 3:15 p.m. Water Based and UV-Cured Coatings for Plastics, Edwin C. Laird, Coatings Resource Corporation, Huntington Beach, CA 3:45 p.m. Waterborne Lacquers for Aluminum Foil, William Marwick, Alcan Interna- tional Limited, England 4:15 p.m. Lower-VOC Coating System Conver- sion Costs for Wood Furniture Indus- try, Mary-Jo Caldwell, Midwest Research Institute, Gary, NC 4:45 p.m. Development of Ultra-Low VOC Wood Furniture Coatings, Eddy W. Huang, Center for Emissions Research & Analysis, Larry Watkins, South Coast Air Quality Management District, and Robert C. McCrillis, EPA/AEERL Session 9: Aerospace Applications, Moderator-Robert B. Pojasek, GEI Consultants, Inc. 3:15 p.m. Replacement of Chromated Epoxy Primers for Ground Support Equipment and Flight Hardware, Marke E. Lindsay, Locheed Missiles & Space Company, Inc., Sunnyvale, CA 3:45 p.m. An Investigation of Flexibility Test Methods for Low-VOC Aerospace Coatings, Angela J. Brown, Boeing Defense & Space Group, Seattle, WA 4:15 p.m. Waterborne Maskant, Mark Jaffari, Malek, Inc., San Diego, CA 4:45 p.m. Low-VOC Organic Coatings for Commercial Aircraft Application, T. D. Leland and C.M. Wong, Boeing Commercial Airplane Group, Seattle, WA Thursday, May 27 Session 10: Auxiliary Systems, Moderator-Michael Kosusko, EPA/ AEERL 8:00 a.m. Low Volatility Surface Preparation: A Hybrid Approach, Joseph A. Lucas, Inland Technology Incorporated, Tacoma, WA 8:30 a.m. Transfer Efficiency and VOC Emis- sions of Spray Gun Technologies in Wood Finishing, Leslie Snowden- Swan, Pacific Northwest Laboratory, Richland, WA, and Pamela Worner, Pacific Northwest Pollution Prevention Research Center, Seattle, WA 9:00 a.m. You Can't Always Judge a Paint Spray Gun Cleaning System By Its Cover, Michael J. Callahan and John P. Kusz, Safety-Kleen Corporation, Elgin, IL Session 11: Applications 2, Modera- tor-Jack Kowal, Coors Brewing Company 9:45 a.m. Priority Manufacturing and Environ- mental Issues at Military Industrial Facilities, John W. Adams, Richard S. Goldman, and Jerry R. Hudson, Concurrent Technologies Corporation, National Defense Center for Environ- mental Excellence, Jamestown, PA 10:15 a.m. Low-VOC Dual-Cure Aerospace Topcoat, Kevin E. Kinzer and Steven J. Keipert, 3M Company, St. Paul, MN 10:45 a.m. UV Pollution Prevention Technology in Can Manufacturing, Erik Donhowe, Coors Brewing Company, Golden, CO Pollution Prevention Opportunities in the Manufacture of Paint and Coatings, Paul M. Randall, U.S. Environmental Protection Agency, Risk Reduction Engineering Laboratory, Cincinnati, OH ------- C. Northeim and E. Darden are with Research Triangle Institute, PO Box 12194, Research Triangle Park, NC 27709. Michael Kosusko is the EPA Project Officer (see below). The complete report, entitled "Proceedings: Pollution Prevention Conference on Low-andNo-VOC Coating Technologies,"(OrderNo. PB94-152246/AS; Cost: $61.00; subject to change) will be available only from: National Technical Information Service 5285 Port Royal Road Springfield, VA 22161 Telephone: 703-487-4650 The EPA Project Officer can be contacted at: Air and Energy Engineering Research Laboratory U.S. Environmental Protection Agency Research Triangle Park, NC 27711 United States Environmental Protection Agency Center for Environmental Research Information Cincinnati, OH 45268 Official Business Penalty for Private Use $300 BULK RATE POSTAGE & FEES PAID EPA PERMIT No. G-35 EPA/600/SR-94/022 ------- |