8 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
ftifj *~ 0 lyOI OFFICE OF
PESTICIDES AND TOXIC SUBSTANCES
MEMORANDUM
SUBJECT: Spray Coating Generic Scenario - Research Project
FROM: Vanessa E. Rodriguez, Chemical Engineer
Chemical Engineering Branch (TS-779)
TO: CEB Staff
The purpose of this project was to obtain information about
occupational exposures and environmental releases associated with
the spray application of coatings, and to present it in a way
that would facilitate its use in PMN reviews.
The attached document presents generic scenarios for
automotive finishing and refinishihg, metal and wood furniture
finishing, large appliance finishing, non-automotive
transportation, and heavy machinery finishing.
Attachment
-------
• Generic Engineering Assessment
Sp ray Coat i ng
Occupational Exposure and. Environmen*aI Release
Vanessa E. Rodriguez
Chemical Engineering Branch
Revised - October 1987
I. Introduc* ion
Under the Toxic Substances Control Act, any person who
intends to manufacture or import a new chemical substance for
corrmercial purposes in the Uni*ed States is required *o submit a
Premanufacture Notice (PMN) at least 90 days prior to it's
manufacture or importation. The Chemical Engineering Branch is
responsible for assessing workplace exposures and environmental
releases of these new chemicals.
A wide variety of coating materials is available *oday.
These are applied on*o substrates for protective, decorative and
functional purposes. Spray coating is a widely used and
convenient application method because of being relatively quick
and simple in comparison with other coating techniques.
Consequently, a large number of PMNs are submitted for chemicals
used in coating formulations designed or intended for spray
application. The purpose of this report is to present generic
spray coating scenarios that contain readily available
information about the occupational exposures and environmental
releases associated with this type of operation. This is
intended to facilitate consistent PMN reviews and efficient
analysis of each case.
-------
Several generic spray roaming scenarios were rhararterized
according to industry of application: automotive finishing and
refinishing, me'al furniture and wood furniture finishing,^ large
*
appliance finishing, non-automotive transportation, and heavy
machinery finishing. Common variables across scenarios were
identified and typical values for each scenario were obtained.
The information is presented in a matrix for each industry so
*ha* it can be easily extracted when needed.
The information presented was obtained from the following
sources: a) Environmental Protection Agency (EPA) and National
Institute of Occupational Safety and Health (NIOSH) technical
publications, b) contractor reports, c) cormnun icat i ons with
various industry representatives, d) non-CBI information included
in PMN submissions, e) product literature, and f) general
*echnical publications.
The information presented is limited in i*s dermal exposure
characterization for spraying operations. No specific
information was found regarding this exposure, other than the
fact that, compared to other coating processes, the major dermal
exposure comes from airborne spray mist, when the coatings are
applied by spray without adequate projection.
It is very difficult to genericaJly describe any type of
coating operation. In each industry category, every facility is
somewhat different in terms of product, coatings, application
techniques, ventilation practices, work practices, health and
-2-
-------
safety precautions, controls, etc. The values presented
represent *he high degree of variability associated with each
parameter and should be used cautiously for mak'ing
exposure/re I ease estimations.
I I. Var iobles
The following describes each variable included in the
matrices and how they can be used for PA/N assessments.
I. Coa*ing Components
Lists corrmon components (not all-inclusive) encountered
in each industry (generic names and/or examples) by
resins, solvents and pigments.0
2. Coa'ing Classifications
Lists corrmon types of formulations encountered in each
industry, not exclusive of other formulation types.
3. Coating Compositions
Gives the percentage of solids (resins, pigments,
additives) typically found in a specific type of
coating formulation. The Values are reported as
percent solids by weight, "as applied" (i.e., after any
dilution the user may need to do before spraying *he
coa*ing), unless otherwise indicated.
a Examples for additives that aid in the formulation and/or
application of coatings are not included. For estimation
purposes it can be assumed *hat add i * i ves-.compr ise less than
2 percent by weight of the formulations.
-3-
-------
4. Coaled Area, Coating Thickness and/or Coa*ing Volume
Per Uni *
Average values for coaling volumes used per uni/ (i.e.
individual item rooted) are listed. Coated area and
coa*ing thickness average values per unit are given for
cases where coa*ing volume was not available. Coa*ing
thickness values are given for each coat applied (no*
for total thickness) and refer to dry thickness.
Appendix I gives examples for using these values in
estimating coating volumes.
5. Worker Ac*ivities
Lists worker activities that involve the handling of
coatings.'1 An estimate of the time spent by workers
during each activity is also included for most cases.
6. Days of Operation Per Year
An approximate value (or range) of the number of days
per year that a typical site would be involved in spray
coating operations is given. For a given P/VM this
value will depend on the amount of coating that could
be formulated with the intended production volume of
the PMN chemical. It is a I/so likely that not only PMN-
containing coatings will be used at any particular
site, but that several other "non-PMM" coatings will be
used as well.
Where information was available, ac*ivi*ies that precede and
follow the direct handling of coatings were also included.
-4-
-------
7. Hours of Plan* Operations Per Doy
Provides an approximate number of hours (based on *he
number of 8-hour shifts per day) during which sp"ray
coa*ing and related operations occur in a typical
plant.0
8. Uni As Coated Per Day
An average number of units coated per day in a typical
plant is given. The term unit refers to the specific
articles coated in each scenario (i.e., cars, desks,
refrigerators, airplanes, tractor motors, etc.).
9. Number of SiAes
Approximate number of existing U.S. sites that handle
finishing operations for each specific scenario is
given. N/A denotes this information was not available.
10. Workers Per Site
The number of workers per site involved with various
aspects of the finishing operations is given. In
addition, estimates of the number of workers per si'e
involved in actual spraying operations are included.
c This should not be mistaken for the: number of hours per day a
worker might be exposed when handling coatings.
Refer to Worker Activities for this information.
d For PMM submissions where no specific scenario can be
determined, rates of application of 105 liters per worker-day
(compressed air spray application) or 280 liters per worker-day
(airless spray application) can be used to estimate a total
number of workers exposed, based on the PMN chemical's
production volume (an average of 120 liters per worker-day can
be assumed as a typical rate when the spraying technique is no4
known). These rates assume workers are spray applying pain*
for 80 percent of the workday (6.4 hours per 8-hour shift).
This *otal number of workers can then be distributed among all
the user s i tes.
-5-
-------
I I. Spray/Atomiza*'on Technique
Typical spraying techniques and *he methods by which
the a^omization of *he coating is accomplished ore
presented for each scenario. These are not exclusive
of any new technology that could be used in any
part icular industry.
I 2. Type of Operation
A distinction between typically manual operations and
automated operations is made in this section. Worker
exposures are expected to be higher with manual
ope rat i ons.
13. Overspray
An approximate percent (or range) is given for most of
the spraying techniques in the scenarios. This percent
reflects the amount of solids in the coating
formulation that are not deposited onto the substrate
during the coating operations. It should be kept in
mind that the reported values are approximations. Each
system's overspray will depend on, among other things,
the spray atomization technique used, the coating type
and composition, and the substrate. All assumptions
should be included in any assesment.
\k. Solvent Discharge
Approximate percents (or ranges) for the amount of
solvent discharged are given for the two major steps
during spraying operations: a) appplication and flash-
off and b) oven and/or air drying. Addi*ional
-6-
-------
information is provided for several industries on
emission ra^es. In addition *o organic solvents, o*her
•»
volatile organics, referred to as "cure volatil*s", may
be released during the drying/curing step. It should
be kept in mind *hat new chemical substances in
coatings may also yield new cure volatiles.
15. Inhalation Exposure Levels
Estimated values based on a series of field studies
conducted by NIOSH (O'Brien, 1981) are given for total
mist levels (mg/m3), and for combined exposures (CE)e
to solvents (dimension I ess). For PMN chemicals that
are a part of the solids in a coating, *he total mist
value can be used to estimate potential worker
exposures.* The Occupational Safety and Health
Administration (OSHA) established Permissible Exposure
Level (PEL) for paint mists (particulates) of 15 mg/m3
should be used when no particular scenario is
representative of the PMN use. For PA/IN chemicals that
are part of solvent systems and/or volatile compounds
e Combined effects of mixtures should' be considered when the
components cause similar exposure effects. In the abscence of
information to the contrary, their effects are considered as
additive. The combined exposure is given by Cn/Ln, where C
is *he airborne concentration of the individual contaminants in
air and L is the corresponding permissible level or limit. The
mixture's permissible level is exceeded when the sum is greater
than I.
' For example: If a PMN chemical comprises 5 percent of an
automotive coating which has 30 percent total solids as
applied, it will then comprise 17 percent of the to*al
solids. From the automotive spray coaling matrix, the total
estimated mi s' 8-hour TWA is 5 mg/mj. The PMN chemical will
contribute 17 percent of the total mist, or 0.85 mg/m3 , 8-hour TWA.
-7-
-------
in the coatings, no general me*hod to estimate
poten*ial worker exposures is available. Airbojne
»>
concentration levels (mg/m3) are listed in the NIOSH
documen* for a variety of known solvents. The CE
values reported in the matrixes are based on these
measured concen*rations. Solvent or volatile compounds
concentrations were, in general, well below the
recorrmended maximums. Some notion of the potential
airborne concentration for a volatile PMN chemical in a
coa*ing can be obtained based on the airborne
concentration of a known similar volatile compound.9
Data from the NIOSH field studies, if available, should
be used when the particular scenario is representative
of the PMN use. Use caution when establishing exposure
scenarios based on these studies, since they are mosMy
based on visits to only one facility in each
industry. The study should be referenced whenever
these values are used in engineering assesments.
16. Protective Equipment
These descriptions of the protection used by workers
during spray coa*ing operations are based mainly on
observations from the NIOSH field studies (O'Brien,
9 The estimated PMN airborne concentration in ppm is given by :
CS x (YP / YS), where CS = measured airborne concentration
of known compound, YP = mole fraction of PMN in coating, and
YS = mole fraction of known compound in coating (assuming
most of the solven* becomes airborne during spray application)
-8-
-------
1981).
17. Exposure/Release Controls
Mainly describes spray booths, the ventilation system
most commonly used in spray coa'ing operations. The
par*iculate removal efficiency percentages were
gathered from product literature and general technical
publications. These represen* the percentage of
overspray cap*ured by water curtains and/or dry filter
banks in spray booths. Dry fil'er booths provide a
mechanical means for filtering and distributing the air
flow evenly through the spray booth. When paint build
up restricts *he air flow, the filter media is
changed. Appendix 2 contains additional information on
dry filter media. Water booths wash the paint out of
the exhausted air stream by either a) drawing the air
through a continuous curtain of moving water where the
suspended paint particles are flushed out, or b)
forcing the air carrying paint particles to make a
sudden change in direction of flow, such that the
centrifugal force will fliryg the solid particles from
the air, through water wash chambers, into a collecting
pan. The water is then treated in such a way tha* the
spent paint particles will either float or sink,
depending on the type of booth or material being used,
for collection and disposal. Appendix 3 provides
additional information on waste manegement for water
wash booths.
-9-
-------
Some specific- design descriptions are given based
on observations fromNIOSH field studies (O'Brien,
1981). Additional details (such as spray booth
dimensions, air flow/velocity, etc.) can be found in
the above mentioned document.
Solvent vapors or fumes will not be removed in any
spray booth. However, they are occasionally vented to
an organic volatiles control device, before their
discharge to the atmosphere.
-10-
-------
CDKTIN:
CTATIN: OXPOENTS
Resins
Arrylic
Ure*hone
Solvents
Ketone
Alcohols
Esters
hydrocarbons
Arcrra*ics
Ethers
Pig-rents
SMIar to
'hose listed for
Refinishing
Resins
Arrylic
Urethane
Epoxies
Solvents (typical)
Ethyl Acetate
Toluene
Butyl acetate
hVdrorarbons
Pigrents
Talk
Clay
Barytes
Iron oxide
Organ ics
Water-based pr inner
(surfacer)
So I vent-based primer
(surfacer)
Wjter -based topcoat
(enarels and lacquers)
Solvent4»sed topcoat
(enarels and lacquers)
Urethanes
Powder coatings
Prirer/Surfacers
50% sol ids (purchased)
35 - 45% sol ids (applied)
QDlor Baseroats
40 - 50% sol ids (applied)
Clearcoats (Topcoats)
45 - 55% sol ids (applied)
Nan-Clearcoated, Oalor
Basecoat
50 - 55% sol ids (applied)
So I vent-based
lacquers and encmels
2-Qnponent Urethanes
r4>i-isocyanate Urethanes
Solvent-basedPrirer
40-50% solids (purchased)
Solvent-based Enarel Topcoat
35 - 40% sol ids (purchased)
SoIvent-based Lacquers
10 - 20% sol ids (applied)
2-Gcnponent Urethanes
25% sol ids (applied)
-------
AJ1CNOTIVE STW OPTING
FINISHIN:
PEFINISHIK:
Solvent-based primer
8 li'ers/car
Solven*-based topcoat
(erxrrel)
12 li'ers/car
(Derails in Tables I & 2.
Can also be estimated as
shon in Appendix I using
data from Tables 3 and 4.
Nsw technologies wi11
will probably tend to rrake
these amounts lower, e.g.
high solids, waterborne.)
Solvent-based primer
I li*er/car
Solvent-based topcoat
4 liters/car
Larquer
6 liters/car
ACTIVITIES
I) Inspecting and
maintaining operations
of autarnted equipment
(6 - 7 hrs/shift)
2) Touchup/sTull parts
coating
(6 - 7 hrs/shift)
3) Cleaning
I) Mixing-Tinting
(5-10 minutes/car)
If faded or odd colors
need to be notched -
up to 30 minutes/car.
2) Spraying -
(40-50 rrinu'es per car)
3) Cleaning
CAYSAEAS
250
(Plan's usually stop
production for several
weeks during the sawner
season for inventory &
model changeover)
200-250
r-CLFS/D&Y
(shifts)
10- 24
(Shi fts con lost up to 10
hours. Some plants run
only one shift, others
up to 3 shifts.the third
one dedicated to cleaning
and (maintenance.)
8
( I shift)
INI 75/C*Y
880 cars
(640 trucks)
55 cars/hr-line
(40 trucks/hr-line)
I - 8 cars and/or trucks
-------
AJltMJTIVE 3FF&Y
FIN19HIN:
REFINISHIN:
MAEBRCF SITES
40-50 (cars)
15 - 20 (Turks)
Thousands
A total of 50 - 200 in the
finishing department.
Between 2-8 vwrkers/shif*
in each manual spraying
station (The nvnbcr of
manual topcoat spraying
stations p«r site wi 11
likely range between I and
20. A similar nurber can
be assumed for fascia,
blackout, etc. stations).
- 5
SffWr/ATCMZATKN
TEChMGLE
Air Atari zed
Electrostatic:
Air atomized
Rotary atarizer
(Turbo BeI Is)
Air Atomized
T«PE CF CPBWICN
Mostly automated
(There are st i11 sore
manual sprayers in most
auto assert) I y lines;
touchups and ami I ports
coating operations are
likely to be manual.)
Manual
Air Atari zed
50-90%
Electrostatic
5 -50%
(Additional information on
Tobies 3 and 4.)
50 -90%
SCLVBMT D19CHRE
Ajjplication/Flashoff
85 -90%
Oven Drying
10 - 15%
See Table 5 for additional
information an Emission
Rates.
Refinishers usually do not
have ovens - if there is one,
solvent discharge during oven
drying wi 11 range be*ween
3 - 5%j the balance is los*
during application/flashoff.
-------
AJKMJTIVE SPRAY
F INI SHIN:
REFINJSHIN:
LB£LS Forrronual spraying
opera*ions levels are no'
e)
-------
FUMITIRE SPRAY
VCCD
1VETAL
(EATING
Resins
Urea Fomnaldehyde
Catalyzed Urethane
Nitrocellulose
Acrylic
Oi I Based
Solvents
Acetates
Acetone
Alcohols
Aromatic hydrocarbons
Ethers
Glyrol Ethers
fetones
Mineral Spirits
Pignents
Silica
Calciun Carbonate
IronOide
Titaniun Dioxide
Talc
Resins-
Acrylics
Amines
Vinyls
Cellulosics
Solvents
Aliphatics
tylene
Toluene
Other Ararat ics
Pigrents
Titan ion Dioxide
Iron
Borytes
Talc
Galcicm Carbonate
Gnroniun
OATlhC
Mostly t»M-solidj,
So I vent-based
Waterborne
Solvent .borne - Conventional &High
Solids
t as applied)
Body Stain
1% sol ids
Wbshroat
8-10% sol ids
Filler
40% sol ids
Sealer (Barrier Cbat)
14-23% sol ids
Glaze
21-24% sol ids
Clear Loquer (Topcoat)
14-15% soI ids
So I vent -based
(conventional)
15-25* solids
So I vent -based
(high-solids)
sol ids
Wfater borne
1 5-25*30 1 ids
-------
SRW CDMINC
CVff^RAY
Air a*omized
rrore *hon 50%
Airless
less "hen 50%
Air-a*anrized - 50% - 73%
Airless - 75%
Electrosta*ic -
Manual - WJ%
Nr»ro*ational au*cmatic - 30%
Rotational (mmual/autaratic) - 5 - 205
DISCWCE
Appl ication/Flashoff-
80 - 90%
Oven Drying
10 - 20%
Application/Flashoff-
8G% (air-atarized)
65 - 70% (electrostatic)
Q/en Drying
20% (air-atomized)
30-35% (electrostatic)
See Tables 7 and 8 for Bnission Rates
Estimations.
limATKN BfCBJE.
EXKBLFE/RzLEASE CINFCL5
To'al rrist-
Est irrated 8-hour TVA
between O.I and 2.5
rrgAr?. (See Table 9 for
breakout)
Organic SoIvents-
Gnbined exposure «Z)
of less than 0.24.
GE s SGVL". where C =
concentration of the
individual contaminant,
L = cH's PH., both <3L
inrrgAr?. (O'Brien, 1981)
Total rrist-
est irrated 8-hour TVA between 0.
and 23.5 rrgAn3 (lower values
were seen for electrostatic
spraying operations).
Organic Solvents-
Gnbined exposure (OE) of less
than 0.83
(O'Brien, 1981)
Coveralls, rubber or cloth
gloves (at the workers
option), air supplied
respirators with replace-
able viewing window, cloth
cap & loose fitting cloth
hood. (O'Brien, 1981)
Optional use of aprons or shop coats
aid gloves.
Vfcterless hand cleaner available.
(O'Brien, 1981)
Spray booths wi th
disposable filters and
turning vanes installed.
Sraller booths are paired
with these or opposite
side of conveyor of a dry
filter design. Filters
on at I booths are changed
at the end of a shift.
Make up air is provided.
(O'Brien, 1981)
Fi Iter bank wi*h make-up air
supplied fran opposite the
apposite the exhaust filter bank,
aid fran filtered-air inlets in
each conveyor exit. Water-washed
spray booths are also used.
Thick rresh pref i Iters are
soTBtkres fi*ted over the water
curtains (side-draft) to reduce
booth cleanup time/frequency.
(O'Brien, 1981)
-------
FLFNITLFE SPFW OPTING
VOD
BfCSLFEAHEASE dNRLS Particle reroval These prefliters are changed
(cont'd) efficiencies could range periodically (same shifts may not
beVeen % - 96& apply enough paint to clog the
filters).
Water ^washed booths efficiencies
could range fran 95 - 95% for
particle reroval.
(end)
-------
UFCE &?L\ftCE SPRAY CEATINI
CCATING
Resins
Epoxies
Acrylics
Polyesters
Alkyds
Urethones
Anines
Solvents
Esters
Ethers
Ar erotics
Alcohols
Aliphatics
Terpenes
Water
Pigrents
Ti ton itm Dioxide
IronCkide
Talc
Silira
Oirarriim
CDMIhG CLASS IFIGMIO6/
dXPG6mCh£
(wt % as applied)
Conventional Solvent Some:
25-33% sol ids
2-15 different solvents
(usually used as topcoats)
Low-Organic Solvent!
I. Wbterborne
45 -6CK water
10-12% organic solvents
25-30% sol ids
(usually used as primers)
-------
L/TCE
(TWIN: CLASS IFIGATIO6/
CCNPC6ITIO6
(ronVd)
2. High Solids
rrore thon 50% solids
3. Powder
Usually used as topcoats.
See Table 10 for additional information.
Pr m coat - ,
0.7 to 8.4 nt; average = 4 nrr
Top coat - ,
0.7 to 7 rrr; average = 3 rrr
(See Table II for breakout)
THICKNESS
Prirre coat - 0.5 to 0.6 mi Is
Top coat - 0.8 to 1.2 mi I s
(see Table II for breakout)
See Appendix I
VCFVS* /CTIVITIES
I) Preparing equipment
(I hour/shift)
2) Inspecting & maintain ing
operations of automated equlament
(6-7 hours/shi ft)
3) Manual air/airless spraying for
touchup operations.
(6-7 hours/ahift)
4) Cleaning
250
HOPS /CAY
(shifts)
16
8-hr shifts)
-------
UfCE tf=R_l>KE SPFW CEATIhC
LNIT5
640 - 1600
(40 - 100 units/hour-line)
CPE^TICN LINES/SITE
Typically 2 related produces lines
(e.g. refrigerators & freezers,
or washers & dryers).
NAB5RCF SITES
200
Lb to 50 sprayers could be involved
in a single topcoat application in
large sites.
SFrW/AKMZATICM
TEONGLE
Ai r-Atarized
Airless
Electrostatic
TiPE CF
Msstly autamted for:
a) vwterbome pr'msrs (air/
airless spray)
b) solvent -borne prrrers/topcoats
(electrostatic bells or disks)
c) powders (electrostatic)
Manual equipment an inly used
for toucriups (air/airless spray
guns)
O&PSPPKt
Air-atari zed - 60%
Airless - 55%
Air Assisted Air less - SCO,
Manual electrostatic:
Airless - 45%
Air-atarized - 40%
Air Assisted Airless - 40%
-------
URE /m.l/*CE SFRAY
(ront'd)
tvbnro*a*ional automated
electrostatic - I5-3S&
Rotational autcmated
electrostatic - 10-20%
Electrostatic - Powder - I-5&
Applica*ion/Flashoff:
70-80%
Oven Baking:
20-30%
(See Appendix k - Estimation
of Solvent Buission Rote)
INFLATION eraiflE
Total mist -
Est Vnited 8-hour TVA
rrean rrist concentration of 35
rrgAr?. The liner operation
was a heavy contributor to
the average concentration
Oreon of 322 rrgAn* for short
teim, 6.4 minutes per
sorple). Based on this,
mist concentrations >*culd be
IS rrgV 8-hoor TVA during
exterior painting operations.
(O'Brien, 1981)
Organic Solvents
Gnbined e^osure (OE) of less *han 0.79.
CE = "S,Cnl\j\t v«nere
C = Concentration of the
individual contarinant,
L = OGH^'s ra_, ,
both C&L inrrg/nrr.
(O'Briert, 1981)
FD1ECTI\€
Gsveralls. Respirator usage is
Irrited to liner painting operations
frnnual) - MO3H approved air supplied
respirator, with replaceable plastic
viewing window, cloth cap, and loose
fifing, plastic coated, cloth hood.
Irrpeirreable rubber gloves.
(O'Brien, 1981)
-------
LfftE /fflJ/KE 9FRAY CEATIN3
E>reSLFEyPEL£ASE OHFCLS D>^rafi or sidedraft spray
^^^ booth wi th dry f i I *ers or wa4er*a 11
par*icula*e reroval systenns. Each
boo*h rray be up to 50 ft. long.
(O'Brien, 1981)
Particulate reroval efficiencies:
dry filters - 67-99.8%
water curtains - 95-99.9%
Powder spray booths - Ventilation
rates are maintained high enough
to keep the powder concentration
safely below its laser e*>losive
IMt UB_). The LH. used by
insurance ccrrpanies W«n no elemental
data are available an the specific
powder is 26 rrgV. M> to 99% parti-
culate recovery/recycle efficiency
can be achieved. Most booths are
designed with a conveyor belt that
moves across the bottan Uiadhered
powder is collected and a dual
vacuun systen reroves i t from the
belt, recycling it to the holding
tank.
For color changes/cleaning opera-
tions, the system is a autaratic-
ally flushed with solvent for a
few seconds. The solvent can be
reused or disposed of (can be
directly sprayed into the spray
booth).
(See Table 12 - Estimated Control/
Coating Technology Efficiencies)
-------
RAILFOO OSR SFFW
CEATIN:
Resins
Alkyd
Epoxy
Ur ethane
Arrylic
Anino
Solvents
Alipaticl-Vdrocobans
Ararat ics
Glyrol ether and ether ester
Xylcne
n-8utanol
Aretane
Toluene
Pig-rents
liO,
Talc
Silica
Chrcmiim
Barytes
IronCkide
CTATIN: CLASS IFICATIO5
Gbnventional Solvent based
alkyd Enanels
Urethanes
Epoxies
Phenolics
Epoxy Phenolics
(Conventional Alkyd Enrol)
5C%Solids as purchased
Sol ids as applied
VOLAE PW IMT
ISO to 190 liters
ACTIVITIES
I) Mwing the cars in and out of
the booth, applying decals,
mixing paint, maintaining spray
guns, and general housekeeping
in the paint area.
U-5 hours/shift)
2) Spraying (2 hours/shift)
-------
RMLFQO OCR SFRAY CTAT1N:
CAY5AE/SR
250
KIRS/CAY
(shifts)
8-16
(I to
8-hour shifts)
3-6
(3 units/shift)
N/A
Tvno painters are required to
finish a railroad car. A third
painter rotates assignments with
the others (e.g. activities other
than spraying that arerrentioned
above).
STW/AKMI2ATICN
TEQ^iGLE
Airless spray
TYPE CF CFBWICN
NtTHJOl
OffERVY
5C%
SCLVe^T DISCHftE
Assure air drying/curing • 100%
released during applicatian/flashoff.
Ir+PLATKNBTCSJE LfiyBJS
Total mist -
The level for paint mist
exceeded that vthich vwuld
be allowed for a full shift's
ensure. Because actual
spraying tirre does not exceed
2 hours per shift, 8-hour tirre-
weighed average levels of total
mist would be below the legal
I hit (C&*PB_of ISrrgArf,
8-hr TVA).
(O'Brien, 1981)
-------
RAILFDD QSR SPRAY (DM INC
IN-PLATICN E>PD8LFE LEVELS
(conf'd)
Organic Solvents -
Grrbined solvent concentre*ions
range f rcm 70 to 200 percent of
the max mm allowed for a full
shift ensure, based an curren*
legal maxrrurs. Because of the
short spraying time, the 8-hr TWA
concentrations would be below the
legal rraximnB.
(O'Brien, 1961)
FFDECTIVE
hbavy cotton hoods, overpants,
hip-length coats, with masking
tape around alI opening at neck
and wrists. A full-facepiece,
air-supplied respirator, and
rubber gloves are also worn, so
that no skin is exposed (respirators
are most typical when u ret hones
are used because of the potential
diisocyonates closure).
(O'Brien, 1981)
E&CBJ&F&EtQE. O^flFCLS
Sari-downdraft spray booth
equipped with a fresh air
supply through banks of filters
running from ceil ing to floor
and water-wash sections to
scrub oversproy fron the air
before it is discharged to the
alrrosphere.
(O'Brien, 1981)
(end)
-------
LIGHT AIRCRAFT SPRAY CCATII^C
GCATIN:
Resins
Ure'hone
Epoxy
Alkyd
Acrylic
Solvents
Aliphatic hydrocarbons
Ararat ics
Acetone
Glycol Ether and Ether Esters
Toluene
tylene
Butanol
Isopropanol
Ethanol
MIB<
Pigrents
Talc
Silica
Barytes
IronCkide
Ghrcmiirn
CDftlirC GLASS IFICATIOS/
OMCSITIOS
as applied)
Solvent based - 2 coTponent system
Prim - 25-63* sol ids
Color Erxmel - 40-50% solids
Prirrer -
Smll Planes - 7 to 12 liters
Large Planes - 12 to 16 liters
CD lor Goat -
tall Planes - 16 liters
Large Planes - 23 liters
-------
LIGHT AIRCRAFT SFRAY CCATIhC
WJVffl ACTIVITIES
I) Preparing equiprent/coa*ings,
masking, cleaning.
(4 to 6 hours/shift)
2) Spraying operations -
(less than I hour for any
particular coating).
250
(shifts)
16 - 2k
(Two 8-hour shifts for coating
operations, an additional shift
is possible for equipment
clean ing/repairs.)
LNT5 CEATB3CAY
5 - 10
MNEB^CF SITES
UCRC5/SITE
/approximately 130 erployed in the
finishing deparfrrent for the 3
shi fts (most work the day and
afternoon shifts). Arraxnvnof
6 spray paint at any time.
SFRAY/ATCMIZATICN
TEO-MOE
Conventional air atarized spray.
TiPE CF CPBWIOJ
M)stly manual
50 - 60%
-------
LIGHT AIKFPFT SFRAY
DISCHDFOE
Assure air drying/curing - 100%
released during applica*ion/flashoff.
ItmATICN
LEVELS
Airborne concentrations of *otal
mist exceeded allovable I inVs
for a full shift's closure.
Because of the short spraying
trre, levels of total mist, on a
8-hour time weighted average, is
below the Jegal limit (CS-AFB.
of ISrrg/nr?, 8-hour "TOW.
(O'Brien, 1981)
Airborne concentrations of organic
solvents in spray application of
the coatings are well below any
existing or proposed standards for
the materials used.
(O'Brien, 1981)
PROTECTIVE
Disposable coveralls and a loose-
fit* ing hood are worn when enter ing
a spray booth. During spraying
operations, NOSH - oproved, half
facepiece respirator with organic
vapor-rcrrDving comisters and mist
prefilters are used (respirators
are most typical *hen urethanes
are used because of the potential
diisccyonates exposures). Rjober
gloves are available but not used
by alI workers.
(O'Brien, 1981)
Df08LPE^B£/€E ONIFCLS
Downdraf* spray booths with poly-
ester filters at the top and non
fire-supporting paper folded into
accordion style pleats with staggered
air holes under the floor. Both
filter systore are changed at 5 week
intervals.
(O'Brien, I960
(end)
-------
SPRAY.FINI9-HN3
CDCTIN3 (DtfCNNrS Resins
Alkyds
Arryl'ics
A-nino
Epoxy
Polyester
Urethone
Vinyls
Silicones
Plastisols
Phenols
Solvents
Metones
Esters
Alcohols
Aliphatics
E*hers
Ararrntir
Terpenes
Pigrents
TiCX
Talc
Qircnriun
Clay
(LASSIFIGfflOB Solvent-based
pr her s/topcoat 9
(lacquers and crenels)
Wbter-based
pr hers/topcoats
So I vent-based
AO - 5 solids (purchased)
Vbter-based
25-50% solids (purchased)
-------
SRRay FINIKIN:
CEATINGVOLNe
See Appendix 5
ACTIVITIES
(I) Paint mixing, paint sludge
sk hiring from booth water
tank, spray guns maintenance
(activities of short duration;
do not contribute sign-
ificantly to painters'
exposure).
(2) Primer, topcoat spraying
(for manual operations) -
5-6 hours/shift.
(3) Inspecting & maintain ing
operations (for automated
operations) - 5-6
hours/shift.
250
hORS/OW
(shifts)
8-16
(one-two 8-hour /shifts)
INITS/SITE-CAY
See Appendix 5
NABff* OF SITES
N/A
Approximately 25 - 50 in finishing
aepartrait. 2-5 workers in
charge of mnual spraying operations.
9FRAY/AKMZATKN TEOMOE
Air spray
Airless spray
Air Assisted Airless
Electrostatic:
Air
Airless
Air Assisted Airless
l-bt spray with all of the above
T»PE CF CPBWICN
IVbnual
Automated (with toucnup
operations generally
done with manual equipment).
-------
HEAVY MKHIhfftf FINI 9HlhC
CvESPRAY
Air/Air Iess
30 - 60%
Electrostatic
10 - 30%
SCLNBtf DISCHKE
Application/Flashoff
70 - 80%
Cven Drying
20- 30%
(These figures should be used only
if it is known that oven drying
will ocurr for a particular case.
100% solvent discharge during
applicatian/f lashoff for air
drying should be assured otherwise.)
INHftLATICN EX508LRE [EJELS
Total rrist -
Estimated airborne levels of
total paint rrist ranging
from 2.0 ± 1.4 to 36.5 t
1.2 ng/rr for short-term
samples. 8-hour TWA
values are objected to be
50% lower.
Organic Solvents -
Contained solvent levels did
not exceed rrore than 5% of
currently allowable levels.
(O'Brien, 1581)
Clean coveralls and safety
glasses are provided at the star!
of each workshift. Before
painting they prepare with head
socks, painters' hats, gloves,
and respirators. They also
coat exposed face areas wi th
petroleun jelly. When hand!ing
electorstatic guns, gloves
used have pa Inns cut out for
grounding purposes. Half-
focepiece respirators with
Nvin organic vapor-reroving
cartridges and mist pre-
fliters used.
(O'Brien, 1981)
-------
I-EA/Y WCHINfftf SPRAY FINIKIN:
E>TOSLF€>PELE^SE ONIFCLS \^Aer washed dwnndraf* spray
booths, enclosed ondwi^h
fresh air supply, (mfce-up air
also supplied through dry
filter banks).
(O'Brien, 1981)
(end)
-------
TABLES
-------
TABLE 1
MATERIALS BALANCE FOR SPRAY APPLICATION
OF SOLVENT BASED PRIMER TO AUTOMOBILES
Coating aopli.cati.on (25% solids) Liters/Car
4 Coating (40% solids as purchased) 5.0
• Thinner 3.0
9 Total coating 8.0
Application Losses (40% efficiency)
• Solids 1.2
4 Solvents 5.3
• Total Application Loss 6.S
Oven Evaporation Loss
• Solvent Discharge 0.7
Net Dry Solids on Body 0.8
TABLE 2
MATERIAL BALANCE FOR SPRAY APPLICATION
OF SOLVENT BASED ENAMEL TOPCOAT TO AUTOMOBILES
Coating Application (25% voi solids) Liters/Car
• Coating (30% vol solids purchased) 10.0
• Thinner 2.0
'Total Coating Applied 12.0
Application Losses (40% efficiency)
• Solid* 1.8
0 Solvents 7.9
• Total Application Loss 9.7
Oven Evaporation Loss
0 Solvent Discharge 1.1
Net Dry Solids on Body 1.2
Source: Automobile and Light-Duty Truck Surface Coating Operations.
USEPA 1979.
-------
TABLE 3
PARAMETERS FOR THE AUTOMOBILE SURFACE COATING INDUSTRY8
Application
PrlM Coat
Sol vent bora* apray
Calhodlc • 1 «c t rodepoa 1 1 lorn
Cali» Coat
Solvantborne eprey
Wetarborne apray
Topcoat
Solventborne apray
Lacquer
Dieneraloa lacquer
Cnaaol
MM coat/clear coat*
ftaae coat
Clear coat
Uattrborne apray
ATM Coated
per vehicle.
It*
450
(220-570)
•SO
(660-1060)
200
(170-2M)
200
(170-280)
240
(170-2M)
240
(170-280)
240
(170-280)
-MO
240
(170-280)
240
(170-280)
240
(170-280)
ma
IkickMaa.
•11
0.8
(0.>-I.5)
O.t
(O.S-0.8)
0.8
(O.S-l.S)
0.8
(0.3-2.0)
2.)
(1.0-3.0)
2.)
(1.0-1.0)
2.)
(1.0-1.0)
2.5
1.0
(0.8-1.0)
l.S
(1.1-1.5)
2.2
(1 .0-2.5)
VOC Coat ant,
Ib/«al-fl20
i.7
(4.2-6.0)
1.2
(1.2-1.5)
5.0
(1.0-S.t)
2.8
(2.6-3.0)
6.2
(5.8-6.6)
5.8
(4.9-5.8)
5.0
(1.0-5.6)
4.7
5.6
(1.4-6.4)
4.0
(1.0-5.1)
2.8
(2.6-3.0)
VoluM Fraction Solid*.
gal/gal -H2<>
0.22
(.20-. 35)
0.84
(.84-.87)
0.30
(.25-. 55)
0.62
(.60-. 65)
0.12
(.10-. 11)
0.17
(.17-. 27)
0.30
(.25-. 55)
0.31
0.20
(.13-. 48)
0.42
(.30-. 54)
0.62
(.60-. 65)
Tranafer
Efficiency,
t
40
(35-50)
100
(85-100)
40
(35-65)
30
(25-40)
40
(30-65)
40
(30-65)
40
(30-65)
*0
40
(»-50)
40
(30-65)
30
(25-40)
*A11 *alu«a for caatlnga aa applied. aHcapt for VOC eoatoat a*4 voluaa fractloa aoll^a which ara for coatinge •• applied alnua water.
•«a«aa In parent h«aae. Low VOC coateat (high eollda) b«ee coet/clear coat* ere still undergoing teat lag aod developecnt.
Coapoelte of baae coat and clear coal.
Source: AP - 42, USEPA 1985.
-------
TABLE 4
PARAMETERS FOR THE LIGHT DUTY TRUCK SURFACE COATING INDUSTRY8
Application
Prlne Coat
Solvent born* apray
Cattodlc electrodapoaltlon
Guide Coat
Bolvantborea spray
Uatarborea spray
Topcoat
SolventbonM apray
Eaanal
laaa coat/claar coat
MM coat
Clear coat
Matarboroa apray
AIM Coatad
per vehicle.
ft*
075
(300-1000)
1100
(850-1250)
475
(100-740)
•75
(100-740)
7M
(300-900)
7 JO
750
(300-900)
75O
(300- WO)
7)0
(300-tOO)
riu
Ihtckneaa,
•11
1.2
(0.7-1.7)
0.6
(0.5-0.8)
0.8
(0.7-1.7)
O.I
(0.5-2.0)
2.0
(1.0-2.5)
2.5
1.0
(O.t-1.0)
1.5
(1.2-1.5)
2.2
(1.0-2.5)
VOC Content,
lb/t*l-n2O
5.7
(4.2-6.0)
1.2
(1.2-1.5)
5.0
(3.0-5.6)
2.8
(2.6-3.0)
5.0
(3.0-5.6)
4.7
5.6
(3.4-6.4)
4.0
(3.0-5.1)
2.8
(2.4-3.0)
Voltnw Fraction Sol Ida.
aal/Bal-H20
0.22
(0.20-.35)
0.84
(.S4-.87)
0.10
(.25-. 55)
0.62
(.40-.65)
0.30
(.2S-.55)
0.33
0.20
(.13-.48)
0.42
(.30-. 54)
0.62
(.60-.65)
Tranifcr
erriclcacy.
t
40
(35-50)
100
(85-100)
40
(35-65)
10
(25-40)
40
(30-65)
40
40
(30-50)
40
(JO-65)
30
(25-40)
*A11 valuaa ara far coatInge aa appltad, except for VOC content and voluna fraction aollda which ara for coattnta aa applied nlnu* water.
in parenthaala. low VOC content (high aollda) naaa coat/clnar coata ara atlll •ndergoUc teat log and development.
Conpoalta of typical kaa«
claar coat.
Source: AP - 42, USEPA 1985.
-------
TABLE 5
EMISSION FACTORS FOR AUTOMOBILE AND LIGHT DUTY
TRUCKS SURfACE COATING OPERATIONS3
EMISSION FACTOR RATING: C
Aucnobll*
Coiciag kiUb)
par vahlcli
Prlaa Co«t
Solvancborea
apray
CathodiC
alactrodapoaltira
Cuid« Coat
Solvaacborn* apray
Uatarborna apray
Topcoat
Lacquar
Dlaparalon lacquar
taanwl
Kaa«coat/claar CMC
Hatarboraa
.
6.61
(14.34)
.21
(.43)
1.89
(4.16)
.64
(1.30)
21. M
(46.31)
14.30
(31.90)
7. OS
(13.38)
6.03
(13.32)
2.23
(4.93)
of VOC
p«r hour
363
(799)
12
(23)
104
229
38
(83)
1208
(2637)
798
(1733)
390
(837)
333
(732)
124
(273)
Lifhc Duty Truck
kf(lb)
p«r vahlclc
19.27
(42.39)
.27
(.38)
6.38
(14.04)
2.3
(3.06)
BA
HA
17. 71
(38.96)
18.91
(41.39)
7.03
(13.47)
of VOC
per hour
732
(1611)
10
(22)
243
(334)
87
(192)
•A
KA
673
(1480)
719
(1581)
267
(388)
All aonMthaaa VOC. factor* an calcwlatad uaiag taa followlag oqvaeioa
aad tha typical Taluaa of paraaotara praoaatad In Taalaa 3 aad 4.
HA - Rot appllcabla.
— A Ci T. V Cj
m ~ » ft C
• aaiaaion factor for VOC,
(azcluaiva of any
•aa par
Btrol
ei
T.
factor: 1 ft/12.000 oil
of tba dry cMCia« fila (all)
7. • VOC (eriaaic •olwe) count of coatiac M appliad, laaa mtar
e (lb ?OC/gal eMClat. I*M Mt
•tar)
cj • eoavaraloa factor: 7.48 galloaa/ft*
S • aolida la coatiag aa appliad. valova fraction (gal aollda/gal
•_ • tramafcr offlciaBcr fraction (fraction of total eoatiac oolida
oMd nhich roaalnt oo coatod MTU)
la: Th« VOC oaiaaloaa per
priH coat.
>bilo fro* a cathodlc •locrrodapoatcad
TOC
'^
^ (85°
la«« on an avi
Ba*ad on aa rvaraf*
^-84 gal/gal) (1
.43 lb VOC/vnaicla (.21
ap«ad of 33 antoaobllaa/hr.
ap««d of 38 light doty trucka/hr.
Source: AP - 42. USEPA 1985.
-------
TABLE 6
TYPICAL WOOD FURNITURE FINISHING SCHEDULE
Operacion
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
IS
16
17
18
19
20
21
22
23
24
25
26
27
28
Operacion
Name
Load
Spray uniform scaia
Dry
Spray NCR scain
Dry
Spray was he oat
Dry
Sand lightly
Spray filler
Flash-off filler
Wipe filler
Dry '
Spray sealer
Dry
Sand
Spray sealer
Dry
Sand
Spray glaze
Wipe and brush
Dry
Distress
Spray lacquer
Dry
Spray lacquer
Dry
Unload
Return to load
TOTAL
Operacion Time
Allowed in Minutes
5
1.5
15
1.5
20
1.5
20
1.5
1.5
2
4
45
1.5
30
3
1.5
30
3
1.5
5
60
2
1.5
45
' 1.5
75
5
15
399
No. of Persons
Per Ooeracion
1
2
2
2
4
2
8
2
7
2
7
2
13
4
2
2
1
^^w
63
Source: Technical paper, Society of Manufacturing Engineers. MS 75-251
TAKEN FROM: Summary of Technical Information for
Selected Volatile Organic Compound
Source Categories, USEFA 198l(b).
-------
TABLE 7
OPERATING PARAMETERS FOR COATING OPERATIONS
FURNITURE SPRAY COATING
Plant Operating Nuaber of lines Line speed* Surface area Liters of
size schedule (•/•in) coated/yr coating used
(hr/yr) . (•*)
Small
Medium
Large
2,000
2,000
2,000
1
(1 spray booth)
2
(3 boo tin/ line)
10
(3 booths/line)
2.5
2.4
4.6
45,000
780,000
4,000,000
5,000
87,100
446,600
Line speed is not used to calculate emissions, oaly to characterize
plant operations.
Using 35 volume 1 solids coating, applied by electrostatic spray at
65 % transfer efficiency.
Source: AP - 42, USEPA 1985.
-------
TABLE 3
EMISSION FACTORS FOR VOC FROM SURFACE
COATING OPERATIONS a'b
FURNITURE SPRAY COATING
Plane Size and Control Techniques
VOC Emission*
kg/m2 coated kg/year kg/hour
Small
Uncontrolled emissions
65 volume X high solids coating
Waterborne coating
Medium
Uncontrolled emissions
65 volume % high solids coating
Vaterborne coating
.064
.019
.012
.064
.019
.012
2,875
835
520
49,815
14,445
8,970
"Calculated using the parameters given in Table 7.
following equation. Values hive been rounded off.
0.0254 A T V D
S Te
where E
A
T
V
D
S
Te
The constant
to liters.
Example:
.42
.26
24.90
7.22
4.48
Large
Uncontrolled emissions
65 volume \ high solids coating
Vaterborne coating
.064
.019
.012
255,450
74,080
46,000
127.74
37.04
23.00
« Mass of VOC emitted per hour (kg)
= Surface area coated per hour (m2)
= Dry film thickness of coating applied (mill)
s VOC content of coating; including dilution
solvents added at the plant (fraction by volume)
* VOC density (assumed to be 0.88 kg/1)
« Solids: content of coating (fraction by volume)
* Transfer efficiency (fraction)
0.0254 converts the volume of dry fila applied per m2
The VOC emission from a medium size plant applying 35
volume % solids coatings and the parameters given in
Table 4.2.2.12-3.
m lw/lk Q.02S4(390m*/hrMl mil)(0.65U0.88 kt/1)
of VOC/hr - s (o'35)(0.65)
a 24.9 kilograms of VOC per hour
^Nominal values of T, V, S and Te:
V I 0.r51(uIcoVtlroli:d")0.35 (65 volu~ X solids) 0 117 (-t.rb.rn.)
S = 0.35 (uncontrolled. 0.65 (65 volu« I solids), 0.35 (waterborne)
Te = 0.65 (for all cases)
Source: AP - 42, USEPA 1985.
-------
TABLE 9
AIRBORNE LEVELS OF PAINT SPRAY MIST
IN WOOD FURNITURE FINISHING
Booth
1
3
4
5
6
7
8
12
13
14
Paint mist (mg/ni3)«
Operation GM GSO
Heavy coat of barrier
finish
Second coat of barrier
finish to top and sides
Manual coat of glazt
to top and sides
Robot application of
heavy coat of glaze
(area saople)
Heavy coat of lacquer
Second coat of lacquer
to top and sides
Light coat of glaze
Barrier coating of
Interior surfaces
Veil lacquer applied
to Interior
Final heavy coat of
lacquer
0.8
0.4
1.0
0.1
0.5
0.4
0.1
0.5
0.1
2.5
1.4
1.6
1.2
2.0
1.2
1.8
5.0
1.1
1.5
1.0
GM: Geometric Man
GSO:Geowtr1c standard deviation
*8-nour t1«e-«e1ghted average (TUA)
Source: O'Brien, 1981.
-------
TABLE 10
CANDIDATES FOR POWDER COATING IN APPLIANCE INDUSTRY
Psrt
WiNiorrtors
Mt KNOTS
Innor Linon 1
ROHM Ptrtl
SIMMS
CasosAOoors
AcryHe Btlu Eiunxi
OM or Two-Co*
Aayttc bk« bum*
Zlne PMi MOI Cto*r
OlpCotflng
Epoxy. PolyurKMM
Acrylic
Epaxy. PMyuritnam
Acrybc
Epoxy. Poryottor
Hyortd
Oiwor
or
Acrylic Poryuromano or Acrylic
Hangs BodiM
Ac/yttc; 'orcsWH
Two-Cool.
Aeryie
Ovon Doors
Myurseitns. Aerykc
PotywrotfUM AcryHc
Potyursfluno: Aerykc
Wa«J»or 4 Oryor
OryorTopsi
Ooon
Oryor Oruns
WachorTopsi
Uds
Two-Cool. Two-SoM
ExutcMon
flow Co*
Epoqr
Two-Coot PorciMn
Two-Cost. Two-Bsko
Aery*
MyvroMns. Aerykc
MyuroMM. Aerykc
EpSRy: Poryunchano
PorywrotruM. Aerykc
PolywwBuno. AeryHc
Tubs
BodkM and Door
PsnotsA
EseuienoM PsnoH
Ricks
Poreslaln:
Ono 4 Two-Coot.
Mono IKro Acryfc
PVCi
Epnry*, Epojy-Phonokc
Polyvrofliino: Aerykc
PVC;
I. A.C. Oyor CMOS
Tws-Csot T
Aeryie How Case
Two-Cost. T
(TGIC)
Potyvromm
SonrMyosfevT
Tws-Cswl T
Op EooKy (low Tomp )
PrwM/Acryae
PofyvraBUM.
OispFrysn
Aeryie
Source: Products Finishing, November, 1986.
-------
TABLE 11 - CIATED tf€A - OMIN3 1HIO*£5S/INIT
RB L/KZ AffLWMB
Appl ionce
Gjrportor
Di shwasher
Dryer
Freezer
Microwave O/en
Rmge
Refrigerator
Wishing Morhine
Wafer Heater
Prime
A(n£)
1.9
0.9
8.4
7.0
0.7
1.9
7.0
6.5
1.9
Goat
t (mils)
0.5
0.5
0.6
0.5
0.5
0.5
0.5
0.6
0.5
Top
Atm2)
1.9
0.9
2.8
7.0
0.7
2.8
7.0
2.3
1.9
Goat
t (mils)
0.8
0.8
1.2
0.8
0.8
0.8
0.8
1.2
0.8
Source: #=-42, (JE5>A 1985.
-------
T#l£ 12
UKE
ESTIMATE) ONFCL/CEAT^
EFFICIENCIES
Control Technology
A?plica*ion
% VCCBnissions Fteduc*ion
Powder
Waterborne
(spray, dip, flowcoat)
Hi cher Solids
ISpray)
Carbon Absorption
Incineration
Top, ex*erior or inferior
single coat.
All applications.
Top or exterior single coat
and sound deadener.
Prims, single or topcoat
application and flashoff areas.
Prime, top or single coat ovens.
95 -
70 -
60 -
90*
90*
99°
90°
80a
a Base case - High organic solvent coa'ing with 25 vol % solids. Transfer efficiency for liquid
coatings assured to be 80% for spray, 90% for dip or flo«coat; 93% for po*ders.
b Reduction is only across the control device and does not account for capture efficiency.
Source: /P-42, LBB>A 1935.
-------
APPENDICES
-------
APPENDIX I
COATING VOLUMES
Using approximate values of coated area per unit and roaming
'hickness, *he amount of coaling (li*ers/day) used in a si'e
be es'ima'ed for a particular case.
(a) Liters of Solids deposited on the units (total)/day:
(units/day) (coated area/unit) (coating Thickness)
For example -
wood furniture - 400. un i ts/day
2 mVunit
2 mi Is coating thickness
can
400 uni ts
day
?m2
un i t
2 mi 1 s
0.001 in
mi 1
m
39,37 in
1000. liters
m3
= 40 liters of solids on furniture/day
(b) Liters of coating used/day:
(Liters of solids deposited on units (totaD/day)
(rransfer efficiency) twt% solids in coating;
For the same example -
For a clear lacquer (15% by wt solids in coating)
applied by air-atomized spray ( 50% transfer efficiency) *o
wood furn i ture:
^ = 535 liters of coating used/day
(0.50)10.I5J
(c) Liters of overspray (so I ids)/day:
(Liters solids on units/day)
I
transfer efficiency
-I
For *he same example -
40 r-^ ' ']
40 liters overspray (solids)/day
-------
(d) Liters of Volatile Organics used/day:
( liters solids on uni's/day) (I - wt% solids in cog- ing)
- ( 'ransfer eft icienry) (% so I ids in coa* ing)
For *he same example -
40 (| . 0.15) = 455 liters of solven*/day
(0.5MO.I5)
For wa*erborne roomings *he wt% of water in the coating needs
to be substracted along with the wt% solids in the above
equat i on .
-------
APPENDIX 2
Characteristics of Spray Booth Dry Filters
Dry filters are classified as baffle or strainer types. The baffle types
redirect air through the filtering media. The heavier particles do not
readily change direction, but instead tend to strike and collect on
media surfaces because of inertia. Strainer types screen overspray from
the exhaust air. Particles finer than the screen get through; coarser
particles do not. Baffle and strainer principles can be combined.
Figure 1 illustrates a general rating of dry filters.
Figure 1
GENERAL RATING OF DRY FILTERS
Metal Pwwi
Kraft
Expanded
Kraft
Non-Woven
doth
Baffle
Baffle
Baffle
Baffle
Strainer
Strainer
Baffle-
Strainer
Poor
Poor
Fair
Excetent
Excellent
Good
Exce«ent
ExceNerrt
Excettertt
ExceNerrt
Good
Poor
Fair
Exce«errt
Source: Industrial Finishing. April, 1987.
-------
Figure 2 lists performance characceriscics of several dry filters.
Efficiency expresses the percentage of overpsray particulate removed
from the air. Holding capacity gives the amount of overspray certain
area of filter retains before the resistance to air flow affects tire
filter's performance.
Figure 2: Performance Characteristics of Filters
FMw
FMtr/Plint Typt EffidMCV (fct) C*MCtty' (to)
Standard eipanded knfl
Air dry enamel 97 0 • 98 0 2 60
Baking enamel 96 0 - 97 0 4 30
lacquer 87 0 • 88 0 1 40
Primer 93 5 • 94 i 7 50
Water emulsion 96 0 - 97 0 3 70
Htyi-c»p nHf M* *rt
: II Al 0 «> •«<•* • r •<•*•« o«A«n.ar mxrrf 1) fiiiaiifcrf tnO' Mv-wwit tarbrfpoto ro*r-
for. JJ OWy MT /«•' uitf M im <; ftmr n»Mimrf tami. /nuMtf M «amr nm-^. jy Ai 9.11 «rt
Source: Products Finishing. September, 1985.
-------
APPENDIX 3: SUMMARY OF CUSTOMARY MANAGEMENT SEQUENCE FOR SPRAY BOOTH WASTE.
I Total Spray Booth Contents: Accumulated paint, water, deflocculatlng chemical. |
j Treated paint solids may be partially separated — floating or settled waste. |
Dispose of contents as a paint/water slurry, or separate solids from booth's water.
Separated solids, with s
residual water.
Determine status of the waste.
whether hazardous or not. per -
RCRA. See attachment (2).
1
Mon-hazardous waste
I
Accumulate waste In containers.
usually drums, or In • dumpster
when waste is sufficiently
dewalered.
1
Ascertain the governmental
agency regulating the local
non-hazardous waste disposal
site (often a city or county
board of health). Coordinate
with them for screening of the
waste to verify Its status.
using analyses or Information
supplied by the waste generator.
They will provide disposal
Instructions.
Deposit waste In disposal site
jind_j>ay their fee. or consign
company.
Hazardous waste
Accumulate In waste containers.
stored 90 day maximum to avoid
EPA regulation as a hazardous
waste storage facility.
Consign waste to approved
hazardous waste specialist for
his pre-treatment (when
indicated), transportation, and
deposition In a hazardous
waste disposal site.
Mater or slurry within
acceptable limits.
i
Obtain discharge permit when
required by local sanitation
district.
1
Discharge water or slurry
sewer. Pay sewer usage
charge.
to
I
Mater subsequently treated by
publlcally owned treatment
works (POTM).
I
Paint/water slurry, or
clarified water with so
residual solids. Recycle
clarified water to booth If
possible.
Determine status of the
fluid for possible sewer
disposal, per clean water
•ct. See Attachment (2).
1
Excessively polluted water.
Provide pretreatment on site
when facilities are available.
prior to sewer disposal, or
consign to approved hazardous
waste special 1st for
pretreatment and disposal.
•Inc. January 1986.
-------
APPErOIX 4
LARGE APPLIANCES
ESTIMATION OF SOLVENT EMISSION RATE
•
A material balance can be used *o calculate emission ra'es of
solvents to the atmosphere in 'he absence of control systems *ha
remove or destroy a known fraction of them. When both a prime
coat and a top coat are used, the emissions from each must be
calculated separately and added to estimate total emissions.
= (2.54 x IP"2) P A t Vo Do + Ld Dd
Vs T
e- Mass of Volatile Organic Compounds (VOC) emissions per
rl UnTVo^oduclTon per-uni* time (units/uni* time)
A = Area coated per unit (nr)
- dry coating thickness (mils)
Vo I proportion of VOC in coating as received* (volume
o density of VOC in coating as received* (kg/li t er)
Vs = proportion of solids in coating as rece.ved* (volume
f rac t ion) :
T = transfer efficiency (%/IOO) „./„«:-, .im->
Ld = Volume of VOC added per unit t.me» (l.ters/uni. ime)
Dd = density of VOC added (kg/ liter)
•When no data is available, the following approximations may be
used:
Vo = 0.38
Vs = 0.62
Do s 0.88 kg/ li ter
Ld s 0 (assumes no solvent added dt plan.).
The constant 2.54 x IO'2 is the product of two conversion
factors: 2.54 x IO'5 m/mi I and 1,000 liters/m3
Source: AP-42, USEPA 1985
-------
APPENDIX 5
HEAVY MACHINERY
COATING VOLLMES & NUMBER OF UNITS
The rowing volumes and *he number of units coated per si'c-
day vary widely for heavy machinery spray finishing operations.
Articles in *his category could include, for example, from "smal
sized" 'ruck engines to fairly big hay stack wagons.
(a) Truck Engines
160 units coated per day
1.3 liters of coating used per unit
approximately 210 liters of coating used day
(b) Hay Stack Wagons
5 units coated per day
38 - 46 liters of coating used per day
I i ters ave.)
190-230 liters of coating used per day
(210 liters ave.)
Since the specific articles to be coated are usually not
know to the engineer, an average of 210 liters of coating used
per site-day can be used for 'his particular scenario.
-------
REFERENCES
ACGIH 1987 American Conference of Governmental Industrial
Hvaienis's.' Threshold Limit Values and Biological Exposure
Indices for 1986-1987. Cincinnati, CH.: ACGIH. ISBN: 0-
936712-69-4.
Adams J. (n.d.) Workshop on Spray Application Processes...
Advantage and Limitation. Sponsor: Association for Finishing
Processes, Society of Manufacturing Engineers, Dearborn,
Michigan.
Cecil L.W. 1986 Focus: Appliance Finishing. Appliances Go
Powder. Products Finishing Magazine. November, 1986: pp. 66-73
DeVILBISS. 1986. Product Literature. Industrial Spray
Booths. Catalog. 520 Wharton Circle, P.O. Box 43226, Atlanta,
GA 30336.
Duff W.W. 1985. MITRE Corp. Support for Premanufacturing Review
for New Chemical Substances. Work Assignment No. 49, Technical
Directive No. 2. Record of telephone report on January 15,
1985. Washington, D.C.: Office of Pesticides and Toxic
Substances, U.S. Environmental Protection Agency. Contrac. 68-
01-6610.
Gikis B, Fowler D, Connolly E, Boughton R. 1983. SRI Internet.
Industrial Process Profiles to Support PMN Review: Pa«n-» .
Varnishes and Coatings. Draft Report. Washing-on, DC: Off.ce
of Pesticides and Toxic Substances, USEPA. Contract 68-01-
6016.
Hul*gren E. 1972. Exhaustion Arrangement and Environmental Care
at Spray Painting Plants. (As reported in Air Pollution
Aspects of Emission Sources: Surface Coatings - Their
Production and Use, a Bibliography with Abstracts. 1974.
USEPA, EPA - 450/1-74-005).
InVireChem, Inc. 1986. Industrial-Environmenta I Chemi stry.
Management and Monitoring of Waste; from Water Wash Paint Spray
Booth*. Seattle, WA 98103 •'
Martens C.R. 197. Technology of Pain's, Varnishes and Lacquers.
Robert E. Krieger Publishing Co., Florida: pp. 656-689.
NIOSH. 1986. Natl. Ins*. Occupational Safety and Health. Spray
Pain*ing - Good Practices for Employees: Your Health and Safe.y
are in Your Hands. Washington, DC: NIOSH, U.S. Dept. Health,
Education and Welfare. DHEW Pub. NIOSH 76-178.
-------
O'Brien DM, Hurley DE. 1981. An Evaluation of Engineering
Control Technology for Spray Painting. Cincinnati, Ohio:
National Inst. for Occupational Safety and Heal'h, Depjf. of
Health and Human Services. DHHS Pub. NIOSH 81-121.
Robinson G.T. 1981. Focus: Improving Produc*ivity. Robots and
Water-Borne Paint Team up at Mack Truck. Products Finishing
Magazine. June 1981 reprint.
Schreberger G.L. 1985. Understanding Paint and Painting
Processes. Third Edition. Hitchcock Publishing Co. Wheaton,
III.
USEPA. 1973. U.S. Environmental Protection Agency. Air
Pollution Engineering Manual. Second Edition. Research
Triangle Park, N.C.: Office of Air Quality Planning and
Standards, USEPA.
USEPA. 1976. U.S. Environmental Protection Agency. Guideline
Series. Con'rol of Volatile Organic Emission from Existing
Stationary Sources - Volume I: Control Methods for Surface -
Coating Operations. Research Triangle Park, N.C. 27711:
Office of Air-Quali*y Planning and Standards. USEPA. EPA-
450/2-76-028.
USEPA. 1977 (a). U.S. Environmental Protection Agency. Control
of Volatile Organic Emissions from Existing Stationary Sources,
Vol. III. Surface Coat ing of Metal Furniture. Research
Triangle Park, N.C.: Office of Air Quality Planning and
Standards, USEPA, EPA 450/2-77-032.
USEPA. I977(b). U.S. Environmental Protect ion Agency. Control
of Volatile Organic Emissions from Existing Stationary Sources,
Vol. V. Surface Coating of Large Appliances. Research
Triangle Park, N.C.: Office of Air Quality Planning and
Standards, USEPA, EPA 450/2-77-034.
USEPA. 1978. U.S. Environmental Protection Agency. Control of
Volatile Organic Emissions from Stationary Sources, Vol.VI.
Surface Coating of Miscellaneous Parts and Products. Research
Triangl* Park, N.C.: Office of Air Quality Planning and
Standards, USEPA, EPA-450/2-78-015.
USEPA. 1979. U.S. Environmental Protect ion Agency. Au*omobile
and Light-Duty Truck Surface coating operations - Background
Information for Proposed Standards. DEIS. Research Triangle
Park, N.C. 27711: Office of Air-Quality Planning and
Standards. USEPA. EPA-450/3-79-030.
USEPA. I980(a). U.S. Environmental Protection Agency.
Background Information for Proposed Standards. DEIS.
-------
Industrial Surface Coating: Appliances. Research Triangle
Park, N.C.: Office of Air Quality Planning and Standards,
USEPA. 'EPAM50/3-80-037A.
*
USEPA. I980(b). U.S. Environmental Pro*ec*ion Agency.
Background Information for Proposed Standards. DEIS. Surface
Coating of Metal Furni*ure. Research Triangle Park, N.C.:
Office of Air Quality Planning and Standards, USEPA, EPA 450/3-
80-007.
USEPA. I98l(a). Environmental Protection Agency. Directory of
Volatile Organic Compound Sources covered by Reasonable
Available Control Technology Requirements. Vol. I. Office of
Air Quality Planning and Standards. Research Triangle Park,
NC, USEPA. EPA 450/4-81-007.
USEPA. I98l(b). U.S. Environmental Protec t ion Agency. Surrmary
of Technical Information for Selected Volatile Organic Compound
Source Categories. Research Triangle Park, NC: Office of Air
Quality Planning and Standards, USEPA. EPA 450/3-81-007.
USEPA. 1985. U.S. Environmental Protection Agency. AP-42,
Coapi lotion of Air Pollution Emission Factors. Research
Triangle Park, N.C.: Office of Air Quality Planning and
Standards, USEPA.
Vickers W. 1985. Improving Over spray Col leetion '"a Dry
Booth. Products Finishing Magazine. September 1985: 52-57.
Vickers W. 1987. How to Calculate Required Efficiency: AlI
About Dry Filters for. Spray Booths. Industrial Finishing
Magazine. April 1987.
------- |