United States Environmental Protection Agency Office of Enforcement and Compliance Assurance Washington, DC 20460 EPA-3QO-F-98~002a February 1998 VyEPA Federal Facilities Toxic Release and Reduction Initiatives Fact Sheet Background Executive Order 12856, entitled "Federal Compliance with Right-To-Know Laws and Pollution Prevention Requirements", was signed by President Clinton on August 3, 1993. The primary objectives of EO 12856 are to encourage Federal facilities to: Develop pollution prevention plans to reduce toxic releases by 50%, Collect and report data on the quantity of hazardous materials stored, used, and released at the facility; » Ensure public access to use and release information. Federal facilities are required to submit annual TRI reports starting in 1995 for data collected in 1994 1,1,1-TRICHLOROETHANE 1995 Waste Management Distribution 6% 13% ¦ Recycling Energy Recovery ¦ Treatment .3 Releases Approach A study was undertaken to analyze Federal facility TRI data for 1994 and 1995 to: 1) determine the most commonly used and released chemicals; 2) identify currently used pollution prevention (P2) approaches and on-going pollution prevention research and development to lower or substitute the use of a chemical: and 3) identify potential RD/transition needs. As of January 1998, fifteen chemical Fact Sheets have been developed Please refer to the back page to order Fact Sheets for other chemicals. This Fact Sheet contains two charts and four main sections: The charts represent the waste management distribution and percent change of TRI reported quantities. Chemical Profile section. Identified and used P2 approaches section. On-going F2 research and development section. P2 research and development/transition needs section. TRI Reported Quantities - Percent Change 1994 and 1995 6 £ TRi Reporting 1994 {ibs) 1995 {lbs) % Change Releases 730,320 326.979 -55% Recycling On-Site Off-Site 0 39.686" 84 25,847 100% -35% Energy Recovery On-Site Off-Site ~ 160,413 59 866 50,220 4,415 -69% -93% Treatment On-Site Off-Site 375" 635.149" 1 24,475 "-100% -96% Releases pi us Off-site Treatment 1,365,469 351.454 -74% Page 1 of 8 1.1,1 -TRICHLOROETHANE ------- CHEMICAL PROFILE: 1,1,1-TRICHLOROETHANE CAS #: 71-55-6 j SYNONYMS " CHLOROTHENE ME HyL CHLOROFORM COMMON USES IN THE U.S. www.eoa.goV/ttn/yatw#hltp://www.epa.gov/ttfi/ual 1,1,1-Trichloroetharie has recently found wide use as a substitute for carbon tetrachloride, w# 1,1,1-Trichtoroethane is used as a solvent and degreasing agent in industry It is an ingredient in consumer products such as household cleaners, glues, and aerosol sprays. ACUTE HEALTH HAZARDS www epa qoWttn/u3twflhttp://vww epa oov/ttn/uat 1,1,1-Trichloroethane s m idly irritating when applied to the skin. w# Effects reported in humans due to acute inhalation exposure to 1,1.1-trichloroethane include nypotension, mild heoatic effects, and CNS depression Cardiac arrhythmia and respiratory arrest may result from the depression of the CNS, Symptoms of acute inhalation exposure include dizziness, nausea, vomiting, diarrhea, loss of consciousness, and decreased blood pressure. CHRONIC HEALTH HAZARDS wwwepa govffln/uatw#hntJ wwww.epa.gov/ttn/uat Some liver damage has been observed in rodents chronically exposed to 1,1,1-trichloroethane wf by inhalation. Most studies have not reported adverse effects from chronic exposure to low levels of 1,1,1- trichloroethane. However, one study reported ventricular arrhythmias in humans repeatedly exposed to high concentrations of 1,1,1-trichloroethane, suggesting heart damage. COMMON P2 INITIATIVES www eoa goy/Hn/uatw#http://www.epa.gov/ttn/uat Source Reduction. Abrasive bias! media i sea as an alternative method for cleaning metal w# parts. Solvent Substitution. Used alternative cleaning solvents with reduced environmental impact (low toxicity. lowVOC, non-HAP. biodegradable) Additional information regarding chemical hazards and access to Material Safety Data Sheets can be reached through the Agency for Toxic Substances and Disease Registry web page: http://atsdr1 atsdr.cdc.gov.8080/- refer to ToxFAQs FEDERAL FACILITIES REPORTING COMMON USES OF: 1,1,1-TRICHLOROETHANE Federal Faculties Reporting in both 1994 and 1995 15 HAND-WIPE SOLVENT HEAVY-DUTY SOLVENT Federal Facilities Reporting Only in 1994 14 PAINT CONSTITUENT Federal Facilities Reporting Only in 1995 1 POLLUTION PREVENTION APPROACHES CURRENTLY IN USE HAND-WIPE SOLVENT KC-135 Systems Program Office, (OC-ALC), switched to cleaners under the MIL-C-87937 specification including DS-108 for wipe-prior-to-paint applications They are continuing to test and evaluate other commercially available solvents including borothene and hydrofluoroethers. Tinker AFB. Oklahoma City ALC Replaced 1,1.1-trichloroethane (TCA) and methyl ethyl ketone (MEK) with a terpene cleaner for hand wiping operations. Martin Marietta Astronautics Replaced MEK with a cleaner approved by the KC-135 SPO at Tinker AFB. methyt-n-propyl ketone (MPK) ASC/RAS, Wright Patterson AFB tsopropyi alcoho! (IPA) is approved as an alternative to MEK. Technical Order 1-1-8 which references T O 1-1-691 contains specific procedures for the use of IPA, T.O. 1-1-691 recommends cleaning products qualified to MIL-C-87937, Type II. Cleaners qualified to MIL-G- 87937B are the most environmentally friendly cleaners authorized for use on C-141 aircraft and its components, (Reference: PRO-ACT Technical Inquiry 8200) HEAVY-DUTY SOLVENT Page 2 of 8 1.1,1-TRICHLOROETHANE ------- POLLUTION PREVENTION APPROACHES CURRENTLY IN USE HEAVY-DUTY SOLVENT Tinker AF8 is installing two vacuum vapor cfegreasers for wax removal. Vacuum vapor degreasers release less solvent to the atmosphere because the work chamber is completely enclosed. The engine parts are placed in an airtight chamber into which solvent vapors are t introduced. After cleaning is complete, the solvent vapors in the chamber are evacuated and captured by chilling and carbon adsorption, Once j the solvent in the chamber is evacuated, the door of the chamber is opened and the workload is withdrawn. The cleaned workload is also free t from any residual solvent, and there are no subsequent emissions. (Reference- USEPA Guide to Cleaner Technologies: Cleaning and ; Degreasing Process Changes. EPA/625/R-93/Q17. February 1994). . Nonhalogenated Systems for Cleaning Metal Parts; Production testing demonstrated the viability of spray and immersion cleaning systems for ; specific cleaning applications. Based on the bench scale testing, NDCEE determined that Brulin formula 815GD is the preferred aqueous J chemistry for mechanically and ultrasomcally agitated immersion systems and will be used for production testing in the Advanced Ultrasonic j Cleaning System. Daraclean 282 was selected for use in the Power Washer Cleaning System, although all of the chemistries down selected for I the bench scale testing effectively emulsified the soils and prevented re con lamination of the parts. NDCEE, POC Richard Pirotta 814-269- t 2810 The Corrosion Control Element. 437 Equipment Maintenance Squadron (EMS), Charleston AFB. South Carolina significantly reduced their j hazardous waste stream by reclaiming a majority of the Methyl Ethyl Ketone (MEK) used in their aircraft refimshing operation They did this j using an off-the-shelf recycling unit purchased from a local automobile body shop supply store This is one example of many recycling options | implemented by Federal Facilities to reduce the disposal of used solvents, ' Abrasive blasting is an alternative to solvents for cleaning. In the blasting process, particulate media is propelled by compressed gases or a liquid to impinge on the contaminated surface. No toxic or hazardous chemicals are used; however, the blasting media can become contaminated with the material being blasted from the surface. There are several different types of blasting media, some multi-purpose and others single purpose. The various types of blasting media are: Mineral Grit/Sand Blasting, Steet Shot. Plastic Media, Plastic Foam, Dry Ice (C02), Wheat Starch, Walnut Shells and Other Food By Products, and Sodium Bicarbonate. ; Nonhalogenated Systems for Cleaning Metal Parts: Production testing demonstrated the viability of spray and immersion cleaning systems for specific cleaning applications. Based on the bench scale testing, NDCEE determined that Brulin formula S15GD is the preferred aqueous chemistry for mechanically and ultrasonically agitated immersion systems and will be used for production testing in the Advanced Ultrasonic Cleaning'System Daraclean 282 was selected for use in the Power Washer Cleaning System, although all of the chemistries downselected for the bench scale testing effectively emulsified the soils and prevented recontammation of the parts NDCEE. POC: Richard Pirotta 814-269- | 2810. { Hill AFB switched to terpenes and an ethyl lactate blend for aircraft cleaning operations. Hill AFB, Ogden ALC I Switched to alternative cleaners for MEK and TCA: Pensolv L805 (a terpene-based. four part cleaner), a four part cleaner (containing MEK and toluene); and DS-108, Commodities Directorate, OC-ALC Using carbon dioxide blast meOia system for cleaning KC-135, C-141. 8-52, 8-1. and F-16 engines. C02 is used in conjunction with solvent j cleaning methods as an initial cleaning step in the process. Both 6.E. and Pratt and Whitney approved the use of C02 for cleaning engines. j Additional technologies successfully implemented to replace solvent usage in propulsion include: power spray washers, water-based cleaners, and water jet, (Reference: B. Ley "Solvent Substitution in Jet Engine Maintenance at Tinker AFB' Proceedings from the 1996 Tn-Services World-Wide Pollution Prevention Conference"}. Tinker AFB i For heavy soil removal, NAVAIR recommends low vapor pressure (LVP) organic solvents. These solvents are volatile organic compounds, but ¦ due to (heir low vapor pressures and slower evaporation rates, they may be exempt from certain air regulations and produce lower air emissions depending on how they are used, managed, and stored LVP solvents are generally composed of aliphatic petroleum hydrocarbons, terpenes. esters, or organic blends with vapor pressures below 5 mmHg at 72 degrees F, Normally, these solvents are applied with a solvent soaked cloth, followed by a surface wipe with a clean cloth. In some cases, a second clean cloth wipe may be required to remove residual solvent to j speed drying, I « Resolved by switching to terpenes and an ethyl lactate blend for aircraft cleaning operations. Hill AFB, Ogden ALC i Steam cabinets or vacuum vapor degreasers will most likely be used at OC-ALC for penetrant removal prior to plating Steam cleaning is a viable solvent alternative for removing oily or greasy residue The heat accelerates emulsification break-down, and removal of caked-on dirt and grease. The high temperature of steam is used to heat surfaces long enough for the steam to vaporize or liquefy the oil, grease, or dirt. The residue can then be effectively washed away with the steam condensate. Steam cleaning can also be used with a degreasing agent (often a surfactant) to enhance the solubility of grease in water. Steam cleaners are available to perform medium duty to heavy duty cleaning jobs and are available in a variety of different system configurations Portable steam cleaners are available through the national stock system These have been used at DOD facilities for removing oil, grease, sand, rust, carbon, and burnt propellant from weapons. The wastewater generated i from the steam cleaning process may be treated at an industrial wastewater treatment plant, depending on the toxicity of the dirt and grease removed. Tinker AFB is installing two vacuum vapor degreasers for wax removal. Vacuum vapor degreasers release less solvent to the atmosphere because the work chamber is completely enclosed. The engine parts are placed in an airtight chamber into which solvent vapors are introduced After cleaning is complete, the solvent vapors in the chamber are evacuated and captured by chilling and carbon adsorption. Once « the solvent in the chamber is evacuated, the door of the chamber is opened and the workload is withdrawn. The cleaned workload is also free from any residual solvent, and there are no subsequent emissions (Reference USEPA Guide to Cleaner Technologies: Cleaning and < Degreasing Process Changes. EPA/625/R-93/Q17. February 1994}. j Page 3 of 8 1,1,1 -TRICHLOROETHANE ------- POLLUTION PREVENTION APPROACHES CURRENTLY IN USE HEAVY-DUTY SOLVENT Using carbon dioxide blast media system for cleaning KC-135, C-141, B-52, 8-1. and F-16 engines. C02 is used in conjunction with solvent cleaning methods as an initial cleaning step in the process. Both G.E. and Pratt and Whitney approved the use of C02 for cleaning engines Additional technologies successfully implemented to replace solvent usage in propulsion include: power spray washers, water-based cleaners, and water jet. (Reference; B. Ley "Solvent Substitution in Jet Engine Maintenance at Tinker AFB" Proceedings from the 1996 Tri»Services World-Wide Pollution Prevention Conference"). Tinker AFB Abrasive blasting is an alternative to solvents for cleaning. In the blasting process, particulate media is propelled by compressed gases or a liquid to impinge on the contaminated surface. No toxic or hazardous chemicals are used; however, the blasting media can become contaminated with the material being blasted from the surface. There are several different types of blasting media, some multi-purpose and others single purpose. The various types of blasting media are Mineral Grit/Sand Blasting, Steel Shot, Plastic Media. Plastic Foam, Dry Ice (C02). Wheal Starch. Walnut Shells and Other Food By Products, and Sodium Bicarbonate Steam cabinets or vacuum vapor degreasers will most likely be used at OC-ALC for penetrant removal prior to plating. Steam cleaning is a viable solvent alternative for removing oily or greasy residue. The heat accelerates emulsification break-down, and removal of caked-on dirt and grease. The high temperature of steam is used to heat surfaces long enough for the steam to vaporize or liquefy the oil, grease, or dirt. The residue can then be effectively washed away with the steam condensate Steam cleaning can also be used with a degreasmg agent (often a surfactant) to enhance the solubility of grease in water Steam cleaners are available to perform medium duty to heavy duty cleaning jobs and are available in a variety of different system configurations. Portable steam cleaners are available through the national stock system. These have been used at DOD facilities for removing oil grease, sand, rust, carbon and burnt propellant from weapons. The wastewater generated from the steam cleaning process may be treated at an industrial wastewater treatment plant, depending on the toxicity of the dirt and grease removed. PAINT CONSTITUENT Low VOC Primer Alternatives (Reduced Solvent Carrier); MIL-P-85582B is water reducible, epoxy catalyst Class N -lead and cbromate free" and MIL-P-53030A Low VOC Topcoat Alternatives (Reduced Solvent Carrier) MlL-C-85285 is a high-solids (i e , lower VOC). lead-free, solvent-borne pofyurethane, and MIL-C-46168 Type IV is a high-solids coating with less than 420 grams VOCs per liter. The Army Research Laboratory (ARL) is currently field-testing water reducible, low-VOC CARC as an alternative to MIL-C-46168 and MlL-C-53039, The product is expected to be available for general use in 1998. ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT HAND-WIPE SOLVENT" ~ ~ ~ ~~;=Im-^==u Surface/Solvent Diagnostics for Metal Cleaning Operations: Army Research Laboratory; POC: Unknown Alternatives for General Aircraft Maintena ce CCAD, POC Unknown Solvent Substitution for Fuel Tank Cleaning: Using is op ropy I alcohol (IPA) as a temporary substitute for the cleaning compound (NSN 5850-00-611-7993) that contains MEK for spot cleaning fuel tanks. The B-52 program office is working with Morton Aerospace to test a substitute sealant (MC-250) that could be removed with a substitute cleaner that does not contain HAPS. USAF, B-52 Program Office; POC: Unknown. Substitute Wipe Solvent: Testing DS-108 as a substitute wipe solvent. DS-108 Solvent was developed and patented by General Dynamics. Fort Worth Division (now Lockheed-Martin Tactical Aircraft Systems) for use in the F-16 program. DS-108 has been qualified to meet a variety of OEM and military specifications and received toxicity clearance from the Surgeon General, Department of the Army. USAF, OC-ALC, POC: Unknown. Substitute Hand-Wipe Solvents Tested 30 commercially available hand-wipe cleaners. Of the 30 cleaners, only four passed ail screening tests. SD 1291 (Brulin Corporation), CitraSafe (Inland Technology); Super 140 (LPS Industries), and De-Solv-lt E&E (Orange-Sol, Inc.). USAF, Warner Robins ALC (WR-ALC/TI). POC Unknown, Substitute Hand-Wipe Solvents: Evaluated 24 cleaners. Testing three potential substitutes for MEK; ISO-BLAST. MD-516F. and A diox 5564. USAF, F-15 Program Office. Wright Patterson AFB, POC Unknown Substitute for Hand-Wipe Solvents: Conducted extensive testing on commercially available, environmentally-friendly hand-wipe solvents for use on the B-2 program at the Air Force Plant 42 Paimdale site. Selected two solvents for implementation in manufacturing operations, Dynamotd DS-108 and DS-108CA Northrop Grumman; POC; Unknown. Solvent Substitution/Low VOC Cleaners: Navy-Patuxant; POC' Unknown Page 4 of 8 1.1.1-TRICHLOROETHANE ------- ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT hand-wipe solvent Non-toxic Small/Medium Caliber Automatic Weapons Cleaning Process: ARDEG; POC Unknown | HEAVY-DUTY SOLVENT Solvent Replacement - Vapor Deqreaser: Allied Signal will demonstrate a replacement for 1,1,1-triohloroethane vapor degraasing. Allied Signal Army Engine Plants; POC: Mr, T Russell, Mr. ; J. Morrell, 203-385-3741. Agueous-based Degreasing Technology: i The Army's Soldier Systems Command (SSCOM) will develop nonpolluting, nontoxic water-based degreasers for cleaning metal/ glass/plastic surfaces using biopolymer emulsifying materials. Develop micrabially produced natural surfactants (emulsans) through fermentation processes and ¦ optimize chemical structure of the new materials for specific oil/grease removal needs. Solve production issues for fermentation and purification of new bioemulsifiers, Relate detergency to chemical structure. Tailor chemical structure of bioemulsifiers for specific degreasing applications, ' Extramural: modify bioemulsifiers by fermentation feeding strategies. Chemically characterize new emuisifiers. Modify other similar Copolymers < with fermentation technique. Optimize bioremediation methods for emulsified oil/grease solutions. NRDEC and AMC-IOC; POC: Dr. Fred Allen 508- ; 233-4266' I Evaluation of Alternatives to Chlorinated Solvents and Cleaners for Army Vehicles: i Identify candidate replacement solvents and recovery systems for chlorinated solvents for Army vehicle maintenance and repair. Test, evaluate and ¦ determine environmental and economic benefits. U.S. Army Materiel Command, TACOM: POC: T.C. Ilandsy, TACOM, 810-574-8834. . Environmentally Acceptable Cleaning Processes: U.S. Army, TARDEC, POC: Unknown Deploy Lactate Esters as Non-toxic, Non-polluting Solvent: Explore the use of inexpensive lactate esters, such as ethyl lactate, for paint equipment cleaning, and honeycomb structure cleaning prior to bonding. Test recovery process. Conduct economic analysis. NCMS/ORNL; POC: Mr Jim Frank. 708-252-7693 Continuous Aqueous Cleaning to Eliminate ODC RIA: POC: Unknown Laser Cleaning and Coatings Removal: i Demonstrate the use of laser cleaning and coating removal on components ranging from turbine engine blades to landing gear and radomes. Prototype laser-based facility will test carbon dioxide and examine laser cleaning and coating removal operations for a variety of aircraft and general equipment cleaning, Wright Lab/MTPN. POC: Mr. Michael Wad dell (513) 255-7277. I APMS&E. for Aircraft Components: [ Field demonstration of laser based facility for component cleaning, coating removal and surface preparation. Wright Lab: POC Robert Hall, WL/MLPJ. DSN 785-2334 APEOOM for Non-chemical Metal Cleaning of Aircraft Components: ; Alternative process, engineering design and operation manual for non-chemical metal cleaning process for aircraft components, including wing skins, fuselage panels and bulkheads, etc., priorto surface preparation, such as anodizing, and subsequent priming in preparation for coating or ; adhesive bonding Air Force Research Laboratory, POC: Phil Mykytiuk, WL/MLSE. DSN 785-3953. (513) 255-3953. APEDOM for a Supercritical Fluid Cleaner for Avionics and Mechanical Components: ; Alternative Process Design and Operation Manual for a supercritical fluid cleaner with an internal chamber sized to accommodate both avionics and mechanical components. Air Force Research Laboratory; POC: Phil Mykytiuk, WL/MLSE, DSN 785-3953, (513) 255-3953, Alternative Bullet Tip Degreasing Agent: I ARDEC/Lake City Army Ammunition Plant; POC: Ms, Branca Roberts, 816-796-7168 Mobile Advanced. Aqueous Solution Recovery Systems: I NDCEE will test advanced separation and filtration technologies for dosed loop recovery of aqueous solutions. NDCEE. POC. David Roberts, 814- 263-28.85, i High Efficiency, Low-Cost Supercritical Fluid Cleaner: I SWRI developed a natural convection supercritical fluids cleaner as a substitute for 1,1,1-trichloroethane. SWRI also designed and built a pre- i production natural convection cleaning system. Under this project, SWRI will establish the cleaning envelope for the natural convection process. As ; of June 1997. SWRI had begun the background contamination study and the particulate filtering system design Southwest Research Institute and Air Force Research Laboratory. POC: Mary Marshall. (210) 522-2183. i Alternative Cleaning Processes for Metal and Composite Honeycomb Parts: Corpus Chnsti Army Depot and NDCEE will develop an environmentally friendly cleaning process for cleaning the honeycomb core, skins, and : structural members prior to bonding. CCAD, NDCEE; POC: Mr. A! Gonzales, 512-939-4073, < Page 5 of 8 1,1,1-TRlCHLOROETHANf ------- ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT HEAVY-DUTY SOLVENT Supercritical Carbon Dioxide Optical Sub-system Cleaning: ARDEC: POC: Mr, Curtis Anderson, 201-724-4287. Nonhalogenated Systems for Cleaning Metal Parts: Production testing demonstrated the viability of spray and immersion cleaning systems (or specific cleaning applications, Based on the bench scale testing, NDCEE determined that Brulin formula 815GD is the preferred aqueous chemistry for mechanically and ultrasonically agitated immersion systems and will be used for production testing in the Advanced Ultrasonic Cleaning System, Daraclean 282 was selected for use in the Power Washer Cleaning System, although alt of the chemistries downselected for the bench scale testing effectively emulsified the soils and prevented recontamination of the parts. NDCEE and ARDEC: POC: Richard Pirotta NDCEE, 814-269-2810; Ms, D. Demons, ARDEC, 201-724-8773, P2 Technology Maturation: Ultraviolet Light/Ozone Cleaning. Wright Lab, McDonnell Douglas, SAIC; POC: Harvey LilenfekJ (314)233-2550. Plasma Dry Cleaning: LAML conducted a technology demonstration of plasma dry cleaning on sample components and is developing industrial process techniques. Process uses an oxygen, radio-frequency plasma to remove hydrocarbon surface contamination such as cutting fluids, oils, and greases from components Resultant by-products are carbon dioxide and water vapor Reaclive ions generated in a plasma bombard the substrate, releasing contaminants, Los Alamos National Laboratory; POC: Harold Davis. Reduce Toxic Pollutant in Ultrasonic Cleaner Discharge Wastewaier NDCEE/ Tobyhanna Army Depot; POC: Unknown Supercritical Carbon Dioxide for Solvent Replacement: LANL conducted a project to develop improved techniques for cleaning with supercritical carbon dioxide, LANL has a Supercritical Fluids Experimental User facility available for exploratory evaluation and long-term R&D Los Alamos National Laboratory; POC" Dale Spall, Ken Laintz. Laser Cleaning for Semiconductor Manufacturing: Joint demonstration of a laser cleaning system manufactured by Neuman MicroTechnologies, Inc for silicon wafers, photomasks, and flat panel display substrates. National Security Agency. Motorola, USEPA, Radiance Services Company. POC: John Robinson. (301) 654-0228, (Radiance Services) liquefied Gases as Substitutes for Traditional Solvents: U.S. Army MICOM, POC Unknown PAINT CONSTITUENT Powder Coating Technology For Small Arms Bullet Tip Identification: Eliminate VOCs associated with painting bullet tips. Demonstrate use of powder coating technologies in bullet tip identification. Armament Research. Development and Engineering Center (ARDEC). POC. 201-724-6518 R&M Improvement, Environmentally Compliant Aircraft Paints and Coatings (Contractor Support From BattelleV Suppliers have been solicited to provide candidate-coating systems with primer and topcoat VOC levels equal to or less than 210 grams per liter as part of this USAF project. The contractor will also do some formulating with low VOC resin systems POC. Unknown, Reduce Or Eliminate VOCs In CARC Paint Formulation Application. & Removal The goals of the Army project are to reduce or eliminate VOCs in CARC paint formulation (MlL-C-53039 and MIL-C-46168), application, and removal. Reformulation will be based on a high performance, water reducible/water dispersible polyurethane binder system Evaluate electroless metallic dispersion or thermoplastic spray coatings for application techniques. Current stripping technologies will be evaluated against the new coatings and optimized as required. US Army Research Laboratory, POC. 1-800-USA-3845 Plastic Laminate As A Replacement For Conventional Topcoats: Tnis Navy effort involves using plastic laminates developed by 3M as a total-body decal to replace traditional topcoats The laminates are currently being flight tested on F-3, F-18, and C-130 aircraft. The plastic film is laminated to the aircraft's primer with an acrylic adhesive. Delaminating an aircraft is accomplished by using steam to release and remove the adhesive. The used laminate can then be land-filled. Advantages over traditional coatings include reduced environmental/OSHA issues associated with traditional paint booth applications, faster installation, elimination of depaint hazardous waste and OSHA issues, lighter weight compared to typical multiple layer coatings, improved corrosion protection due to the impenetrable nature of the plastic film, and improved survivability. In addition to these advantages, commercial airline testing of the laminates have shown a fuel savings due to decreased drag Navy, POC' Dave Pulley 3CW342-8050 Topcoat Refo rmu lation: JG-APP is currently sponsoring a project with Raytheon Tl Systems. Inc. (formerly Texas Instrument Defense Systems and Electronics) to identify reduced VOC topcoat and primer formulations Specifically. Raytheon is targeting reductions in methyl ethyl ketone (MEK). toluene, and xylene releases associated with conventional, wet-spray coating of primer, ground support equipment topcoat, and airborne topcoat applications To date, this project has developed test protocols and will shortly be testing individual primer and topcoat formulations JG-APP- POC Mr Luis Garcia- Baco. 703/617-2818. Page 6 of 8 1,1,1 -TRICHLOROETHANE ------- ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT PAINT CONSTITUENT High solids primer properties enhancements: This USAF effort is So define the nature and extent of problems associated with the existing high solids primers. Problems with adhesion and excessive curing times have been reported. Potential solutions will be evaluated utilizing existing material and process options Interaction with j coating manufacturers to reformulate primers to correct problems that cannot be corrected by existing options will be accomplished. Additional S pollution minimization may be achieved through reduced need for rework due So improved performance of the primers as well as reduced flow time j for aircraft re-coating. POC: Unknown. { Unitized Coating Application Facility: E-Coat & Powder Coat: ! This project will investigate painting application technologies which reduce VOC emissions and improve coaling quality. Identify present processes, research on state-of-the-art techniques. Development of demonstration facility and transition to a DOD facility. NDCEE; POC; Unknown. Topcoat for SAOABM Projectile: i The goats of this Army project are to develop thin CARC paint coat for SAOARM Projectile which meets VOC requirements. Armament Research, ; Development and Engineering Center (ARDEC); POC: 201-724-6518. i Non-Toxic, Low VOC Wash Primer: t Develop a non-toxic, low VOC wash primer as a universal metal pretreatment for Army equipment Evaluate water-borne polymers that are > compatible with moderate levels of mineral and organic acids and test their ability to act as adhesion-promoting primers and surface passivators. ; Armament Research. Development and Engineering Center (ARDEC): POC 201-724-6518 Large Area Powder Coatings Program (Contractor Support From BBM Inc.. METTS Inc., Univ. of Southern Mississippi, and Weidman Associates): ; The goal of this USAF project is So provide powder materials and technology to improve aircraft coating performance and increase environmental acceptability. The use of polymeric beads (powder) can significantly reduce the VOCs in aircraft coating formulations. Powders are also required for high velocity thermal spray coatings, which promise zero VOCs. This program will develop, optimize and produce powders that will provide the desired improvements in coating systems. In FY97, the processes and equipment developed will be demonstrated at WR-ALC on tactical mobile shelter structures and other applications. POC. Unknown High Velocity Thermal Spray Coatings (Contractor Support From Aspen Systems, Weidman Associates, and SAIC): This program at WR-ALC is to develop the high velocity thermal spray (HVTS) process of applying powder based coatings and systems It includes development of AF specific HVTS application equipment and the development of powder based coatings. Note: Thermal Spray Coatings contain zero to little solvent borne carriers. POC: Unknown. Environmentally Compliant, Zero VOC Coatings (Contractor Support From Foster Miller): The goal of this USAF project is to develop a two component, zero VOC coating thai cures at room temperature in less than 24 hours. A no-VOC polyurethane'vmyl dioxolane (PVD) coating was developed in phase 1 that required a 50s C cure for several hours to develop adequate hardness properties. This development program will address room temperature cure capability by evaluating increased catalyst levels, more reactive catalysts, catalyst promoters and accelerators. The C-17 Advanced Performance Coating requirement document will be used to quantify coating performance POC. Unknown. Environmentally Compliant Protective Coatings' The goals of this Army project are VOC reduction and removal of hazardous materials from protective coatings. US Army Research Laboratory; POC: 1-800-USA-3345. | Advanced Corrosion Resistant Aircraft Coatings (Contractor Support From Boeing Defense and Space): j The objective of this USAF program is to develop, demonstrate and commercialize effective coating materials and processes for aluminum alloys which prevent pollution reduce or eliminate hazardous waste treatment and disposal costs, and are safe to use. The new processes will be environmentally benign and will meet DOD performance demands. The materials will eliminate the use of heavy metals (chromium) and volatile « organic compounds (VOCs). The program employs a two-part parallel effort to develop a near-term coating system that will meet Aerospace NESHAP requirements and a long-term, totally "green" system. The near-term system includes non-chromate conversion coatings, non-chromate ; and low VOC primers and topcoats. The long-term solution will utilize sol-get to replace conversion coatings, interface coatings, and low VOG, non- isocyanate topcoats. POC' Unknown Waterborne primer system improvements: s This USAF effort involves assessing existing Mll-C-85582 primer problems that prevent USAF full-scale usage. Baseline laboratory integration and i field transition testing of material and process improvements will be conducted. Assistance in transitioning the improved systems will be provided . where required. This effort is proactive in solving current waterborne coatings technical issues for the purpose of transitioning from solvent-borne ; coating systems to low or zero VOC waterborne coating systems. POC: Unknown. KC-135 Integration Testing: } The USAF High Performance Aerospace Coating System (HPACS) program has performed testing of alternative aerospace coating systems (ex: low-VOC) on C-17 aircraft: laboratory data as well as flight test data from the C-17 program is available Proposed efforts are to transition the application of high performance aerospace coating systems to KC-135 aircraft. POLLUTION PREVENTION RESEARCH AND DEVELOPMENT / TRANSITION NEEDS HAND-WIPE SOLVENT On-going R&D and existing commercial off-the-shelf technology solutions are adequately addressing the pollution prevention needs for this use Page 7 of 8' 1,1,1 -TRICHLOROETHANE ------- POLLUTION PREVENTION RESEARCH AND DEVELOPMENT / TRANSITION NEEDS HEAVY-DUTY SOLVENT On-going R8D and existing commercial off the shelf technology solutions are adequately addressing the pollution prevention needs fo this use PAINT CONSTITUENT On-going R&D and existing commercial off the shelf technology solutions are adequately addressing the pollution prevention needs for this use. Additional R&D may be necessary for paints that do not contain ethylene glycol. Federal Facilities Which Reported for Both 1994 and 1995 1994 Release* 1995 Release* Percent Facility Off-site Treatment Off-site Treatment Change U.S. ARMY LAKE CITY ARMY. INDEPENDENCE. MO 32,604 28,490 -13% NASA JOHN F. KENNEDY SPACE. KENNEDY SPACE CENTER. FL 25,080 16,374 -35% THIOKOL ORDNANCE LONGHORN ARMY, KARNACK, TX 20,245 0 -100% U.S. AIR FORCE. ROBINS AIR FORCE BASE, GA 87,073 44.486 -49% U S. AIR FORCE. TINKER AFB. OK 42,363 12.722 -70% U S. AIR FORCE CAPE CANAVERAL, CAPE CANAVERAL, FL 0 12.000 100% U S AIR FORCE MCCLELLAN AIR, SACRAMENTO. CA 12,200 0 -100% U S AIR FORCE OGDEN AIR, HILL AFB, UT 115,000 24.000 -79% U S AIR FORCE PLANT 03 OK. TULSA, OK 24,022 0 -100% U S AIR FORCE PLANT 04 TX, FORT WORTH, TX 13,300 0 -100% U S. AIR FORCE PLANT 06 GA. MARIETTA. GA 37,440 27.045 -28% U.S AIR FORCE PLANT 44 AZ. TUCSON, A2 35,250 0 -100% U S ARMY FORT HOOD, FORT HOOD. TX 34,618 0 -100% NASA, HUNTSVlLIE. AL 13,000 0 -100% U S. ARMY IOWA AMMUNITION, MIDDLETOWN. IA 78 0 -100% U S. NAVY NAVAL SURFACE, LOUISVILLE, KY 40,350 0 -100% U S ARMY IETTERKENNY ARMY. CHAMBERSBURG, PA 52.000 67.300 29% U S. ARMY LONGHORN AMMUNITION, KARNACK, TX 20.245 0 -100% U.S ARMY MCALESTER, MC-ALESTER, OK 13,092 17.740 36% U S. ARMY TOOELE CHEMICAL, TOOELE, UT 17.700 0 -100% U.S. BUREAU OF PRISONS FEDERAL, FLORENCE, CO 24,412 0 -100% U.S DOE STANFORD LINEAR. MENLO PARK, CA 13,300 0 -100% U S MARINE CORPS. BARSTOW, CA 39,562 24,109 -39% U S MARINE CORPS LOGISTICS, ALBANY, GA 36,500 24,100 -34% U S NAVY. JACKSONVILLE FL 34.000 10,682 -69% U S. NAVY. NORFOLK, VA 25.025 9,831 -61% U.S NAVY, PORTSMOUTH. VA 23,000 17,2:00 -25% U.S NAVY, SAN DIEGO, CA 9,000 0 -100% U.S. NAVY NAVAL SURFACE, CRANE, IN 0 13,000 100% U.S ARMY FORT MCCOY, CAMP MC COY, Wl 525,000 2.295 -100% If you have additional information regarding an identified or used P2 approach, on-going P2 research and development, or any P2 research and development/transition needs, please notify Will Garvey, US EPA, 1200 Pennsylvania Avenue, NW. Ariel Rios Building. 3rd Floor, Washington, DC 20004-2403, or fax (202) 501-0069. Page 8 of 8 1,1,1-TRICHLOR.OETHANE ------- |