United States
Environmental
Protection Agency
Office of Enforcement and
Compliance Assurance
Washington, DC 20460
EPA-300-F-98-002d
February 1998
nSrEPA 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.
DICHLOROMETHANE
1995 Waste Management Distribution
J3%
]~2%
Lm 11%
I 84%
Recycling
t
Energy Recovery
¦ Treatment
(C 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 P2 research and development section.
•	P2 research and development/transition needs section.
TRI Reported Quantities - Percent Change 1994 and 1995
6
TRI
Releases
Recycling
Energy Recovery
Treatment
Releases plus
Reporting

On-Site Off-Site
On-Site
Off-Site
On-Site
Off-Site
Off-site Treatment
1994 (lbs)
2 100 463
0' 42146
30,212
30,775 "
60,270
165,683
2.266,146
1995 (lbs)
1.494,943
0 45,880
3
36,454
80,183
142.564
1,837,507
% Change
-29%
' 0%' " 9% "
-100%
18%
0%
-14%
-28%
Page 1 of 9
DICHLOROMETHANE

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CHEMICAL PROFILE: DICHLOROMETHANE
CAS #: 75-09-2
SYNONYMS
METHYLENE DICHLORIDE
METHYLENE CHLORIDE
COMMON USES IN THE U.S.
www.epa,govrttn/uatw#hltp://www. epa.gov/ttn/uat
w#
Methylene chloride is approved for use as a postharvest fumigant for grains and strawberries
and as a degreening agent for citrus fruit,
•	Methylene chloride is used as a propeflant in aerosols for products such as paints, automotive
products, and insect sprays. It is used as an extraction solvent for spice oleoresins arid hops
and for the removal of caffeine from coffee. However, due to concern over residual solvent,
most decaffemators no longer use methylene chloride
•	Methylene chloride is predominantly used as a solvent in paint strippers and removers; as a
process solvent in the manufacture of drugs and pharmaceutical and film coatings; and as a
metal cleaning and finishing solvent in electronics manufacturing.
ACUTE HEALTH HAZARDS
www e pa q ov/ttrvu a tw#ht to - //www e pa oo v/tt n/u at • Tests involving acute exposure of animals, such as the LD50 and LC50 tests in rats, have
w#	shown methylene chloride to have moderate acute toxicity from oral and inh'alation exposure.
• Acute inhalation exposure so high levels of methylene chloride in humans has resulted in
effects on the nervous system including decreased visual and auditory functions, but these
effects are reversible once exposure ceases Methylene chloride also irritates the nose and
throat at high concentrations.
CHRONIC HEALTH HAZARDS
www epa qov/ttn/uatw#http //www epa qov/ttn/uat
w#
Case studies of methylene chloride poisoning during paint stripping operations have
demonstrated that inhalation exposure at very high levels can be fata! to humans
EPA considers methylene chloride to be a probable human carcinogen (cancer-causing agent)
and has ranked it in EPA's Group B2.
Animal studies indicate that the inhalation of methylene chloride causes effects on the liver,
kidney, and cardiovascular system
The major effects from chronic (long-term) inhalation exposure to methylene chloride in humans
are effects on the CNS, such as headaches, dizziness, nausea, and memory loss
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; DICHLOROMETHANE
Federal Facilities Reporting in both 1994 ancJ 1995 15
Federal Facilities Reporting Only in 1994	10
Federal Facilities Reporting Only in 1995	0
HEAVY-DUTY SOLVENT
PAINT REMOVER
PAINT CONSTITUENT
POLLUTION PREVENTION APPROACHES CURRENTLY IN USE
HEAVY-DUTY SOLVENT
•	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-93/017 February 1994)
•	The Corrosion Control Element, 437 Equipment Maintenance Squadron (EMS), Charleston AFB, South Carolina significantly reduced their
hazardous waste stream by reclaiming a majority of the Methyl Ethyl Ketone (MEK) used in their aircraft refimshing operation They did this
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 imomge 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), Wheat Starch, Walnut Shells and Other Food By Products, and Sodium Bicarbonate.
Page 2 of 9
DICHLOROMETHANE

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POLLUTION PREVENTION APPROACHES CURRENTLY !N USE
HEAVY-DUTY SOLVENT
•	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
cnemistry for mechanically and ultrasomcally agitated immersion systems and will be used for production testing in the Advanced Ultrasonic
Cleaning System, Oaraclean 282 was selected for use in the Power Washer Cleaning System, although all of the chemistries downseiected for
the bench scale testing effectively emulsified the soils and prevented recontaminatlon 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
•	Steam cabinets or vacuum vapor degreasers wilt 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 propeilant 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
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POLLUTION PREVENTION APPROACHES CURRENTLY IN USE
PAINT CONSTITUENT
•	Low VOC Topcoat Alternatives (Reduced Solvent Carrier): MIL-C-85285 is a high-solids (i.e., lower VOC). lead-free, solvent-borne
polyurethane; 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-VOG CARC as an alternative to MIL-C-46168 and MIL-C-53039. The product is expected to be
available for general use in 1998,
•	Low VOC Primer Alternatives {Reduced Solvent Carrier): MIL-P-85582B is water reducible, epoxy catalyst, Class N -lead and chromate free;
and MIL-P-53030A
PAINT REMOVER
» Mobile Manipulation of a C02 Turbine Wheel Coatings Removal System. NDCEE tested and demonstrated the use of a ceninfugally
accelerated carbon dioxide pellet turbine wheel (C02 TW) device manufactured by Cryogenics. Inc The device was tested using Navy
equipment and compared results with current coatings removal methods. POC: Frederick Lancaster, NDCEE, 814-269-2806.
•	Automated Ultra-High Pressure Waterjet System Workcell UHPWJ (N.Q20). This project will evaluate the automated UHPWJ process for
tnermal spray coatings removal, aid in transitioning this technology !o DOD repair/refurbishment depots. and explore UHPWJ stripping as a
possible alternative to other waste-generating coatings removal processes, which utilize acid dip/media blast steps that generate hazardous
waste and damage engine components. ARDEC, Corpus ChrisEi Army Depot (CCAD). NDCEE. POC. Frederick Lancaster. NDCEE. 814-269-
2806.
•	Abrasive blasting is an alternative to solvents for coatings removal 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), Wheat Starch, Walnut Shells and Other Food By Products, and Sodium Bicarbonate.
•	Automated Ultra-High Pressure Waterjet System Workcell UHPWJ (N.020V This project will evaluate the automated UHPWJ process for
thermal spray coatings removal, aid in transitioning this technology to DOD repair/refurbishment depots, and explore UHPWJ stripping as a
possible alternative to other waste-generating coatings removal processes, which utilize acid dipfanedia blast steps that generate hazardous
waste and damage engine components. ARDEC. Corpus Chnsti Army Depot (CCAD). NDCEE: POC: Frederick Lancaster NDCEE 814-269-
2808.
•	Mobile Manipulation of a C02 Turbine Wheel Coatings Removal System1 NDCEE tested and demonstrated the use of a centnfugally
accelerated carbon dioxide pellet turbine wheel (C02 TW) device manufactured by Cryogenics, Inc The device was tested using Navy
equipment and compared results with current coatings removal methods POC. Frederick Lancaster, NDCEE, 814-269-2806.
•	Abrasive blasting is an alternative to solvents for coatings removal. 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). Wheat Starch. Walnut Shells and Other Food By Products, and Sodium Bicarbonate.
ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
HEAVY-DUTY SOLVENT
Environmentally Acceptable Cleaning Processes:
U S Army, TARDEC. 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 Lamtz.
Reduce Toxic Pollutant in Ultrasonic Cleaner Discharge Wastewater-
NDCEE' Tobyhanna Army Depot. POC Unknown
Plasma Dry Cleaning:
LOlNL 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 Reactive ions generated in a plasma bombard the substrate, releasing
contaminants Los Alamos National Laboratory, POC' Harold Davis
P.2 Technology Maturation:
Ultraviolet Light/Ozone Cleaning, Wright Lab, McDonnell Douglas, SAIC; POC: Harvey Lilenfeld (314) 233-2550.
Page 4 of i
DICH LOROM ETHAN E
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
HEAVY-DUTY SOLVENT
Nonhalooenated 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 chemistry for mechanically and ultrasomcally 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 '
recontamination of the parts. NDCEE and ARDEC; POC: Richard Pirotta NDCEE, 814-269-2810; Ms. D, Demone, ARDEC. 201-724-6773
Mobile Advanced. Aqueous Solution Recovery Systems:	;
NDCEE will test advanced separation and filtration technologies for closed loop recovery of aqueous solutions. NDCEE; POC: David Roberts, 814-
269-2885.
Liquefied Gases as Substitutes for Traditional Solvents:	;
U.S. Army, MICOM; POC: Unknown
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
Evaluation of Alternatives to Chlorinated Solvents and Cleaners for Army Vehicles:
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
Supercritical Carbon Dioxide Optical Sub-system Cleaning1
ARDEC; POC: Mr. Curtis Anderson, 201-724-4287,
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 io Eliminate ODC
RIA, POC. Unknown
Aqueous-based Decreasing Technology:
The Army's Soldier Systems Command (SSCOM) will develop nonpoltutmg. nontoxic water-based degreasers for cleaning metal/ glass/plastic
surfaces using biopolymer emulsifying materials Develop microbial!/ 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 biopolymers
with fermentation technique. Optimize bioremediation methods for emulsified oil/grease solutions NRDEC and AMC-IOC; POC. Dr. Fred Allen 506-
233-4266	i
APMS&E for Aircraft Components:
Field demonstration of laser based facility for component cleaning, coating removal and surface preparation Wright Lab. POC Robert Han.
WL/MLPJ, DSN 785-2334.
APEDOM 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.. prior to surface preparation, such as anodizing, and subsequent priming in preparation for coating or
adhesive bonding Air Force Research Laboratory. POC: Phil Mykytiuk. WUMLSE. 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 componenss. Air Force Research Laboratory, POC' Phil Mykytiuk, WUMLSE, DSN 785-3953, (513) 255-3953,	>
Alternative Cleaning Processes for Metal and Composite Honeycomb Parts:	'
Corpus Christ! 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. Al Gonzales, 512-939-4073.
Alternative Bullet Tip Deoreasing Agent
ARDEC/Lake City Army Ammunition Plant; POC; Ms, Bianca Roberts, 816-796-7168
Solvent Replacement - Vapor Deoreaser:	,
Allied Signal will demonstrate a replacement fori 1 i trichloroethane vapo deg easing. Allied Signal Army Engine Plants; POC: Mr, T, Russell, Mr,
J. Morreli, 203-385-3741,
Services)
Page 5 of 9
DICHLOROMETHANE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
HEAVY-DUTY SOLVENT
High Efficiency, Low-Cost Supercritical Fluid Cleaner
SWRI developed a natural convection supercritical fluids cleaner as a substitute for 1.1,1-trichloroeihane SWRI also designed and built a pre-
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,
Laser Cleaning and Coatings Removal:
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 Waddell <513) 255-7277,
PAINT CONSTITUENT
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 that cures at room temperature in less than 24 hours. A no-VOC
polyurethane/vinyl dioxolane (PVD) coating was developed in phase 1 that required a 50° C cure for several hours to develop adequate hardness
properties. This development program will address room temperature cure capability by evaluating increased catalyst levels, m6re reactive
catalysts, catalyst promoters and accelerators The C-17 Advanced Performance Coating requirement document will be used to quantify coating
performance POC: Unknown.
High solids primer properties enhancements'
This USAF effort is to 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
coating manufacturers to reformulate primers to correct probiems that cannot be corrected by existing options will be accomplished. Additional
pollution minimization may be achieved through reduced need for rework due to improved performance of the primers as well as reduced flow time
for aircraft re-coating. POC Unknown.
R&M.Improvement, Environmentally Compliant Aircraft Paints and Coatings (Contractor Support From Battelle):
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
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 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-3845.
Unitized Coating Application Facility E-Coat& Powder Coat
This project will investigate painting application technologies which reduce VOC emissions and improve coating 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 Reformulation:
JG-APP is currently sponsoring a project with Raytheon Tl Systems. Inc. (formerly Texas Instrument Defense Systems and Electronics) to identity
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.
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 (MIL-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 electro less
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
Waterborne primer system improvements:
This USAF effort involves assessing existing MIL-C-85582 primer problems that prevent USAF full-scale usage. Baseline laboratory integration and
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.
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 {ARDECV POC 201-724-6518.
Page 6 of 9
DICHLOROMETHANE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
PAINT CONSTITUENT	"	i
Plastic Laminate As A Replacement For Conventional Topcoats:
This 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. Delammatmg 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 environmentsl/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, tn addition to these advantages, commercial airline testing of the laminates have
shown a fuel savings due to decreased drag. Navy; POC: Dave Pulley 301/342-8050.	\
Non-Toxic, Low VOC Wash Primer.
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.	i
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 to 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.
KC-135 Integration Testing:	i
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.
Advanced Corrosion Resistant Aircraft Coatings (Contractor Support From Boeing Defense and Space):
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 mee! 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-gel to replace conversion coatings, interface coatings, and low VOC, norv
isocyanate topcoats POC Unknown	<
Topcoat for SAOARM Projectile:
The goals of this Army project are So develop thin CARC pamt coat for SAOARM Projectile which meets VOC requirements. Armament Research,
Development and Engineering Center (ARDEC). POC' 201-724-6518.
PAINT REMOVER
Evaluation of Polymedia-lite Dry Bias! Media:
This effort was to evaluate new dry blast media for paint stripping. Tests will be conducted to determine if acceptable stripping rates can be
achieved with the same or less damage to the aircraft than conventional dry blast media This is applicable to the C-5, F-15, A-10 and C-130	.
POC WL/MLSS-CTIO. MAJW Kevin Kuhn (937)-255-0943	j
Selective Stripping Process Development:	s
Identify "smart" stripping processes capable of selectively removing topcoats from long-life foundation layers (primers) Would allow use of	j
permanent foundation layers to achieve "paint for Life" systems Any required HAPs, e g chromate corrosion inhibitors, could be contained within j
the permanent foundation layer. If this is not stripped, then there is no pollution from stripping process. POC: WL/MLSS - CTIO; MAJ W Kevin	j
Kuhn (937J-255-0943,	;
I
Polvmedia Lite Evaluation for Composites:
The effort is to evaluate new dry blast media for stripping paint from composite laminates (graphite, glass , Kevlar). Tests will be conducted to	j
determine if acceptable stripping rates can be achieved with insignificant or no damage to the aircraft This is applicable So C-17 and F-22 aircraft
with potential application to other aircraft. POC: WL/MLSS - CTIO; MAJ W. Kevin Kuhn (937)-255-0943	"
Water Jet Paint Stripping:	I
This effort is to develop a process to strip coatings from military ground vehicles, and small aircraft, contain the wastes, and recycle the water,
POC: TACOM; Mr. Carl Handsy <313>-574-8834	I
Next Generation Energetic Stripping:	t
Identify and develop novel ideas using energetic means to REMOVER coating layers, i.e. laser-stripping, flashjet, pinchlamp, etc, , which wilt allow <
reduction of hazardous waste, cost and downtime of aircraft. POC: WL/MLSS - CTIO; MAJ W. Kevin Kuhn (937)-255-0943	^
Medium Pressure Water Stripping:	i
This effort is to evaluate semi-automation and industrialization of a pressurized water process. This process can replace or enhance methylene
chloride chemical applications. It applies to C-130, C-141 and other large aircraft. Recycled water can be used in the water stripping process. ;-
POC: WL/MLSS - CTIO; MAJ W. Kevin Kuhn (937)-255-0943.
Page 7 of 9
DICHLOROMETHANE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
PAINT REMOVER
Improved Non-HAPs Chemical Strippers:
Identify/develop environmentally acceptable chemical paint strippers with a maximum dwell time of 1-hour and t p ate comparable to methylene
Chloride. POC: WUMLSS - CTIO: MAJ W. Kevin Kuhn (937)-255-0943
Environmentally Acceptable Chemical Strippers:
This effort is to determine the range of parameters for viable environmentally acceptable processes and to evaluate handling issues. Potential
benefits are to reduce or eliminate the use of toxic chemicals (HAPs) POC. WL/MLSS - CTIO: MAJ W. Kevin Kuhn (937J-255-0943.
Dry Media Stripping of Thin Skin Aluminum:
This effort will determine the effects of dry media blasting (DMB) on thinner skin aluminum, .032 and .025 inch 2024 - T3 and bare alloy. Three
different DMB will be evaluated: acrylic, polymedia-lite and polymerized wheat starch Material characterization data for comparison of the three
media will be developed from the JPATS airframe If successful, 3 follow-on integration project will be started in FY98. POC WL/MLSS - CTIO'
MAJ W. Kevin Kuhn (937)-255-0943
Development of NDE for Selective Stripping:
This effort is to develop non destructive evaluation techniques for determining the health of the primer or "foundation layer" that is to be left on the
substrate and to inspect for corrosion under the primer or "foundation layer." POC. WUMLSS - CTiO, MAJ W Kevin Kuhn (977)-255-0943
Biodegradable Plastic Media - Foster Miller (SBIR):
This effort is to develop biodegradable plastic media and an associated biotreatment system, which can be, used in current generation plastic media
blasting (PMB) aircraft coatings REMOVER processes. This could significantly reduce the amount of heavy metals contaminated waste from
stripping chromate and cadmium containing paints POC WL/MLSS - CTIO. MAJ W Kevin Kuhn (937J-255-0943.
Aqueous Paint Coating & Stripping1
This Army project will design and produce new protein-based coatings for specific substrates (metals) and clean REMOVER strategy based on new
aqueous-based systems. Armament Research, Development and Engineering Center (ARDEC), POC, 201-724-6516
Aircraft Depaintinq Technology:
This program will identify the best alternatives from existing/developmental methods such as non-hazardous chemical paint strippers (i e.. no
chrome. MeCL, etc ) and mechanical procedures (PMB. Flash Lamp, dry ice. water jet. etc.) Procedure efficiency, substrate surface effects,
nazardous waste generation and A/C applicability will be investigated in order to determine the best procedure for Navy applications Comparison of
the advantages and disadvantages of each technique will also be performed. Mechanical procedures eliminate hazardous chemicals, but can
damage substrate surfaces Since some aircraft skins are very thin, this is not acceptable However, combinations of some techniques (i.e., flash
lamp/dry ice) could efiminate or minimize surface damage to an acceptable level, POC: NAWCAD, Patuxent River; Mr. Steve Hartte (301 >342-
8006..
Plastic Laminate As A Replacement For Conventional Topcoats:
This 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 301/342-8050.
Paint Stripping Methods - Auto crawler:
This program is aimed at developing an autonomous or remotely piloted vehicle prototype designed to remove aircraft coatings. The approach is to
take the existing autocrawler prototype and develop end effecter delivery systems capable of stripping coatings The end effecters being evaluated
~re 1) medium/high pressure water, 2) wheat starch, and 3) flash lamp The program includes a prototype built for one system POC WL/MLSS -
CTIO. MAJ W. Kevin Kuhn (937)-255-0943
Alternate Chemical Paint Strippers'
Environmentally compatible paint strippers provide an alternative to the more hazardous products based on methylene chloride or caustic agents
The products are effective in removing thick layers of paint buildup with minimal damage to the substrate surface. The demonstration/validation
(D/V) project confirmed that products effectively remove interior and exterior LBP from wood surfaces. POC: CERL, Susan Drodz (217.1-373-6732
POLLUTION PREVENTION RESEARCH AND DEVELOPMENT / TRANSITION NEEDS
HEAVY-DUTY SOLVENT
•	On-going R&D and existing commercial off the shelf technology solutions are adequately addressing the pollution prevention needs tor 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.
PAINT REMOVER
Page 8 of 9
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POLLUTION PREVENTION RESEARCH AND DEVELOPMENT I TRANSITION NEEDS
PAINT REMOVER
• On-going R&D and existing commercial off the shelf technology solutions are adequately addressing the pollution prevention needs for tn s e
Federal Facilities Which Reported for Both 1994 and 1995
1994 Release*	1995 Release+ Percent
Facility
Off-site Treatment
Off-site Treatment
Chant
U S DOE PINELLAS PLANT, LARGO, FL
8,700
0
-100%
U S AIR FORCE. KELLY AFB. TX
28,344
38,780
47%
U S AIR FORCE, ROBINS AIR FORCE BASE GA
444,231
292,509
-34%
U.S. AIR FORCE, TINKER AFB, OK
857,500
546,111
-36%
U S AIR FORCE MCCLELLAN AIR SACRAMENTO, CA
100,000
124,000
24%
U S AIR FORCE OGDEN AIR, HILL A F B, UT
88,000
115,000
31%
U S AIR FORCE PLANT 06 GA MARIETTA, GA
18.917
0
-100%
U S ARMY, ABERDEEN PROVING GROUND, MD
8,736
0
-100%
U.S ARMY. ANNISTON. AL
152,315
132,300
-13%
U.S ARMY, TOBYHANNA. PA
11,388
0
-100%
U S ARMY LETTERKENNY ARMY. CHAMBERSBURG, PA
9,800
18,000
84%
NASA JOHNF KENNEDY SPACE KENNEDY SPACE CENTER, FL
17,121
14,751
-14%
U.S BUREAU OF PRISONS FEDERAL. FLORENCE. CO
10,958
19,510
78%
U S NAVY PUGET SOUND, BREMERTON. WA
14,000
0
-100%
U S MARINE CORPS. CHERRY POINT. NC
56,000
30,000
-46%
U S MARINE CORPS CAMP LEJEUNE. CAMP LEJEUNE, NC
21,848
0
-100%
U.S. MARINE CORPS LOGISTICS. ALBANY, GA
93,650
68,300
-27%
U.S NATIONAL CANCER INSTITUTE. FREDERICK. MD
6,750
0
-100%
U S. NAVY. JACKSONVILLE. FL
161,680
168,156
4%
U S. NAVY, NORFOLK. VA
66,000
43,000
-35%
U S NAVY. PENSACOLA, FL
23,100
0
-100%
U.S NAVY, PORTSMOUTH, VA
5,090
6,090
20%
U.S NAVY, SAN DIEGO, CA
13.848
21,000
52%
U.S NAVY NAVAL AIR STATION, ALAMEDA. CA
46.000
0
-100%
U.S ARMY PINE BLUFF ARSENAL, PINE BLUFF, AR
4,170
0
-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, piease notify Will Garvey, US EPA, 1200 Pennsylvania Avenue.
NW. Ariel Rios Building. 3rd Floor. Washington. DC 20004-2403, or fax (202) 501-0069.
Page 9 of 9
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