United States
Environmental
Protection Agency
Office of Enforcement and
Compliance Assurance
Washington, DC 20460
EPA-300-F-98-002m
February 1998
EPA 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
TOLUENE
1995 Waste Management Distribution
7%
16%
¦¦11%
r
3E£66%
Recycling
Energy Recovery
¦ Treatment
; Releases
Approach
A study was undertaken to analyze Federal facility TR! 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-gotng 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.
1.00
0.80
0.60
0,40
0.20
eg
.c
0.00
O
aP
-0 20
-0.40
-0.80
-0.80
-1 00
TRI
Reporting
1994 (lbs)
1995 (lbs)
% Change
TRI Reported Quantities - Percent Change 1994 and 1995
Releases
429,175
242.598
-43%
Recycling
On-Site Off-Site
30,700 69,375"
0 24,694
" -100%' -64%
Energy Recovery
On-Site Off-Site
10,415 255787~
0 57.145
-100%"" " -78%
Treatment
On-Site
167,068
18,167
-89%
Off-Site
61,810
22.873
-63%'
Releases plus
Off-site Treatment
"~490,985*
"265.471 ¦
~ "-46%
Page 1 of 10
TOLUENE
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CHEMICAL PROFILE: TOLUENE ......... CAS #: 108-88-3
SYNONYMS METHYLBENZENE TOLUOL PHENYlMETHANE
COMMON USES IN THE U.S.
www.epa.qov/ttn/uatw#http.7/www,epa.gov/ttn/uat
w#
ACUTE HEALTH HAZARDS
www.epa.nov/ttri/uatw#hnp //www. epa. gov/ttn/uat
w#
CHRONIC HEALTH HAZARDS
www epa gov/t!n/uatw#nttp-//www epa qov/ttn/uat
w#
COMMON P2 INITIATIVES
Forty nine Federal facilities reported releases of toluene in their 1994 or 1995 TRI reports The
majority of the facilities use toluene in painting and depainting operations or cleaning The
single largest releaser is Robins AFB (14% of the total 1994 releases), followed by the Air
Force Flight Test Center, Edwards. CA (7%).
Toluene is used in the manufacture of benzene and styrene, dyes, and explosives. It is
commonly used as a solvent for extraction processes. Toluene is a component of paints and
paint thinners, degreasers, adhesives and sealants.
Exposure can irritate the nose, throat, and eyes. Higher levels can cause dizziness and
fainting. Death can. occur.. Lower leyeis may cause trouble concentrating, headaches, and
slowed reflexes
Toluene may cause genetic mutations, further study is needed to determine if it is
carcinogenic Toluene may damage the developing fetus Other long term effects: repeated
exposure may cause damage to bone marrow, causing a low blood cell count. Prolonged
contact can cause drying and cracking of the skin, and a rash Repeated exposure can cause
headaches, lack of appetite, nausea, and liver and kidney damage, and may cause brain
damage.
www epa gov/ttn/uatw#hftp:flwww epa.qov/ttn/uat Process efficiency improvement Abrasive blast media is used as an alternative method for
w# cleaning metal parts. Aqueous jet washers, vacuum vapor degreasers, and other parts washer
systems reduce solvent wastes and fugitive emissions.
» Degreasing.
Solvent substitution. Switch to cleaning solvents with reduced environmental impact (low
toxicity, low VOC. non-HAP, biodegradable).
Recycling Toluene based paint thinners can be recycled on-site or off-site in recycling units.
Process efficiency improvements. Use more efficient paint guns to improve transfer efficiency;
use alternative paint stripping equipment.
Painting and Paint Stripping
Material substitution. Switch to non-toluene based paints, coatings, and paint thinners.
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: TOLUENE
Federal Facilities Reporting in both 1994 and 1995 22 HAND-WIPE SOLVENT HEAVY-DUTY SOLVENT
Federal Facililties Reporting Only in 1994 28 PAINT REMOVER
Federal Facililties Reporting Only in 1995 1
POLLUTION PREVENTION APPROACHES CURRENTLY IN USE
HAND-WIPE SOLVENT
Replaced MEK with a cleaner approved by the KC-135 SPO at Tinker AFB, methyl-n-propyl ketone (MPK). ASC/RAS, Wright Patterson AFB
KC-135 Systems Program Office. (OC-ALC). switched to cleaners under the MtL-C-87937 specification including DS-108 for wipe-prior-to-pamt
applications. They are continuing to test and evaluate other commercially available solvents including borothene and hydrofluoroethers Tinker
AFB, Oklahoma City ALC
tsopropy! alcohol (IPA) is approved as an alternative lo 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-C-
87937B are the most environmentally friendly cleaners authorized for use on C-141 aircraft and its components. (Reference: PRO-ACT
Technical Inquiry 8200)
Page 2 of 10
TOLUENE
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POLLUTION PREVENTION APPROACHES CURRENTLY JN USE
HAND-WIPE SOLVENT
Replaced 1,1, 1-trichloroethane (TCA) and methyl ethyi ketone (MEK) with a terpene cleaner for hand wiping operations. Martin Marietta
Astronautics
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 capfured by chilling and carbon adsorption Once
(he 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).
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), Wheat Starch. Walnut Shells and Other Food By Products, and Sodium Bicarbonate.
Nonhaiogenated 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 uitrasonically 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, POC. Richard Pirotta 814-269-
2810.
Hill AFB switched to terpenes and an ethyi 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 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.
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
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).
Using carbon dioxide blast media system for cleaning KC-135, C-141, B-52, B-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 include1 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 AF8
For heavy soil removal. NAVAfR recommends low vapor pressure (LVP) organic solvents. These solvents are volatile organic compounds, but
due to their 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
speed drying.
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 car, 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
Toluene is found in many heavy degreasing and stripping products often as an additive instead of as the primary ingredient. It is a major
component in blanket wash cleaners used in lithographic printing. Many Federal facilities have successfully found less toxic alternatives for
toluene in cleaning processes In many cases, facilities have modified both the cleaning agent and the cleaning equipment. Aqueous jet
washers, for example, are now commonly found at most DOD facilities.
Page 3 of 10
TOLUENE
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POLLUTION PREVENTION APPROACHES CURRENTLY IN USE
HEAVY-DUTY SOLVENT
Steam cabinets or vacuum vapor degreasers will most likely be used at OC-ALC (or penetrant removal prior to plating. Sieam cleaning is a
viable solvent alternative for removing oily or greasy residue. The heat accelerates ernulsification 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 degreaslng 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 She 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.
Using carbon dioxide blast media system for cleaning KC-135, C-141, B-52, B-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 CO£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 Tn-Services
World-Wide Pollution Prevention Conference"). Tinker AFB
Resolved by switching to terpenes and an ethyl lactate blend for aircraft cleaning operations Hill AFB, Ogden ALC
PAINT REMOVER
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 GnfSand Blasting. Steel Shot. Plastic Media, Plastic Foam, Dry Ice
(C02), Wheat Starch, Walnut Shells and Other Food By Products, and Sodium Bicarbonate
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.
Mobile Manipulation of a C02 Turbine Wheel Coatings Removal System. NDCEE tested and demonstrated the use of a centrifugaliy
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 UBPWJ (N.020); This project will evaluate the automated UHPWJ process for
thermal spray coatings removal, aid in transitioning this technology to DOD repatr/refurbtshment 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 Christi Army Depot (CCAD), NDCEE, POC: Frederick Lancaster, NDCEE, 814-269-
2806,
Mobile Manipulation of a C02 Turbine Wheel Coatings Removal System: NDCEE tested and demonstrated the use of a centrifugaliy
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.020): 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 dip/media blast steps that generate hazardous
waste and damage engine components. ARDEC. Corpus Christi Army Depot (CCAD), NDCEE; POC: Frederick Lancaster, NDCEE, 814-269-
2806.
ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
HAND-WIPE SOLVENT
Surface/Solvent Diagnostics for Metal Cleaning Operations:
Army Research Laboratory; POC. Unknown
Alternatives for General Aircraft Maintenance:
CCAD. POC. Unknown
Solvent Substitution for Fuel Tank Cleaning:
Using isopropyl alcohol (IPA) as a temporary substitute for the cleaning compound (NSN 6850-00-611-7993) 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; POC1 Unknown.
Page 4 of 10
TOLUENE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
HAND-WIPE SOLVENT '
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-15 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: i
Tested 30 commercially available hand-wipe cleaners Of the 30 cleaners, only four passed all screening tests: SD 1291 (Brulm 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: I
Evaluated 24 cleaners Testing three potential substitutes for MEK: ISO-BLAST, MD-516F. and Androx 5564 USAF, F-15 Program Office, Wright
Patterson AFB; POC: Unknown. I
Substitute for Hand-Wipe Solvents: ¦ - - I
Conducted extensive testing on commercially available, environmentally-friendly hand-wipe solvents for use on the B-2 program at the Air Force
Plant 42 Palmdale site Selected two solvents for implementation in manufacturing operations, Dynamold DS-108 and DS-108CA. Northrop
Grumman; POC: Unknown.- i
Solvent Substitution/Low VOC Cleaners:
Navy-Patuxant. POC. Unknown
Non-toxic Small/Medium Caliber Automatic Weapons Cleaning Process:
ARDEC, POC. Unknown
HEAVY-DUTY SOLVENT
Liquefied Gases as Substitutes for Traditional Solvents: j
U.S. Army, MICOM; POC: Unknown I
j
High Efficiency. Low-Cost Supercritical Fluid Cleaner: I
SWRI developed a natural convection supercritical fluids cleaner as a substitute for 1,1,1-tnchloroethane 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 She background contamination study and the particulate filtering system design. Southwest Research Institute and
Air Force Research Laboratory; POC: Mary Marshall. (210) 522-2183
APMS&E for Aircraft Components:
Field demonstration of laser based facility for component cleaning, coating removal and surface preparation Wright Lab, POC. Robert Hail,
WL/MLPJ, DSN 785-2334.
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 Laint2
Reduce Toxic Pollutant in Ultrasonic Cleaner Discharge Wastewater
NDCEE/ Tobyhanna Army Depot, POC Unknown
Plasma Dry Cleaning: j
LANL 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
P2 Technology Maturation:
Ultraviolet Light/Ozone Cleaning. Wright Lab, McDonnell Douglas, SAIC, POC Harvey Lilenfeld (314) 233-2550.
APEOOM 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.
Mobile Advanced, Aqueous Solution Recovery Systems
NDCEE will test advanced separation and filtration technologies for closed loop neco ery of aqueous solutions NDCEE; POC1 David Roberts, 814-
269-2885
Alternative Cleaning Processes for Metal and Composite Honeycomb Parts:
Corpus Christi Army Depot and NDCEE will develop an environmentally friendly cleaning process for cleaning the honeycomb core, skins, and j
structural members prior to bonding CCAD, NDCEE, POC" Mr Al Gonzales, 512-939-4073.
Page 5 of 10
TOLUENE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
HEAVY-DUTY SOLVENT
Laser Cleaning for Semiconductor Manufacturing.
Joint demonstration of a laser cleaning system manufactured by Newman MicroTechnologies. Inc. for silicon wafers, photomasks, and fiat panel
display substrates. National Security Agency. Motorola, USEPA, Radiance Services Company; POC John Robinson. (301) 654-0228, (Radiance
Services)
Laser Cleaning and Coatings Removal:
Demonstrate the use of laser cleaning and coating removal on component 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 Wadded (513) 255-7277.
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
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 struct e 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:
RtA; POC: Unknown
Nonhaloqenated 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 Srulin formula 815GD is the preferred aqueous chemistry for mechanically and ultrasonically agitated immersion
systems and will toe 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 (he soils and prevented
recontamination of the parts. NDCEE and ARDEC: POC. Richard Pirotta NDCEE, 814-26S-2810: Ms. D. Demone, ARDEC, 201-724-6773.
Solvent Replacement - Vapor Oeqreaser:
Allied Signal wilt demonstrate a replacement for 1.1,1-trichloroethane vapor degreasing. Allied Signal Army Engine Plants; POC: Mr. T. Russell, Mr.
J. Morrell. 203-385-3741.
Aqueous-based Degreasing Technology:
The Army's Soldier Systems Command (SSCOM) will develop nonpolluting, nontoxic water-based degreasers for cleaning metal/ glassi'plastic
surfaces using biopolymer emulsifying materials. Develop microbially 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 emulstfiers. Modify other similar biopolymers
with fermentation technique. Optimize bioremedialion methods for emulsified oil/grease solutions. NRDEC and AMC-IOC1 POC1 Or Fred Allen 508-
233-4266
Supercritical Carbon Dioxide Optical Sub-system Cleaning:
ARDEC: POC1 Mr Curtis Anderson. 201-724-4287
Alternative Bullet Tip Degreasing Agent:
ARDEC/Lake City Army Ammunition Plant; POC: Ms, Bianca Roberts, 816-796-7168
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 subseguent priming in preparation for coating or
adhesive bonding. Air Force Research Laboratory; POC: Phil Mykytiuk, WUMLSE, DSN 785-3953, (513) 255-3953.
PAINT CONSTITUENT
Reduce Or Eliminate VOCs In CARC Pain! Formulation, Application. & Removal:
The goals of the Army project are to reduce or eliminate VOCs in CARC paint formulation (MtL-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 reguired. US Army Research Laboratory, POC: 1-800-USA-3845
KC-135 integration Testing:
The USAF High Performance Aerospace Coating System (HPACS) program has performed testing of alternative aerospace coating systems (ex:
iow-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.
Page 6 of 10
TOLUENE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
PAINT CONSTITUENT
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 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-gel to replace conversion coatings, interface coatings, and low VOC, non-
isocyanate topcoats. POC1 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-B00-USA-3845.
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, more 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 opfrons. Interaction with
coating manufacturers to reformulate primers to correct problems 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.
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 So little solvent borne carriers POC: Unknown.
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.
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 depamt 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.
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.
Topcoat for SA.DARM Projectile:
The goals of this Army project are to develop thin CARC paint coat for SADARM Projectile which meets VOC requirements Armament Research,
Development and Engineering Center (ARDEC): POC; 201-724-6518
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.
To pcoat Reform u I ati on:
JG-APP is currently sponsoring a project with Raytheon Tt 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? of 10'
TOLUENE
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ON-GOING POLLUTION PREVENTION RESEARCH AND.DEVELOPMENT.
PAINT CONSTITUENT
Watefbome primer system improvements:
This USAF effort involves assessing existing MIL-C-95582 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.
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 reguired
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.
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.
PAINT REMOVER
Improved Non-HAPs Chemical Strippers.
Identify/develop environmentally acceptable chemical paint strippers with a maximum dwell time of 1-hour and strip rate comparable to methylene
chloride. POC: WUMLSS - CTIO: MAJ W. Kevin Kuhn (937J-255-0943.
Water Jet Paint Stripping:
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 Car! Handsy (313)-574-8834
Selective Stripping Process Development.
Identify "smart" stripping processes capable of selectively removing topcoats from long-life foundation layers {primers). Would allow use of
permanent foundation layers to achieve "paint for Life" systems. Any required HAPs, e.g chromate corrosion inhibitors, could be contained within
the permanent foundation layer If this is not stripped, then there is no pollution from stripping process. POC. WUMLSS - CTSO; MAJ W Kevin
Kuhn (937J-255-0943.
Polymedia 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
determine if acceptable stripping rates can be achieved with insignificant or no damage to the aircraft. This is applicable to C-17 and F-22 aircraft
with potential application to other aircraft. POC' WUMLSS - CTIO. MA j W. Kevin Kuhn (937J-255-0943.
Plastic Laminate As A Replacement For Conventional Topcoats.
This Navy effort involves using plastic laminates developed by 3M as a totaf-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 - Autocrawier:
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 autocrawier prototype and develop end effecter delivery systems capable of stripping coatings. The end effecters being evaluated
are 1) medium/high pressure water, 2) wheat starch, and 3) flash lamp. The program includes a prototype built for one system. POC, WUMLSS -
CTIO; MAJ W. Kevin Kuhn (937)-255-0943.
Aircraft Depaintinq Technology:
t his 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,
hazardous 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 eliminate or minimize surface damage to an acceptable level. POC: NAWCAD, Patuxent River Mr. Steve Hartle (301)-342-
8006.
Medium Pressure Water Stripping:
This effort is to evaluate semi-automation and industrialization of a pressurized water process. This process can replace or enhance methylene
chloride chemical applications, tl applies to C-130. C-141 and other large aircraft. Recycled water can be used in the water stripping process
POC: WUMLSS - CTIO; MAJ W. Kevin Kuhn (937)-255-0943.
Page 8 of 10
TOluENE
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ON-GOING POLLUTION PREVENTION RESEARCH AND DEVELOPMENT
PAINT REMOVER [
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 ]
(DA/) project confirmed that products effectively remove interior and exterior LBP from wood surfaces POC' CERL Susan Drodz (217)-373-6732 i
Evaluation of Polymedia-lite Dry Blast Media: 5
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 5
POC WL/MLSS - 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 (937)-255-0943.
Dry Media Stripping of Thin Skin Aluminum
This effort will determine the effects of dry media blasting (DMBS on thinner skin aluminum, .032 and 025 inch 2024 -13 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, a 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: WL/MLSS - CTIO. MAJ W Kevin Kuhn (937)-255-0943
Biodegradable Plastic Media - Foster Miller (SB1RV t
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 cnromate and cadmium containing paints. POC. WUMLSS - CTIO, MAJ W Kevin Kuhn (937)-255-0943.
Aqueous Paint Coating & Stripping'
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: 201-724-5518.
Next Generation Energetic Stripping: «
identify and develop novel ideas using energetic means to REMOVER coating layers, i.e. laser-stripping, tlashjet, pinchlamp. etc , which will allow
reduction of hazardous waste, cost and downtime of aircraft. POC: WL/MLSS - CTIO: MAJ W. Kevin Kuhn (937)-255-0943.
POLLUTION PREVENTION RESEARCH AND DEVELOPMENT / TRANSITION NEEDS !
HAND-WIPE SOLVENT " ~
On-going R&D and existing commercial off-the-shelf technology solution* are' adequately addressing the pollution prevention needs for this use, >
HEAVY-DUTY SOLVENT ;
It appears as though these pollution prevention needs can be resolved either through current techniques and commercially available products or
on-going R&D. No additional R&D seems necessary to resolve the need
PAINT REMOVER i
On-going R&D and existing commercial off the shelf technology solutions are adequately addressing the pollution prevention needs for this use.
Federal Facilities Which Reported for Both 1994 and 1995
Facility
1994 Release* 1995 Release* Percent
Off-site Treatment Off-site Treatment Change
U S. AIR FORCE PLANT 04 TX. FORT WORTH. TX
U S BUREAU OF PRISONS FEDERAL, FLORENCE, CO
U.S ARMY RED RIVER ARMY DEPOT, TEXARKANA, TX
U.S. ARMY LAKE CITY ARMY. INDEPENDENCE, MO
U.S. ARMY FORT MCCOY, CAMP MC COY. Wl
U.S. ARMY FORT HOOD. FORT HOOD, TX
U.S. ARMY FORT CAMPBELL. FORT CAMPBELL, KY
U S ARMY FiTZSIMONS, AURORA, CO
2.025
17.770
7,000
5,953
6,334
11,335
2,100
3,200
1,264 -82%
2,004 -66%
1.400 -78%
7,200 -36%
2,357 12%
0 -100%
0 -100%
0 -100%
Page 9 of 10
TOLUENE
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1994 Release+
1995 Release*
Percent
Facility
Off-site Treatment
Off-site Treatment
Change
U S ARMY DUG WAY PROVING, DUGWAY. UT
1
0
-100%
U S ARMY, FORT MC CLELLAN, AL
150
150
0%
NASA JOHN F KENNEDY SPACE, KENNEDY SPACE CENTER, FL
12,629
10,811
-14%
U S AIR FORCE PLANT 06 GA, MARIETTA, GA
24,000
14,570
-39%
U S. DEFENSE LOGISTICS AGENCY. CHARLESTON, SC
1,610
0
-100%
U S AIR FORCE PLANT 03 OK, TULSA, OK
4,216
0
-100%
U.S. AIR FORCE OGDEN AIR, HILL A F B. UT
18,300
6,210
-66%
U S AIR FORCE MCCLELLAN AIR. SACRAMENTO. CA
29,000
8,800
-70%
U S AIR FORCE FLIGHT TEST, EDWARDS, CA
- . . 34,656
0
-100%
U.S. AIR FORCE ACADEMY, U S A F ACADEMY, CO
4,660
0
-100%
U S AIR FORCE, TYNDALL AFB, FL
62
0
-100%
U.S. AIR FORCE. TINKER AFB, OK
17,822
24,782
39%
U.S. AIR FORCE. ROBINS AIR FORCE BASE, GA
66,913
68,080
2%
U S AIR FORCE. KELLY AFB, TX
10,885
0
-100%
U.S. AIR FORCE, CANNON A F B, NM
13,086
11,018
-16%
U.S. ARMY, ANNISTON. AL
19,026
19,380
2%
U.S. DOE NAVAL PETROLEUM, TUPMAN, CA
5,988
0
-100%
U S NAVY, SAN DIEGO, CA
0
1,432
100%
U.S. NAVY, PORTSMOUTH. VA
26.000
0
-100%
U.S NAVY. PENSACOLA, FL
10.300
0
-100%
U S NAVY, PATUXENT RIVER. MD
19,878
0
-100%
U S. NAVY, MAYPORT, FL
7,500
0
-100%
U.S. NAVY, JACKSONVILLE, FL
18,400
0
-100%
U.S. MARINE CORPS LOGISTICS, ALBANY, GA
17,001
15,500
-9%
U S. MARINE CORPS. CHERRY POINT. NC
37,000
31.000
-16%
U S MARINE CORPS. BARSTOW, CA
14,053
6.850
-51%
U.S. EPA NATL VEHICLE &, ANN ARBOR, Mi
13
7
-46%
U S COAST GUARD YARD, BALTIMORE, MD
10,231
9,660
-6%
U.S. DOE SANDIA NATL. LAB, ALBUQUERQUE, NM
440
0
-100%
U.S. DEFENSE LOGISTICS AGENCY. ANCHORAGE. AK
339
0
-100%
U.S. DOE NAVAL PETROLEUM, CASPER, WY
0
19.746
100%
U S DOE IDAHO NATIONAL, SCOVILLE, ID
300
330
10%
U.S. DEFENSE LOGISTICS AGENCY, WHITTIER, AK
79
0
-100%
U.S DEFENSE LOGISTICS AGENCY, VERONA, NY
2,250
0
-100%
U.S. DEFENSE LOGISTICS AGENCY, SEARSPORT, ME
690
0
-100%
U.S DEFENSE LOGISTICS AGENCY, MACDILL AFB. FL
430
0
-100%
U.S. DEFENSE LOGISTICS AGENCY. GRAND FORKS, ND
3,900
0
-100%
U.S. DEFENSE LOGISTICS AGENCY. GLADSTONE, Ml
1,000
0
-100%
U.S. DEFENSE LOGISTICS AGENCY, CINCINNATI, OH
220
0
-100%
U.S. NAVY INDIAN HEAD DtV., INDIAN HEAD, MD
0
2,920
100%
U.S. DOE SAVANNAH RIVER SITE, AIKEN, SC
2,240
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, 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 10 of 10
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