Overview of Manual
This manual is broken down into nine chapters as described below. Supporting
case studies, tables, figures and appendices are also provided.
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Chapter 1 provides background information on paints and coatings, including
a discussion of the coatings process and wastes generated.
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Chapter 2 presents an overview of federal regulations that affect coatings
processes.
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Chapter 3 provides specific information on the role of technical assistance
providers in promoting pollution prevention.
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Chapter 4 is an overview of pollution prevention options for surface preparation,
coatings applica- tion/curing and equipment cleaning.
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Chapter 5 discusses surface preparation methods with an emphasis on reducing
solvent use.
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Chapter 6 presents alternatives to solvent-borne coatings, including high-solids,
waterborne and powder coatings.
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Chapter 7 provides an overview of application techniques (i.e., spray painting
and other methods) along with a discussion of transfer efficiency.
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Chapter 8 presents information on curing methods.
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Chapter 9 discusses alternatives to traditional equipment cleaning methods.
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Appendix A presents information resources for coatings.
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Appendix B presents information on how to calculate VOC/HAP emissions.
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Appendix C provides information on conducting an economic analysis of paint
costs.
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Appendix D presents purchasing guidelines for HVLP spray guns.
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Appendix E presents information on coatings testing.
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Appendix F provides a glossary of terms pertaining to the coatings process.
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Appendix G provides information on calculating transfer efficiency.
Audience
NEWMOA designed this manual for individuals who are involved in providing
technical assistance to firms seeking information on P2 for paint and coating
processes. NEWMOA believes that the information in this manual also would
be useful for environmental inspectors and permit writers who are involved
in regulatory compliance activities. Comments and suggestions from manual
users on content and format are welcomed. Please take a moment and complete
the evaluation form included with this document to help us with future
versions of this manual and related manuals, or call NEWMOA at (617) 367-8558
to speak with us directly.
Using This Manual
This manual is designed to serve as a complete reference on P2 methods
for paint and coating processes, however, it alone should not be used to
advise companies on the selection of a particular coating system. The selection
of a coating system depends on a number of application-specific factors,
including the type of surface to be coated as well as the required performance
characteristics of the coating. Companies that decide to adopt an alternative
system should do so only after consultation with the appropriate coating
and equipment vendors, and careful in-house analyses of the costs and benefits
as well as technical feasibility of the alternative system.
Disclaimer
The views expressed in this report do not necessarily reflect those of
NEWMOA, NEWMOA member states, Waste Management and Research Center (WMRC),
or U.S. EPA. Mention of any company, process, or product name should not
be considered an endorsement by NEWMOA, NEWMOA member states, WMRC, or
U.S. EPA.
Table of Contents
Definition
of Terms
Uses
for Paints and Coatings
Paint
Composition
Description of Coatings Processes
Examples
of Typical Systems
Sources
of Wastes
Summary
Clean Air Act
Resource Conservation and Recovery Act
Clean Water Act
Characterizing
a Facility
Planning
Identify
Pollution Prevention Opportunities
Analyze
and Select Options
Pilot
Test or Validate Preferred Options
Procure
and Implement New System
Evaluate
and Keep the Program Going
Rigid
Inventory Control
Good
Housekeeping
Paint
Mixing
Operator
Training
High
Transfer Efficiency Equipment
Alternative
Coatings
Proper
Cleaning Methods
Filters
On-Site
Solvent Recycling
General
Description
Pollution
Problem
Mechanical
Cleaning
Chemically-Assisted
Cleaning
Conversion
Coatings
Stripping
General P2 Options for Surface Preparation
Cleaning
Solvent
Vapor Degreasing
Degreasing
with Liquid Solvents (Cold Cleaning)
Alternative Cleaning Methods
Conversion Coatings
Stripping
Conventional
Paint Composition
Switch
to Surface-Free Coating
Alternative
Coatings
High-Solids Coatings
Waterborne Coatings
Powder Coating
Radiation Curing
Emerging
Technologies
Advantages
and Disadvantages
Cost
and Implementation Issues
General
Description of Spray Systems
Pollution
Problem
General
P2 Options
Transfer
Efficiency and Paint Application
Strategies to Improve Transfer Efficiency
Conventional Air Spray (LVHP)
High-Volume/Low-Pressure (HVLP) Air Spray
Low-Pressure/Low-Volume
(LPLV)
General
Description
Airless Spray
Electrostatic Spray
Other
Methods
Advantages
and Disadvantages
Cost
and Implementation Issues
Paint
Booths
General
Description
Pollution
Problem
P2 Options
List of Tables
Table
1. Common Solvents, Federal Regulatory Status
Table
2. Scheduled Date for MACT Standards for Surface Coating
Table
3. EPA Guidelines for Maximum VOC Content of Coatings
Table
4. Hazardous Wastes Generated from Coatings Operations
Table
5. Overview of Assessment Information
Table
6. Opportunities for Improved Housekeeping in Coating Operations
Table
7. P2 Options for Coatings Processes
Table
8. Alternatives to Chlorinated Solvent Cleaning
Table
9. Advantages and Disadvantages of Plastic Media Blasting
Table
10. Advantages and Disadvantages of Vacuum Sanding Systems
Table
11. Advantages and Disadvantages of Sodium Bicarbonate
Table
12. Advantages and Disadvantages of Wheat Starch Blasting
Table
13. Advantages and Disadvantages of Carbon Dioxide Blasting
Table
14. Advantages and Disadvantages of Sponge Blasting Systems
Table
15. Advantages and Disadvantages of Water Blasting Systems
Table
16. Advantages and Disadvantages of Fluidized Bed Stripping
Table
17. Overview of Alternative Surface Preparation Technologies
Table
18. Health Effects of Solvents Used in Paint Formulations
Table
19. Overview of Alternatives to Solvent-Borne Coatings
Table
20. Advantages and Disadvantages of High-Solids Coatings
Table
21. Advantages and Disadvantages of Waterborne Coatings
Table
22. Characteristics of Powder Coating Techniques
Table
23. Advantages and Disadvantages of Powder Coatings
Table
24. Summary of Powder Coating Resin Properties
Table
25. Advantages and Disadvantages of Radiation-Cured Coatings
Table
26. Advantages and Disadvantages of VIC
Table
27. Advantages and Disadvantages of Unicoat Paint Technology
Table
28. Cost/Benefit Summary for Spray Application Methods
Table
29. Advantages and Disadvantages of HVLP Spray Guns
Table
30. Advantages and Disadvantages of LPLV Spray Guns
Table
31. Advantages and Disadvantages of Airless Spray Systems
Table
32. Advantages and Disadvantages of Electrostatic Spray Guns
Table
33. Advantages and Disadvantages of E-Coat Systems
Table
34. Advantages and Disadvantages of Autodeposition Systems
Table
35. Advantages and Disadvantages of Dip Coating Systems
Table
36. Advantages and Disadvantages of Flow Coating Systems
Table
37. Advantages and Disadvantages of Curtain Coating Systems
Table
38. Advantages and Disadvantages of Roll Coating Systems
Table
39. Advantages and Disadvantages of Plural Component Proportioning Systems
Table
40. Advantages and Disadvantages of Supercritical Carbon Dioxide
Table
41. Tansfer Efficiencies of Various Application Technologies
Table
42. Overview of Application Technologies
Table
43. Advantages and Disadvantages of Dry Filter Booths
Table
44. Air/Force Dry Vs. Bake
Table
45. Typical RACT Limits for Miscellaneous Metal Parts Coating
List of Figures
Figure 1. Overview of the Coating Process
Figure 2. Coating Process and Waste Generation
Figure 3. Emissions vs. VOC Content
Figure 4. Major Resin Fluidization Methods
Figure 5. HVLP System
Acknowledgments
NEWMOA is indebted to the U.S. Environmental Protection Agency's Office
of Pollution Prevention for its support for this project. The Northeast
states provided additional in-kind support.
NEWMOA would also like to thank those who provided advice and assistance,
especially those who volunteered on the peer review committee:
Alan Buckley, Massachusetts Office of Technical Assistance
Mike Callahan, Jacobs Engineering Group Inc
Dean Cornstubble, Research Triangle Institute
Lynn Corson, Ph.D., Purdue University
Mike Eck, U.S. Army Environmental Center
Tim Greiner, Greiner Environmental
Paul Pagel, MnTAP
Jeff Palmer, The Powder Coating Institute
Alice Pincus, Pincus Associates
Paul Randall, U.S. EPA
Alexander Ross, RadTech
Mike Simek, Rutgers
Rodger Talbert, Chemical Coaters Association International
David Liebl, Solid and Hazardous Waste Education Center
Kathy Blake, New Hampshire Department of Environmental Services
Project Staff/Contributors
Terri Goldberg, NEWMOA P2 Program Manager—Editor/Manager
Lisa Regenstein, NEWMOA P2 Project Manager—Research/Writer
Jennifer Shearman, NEWMOA Technical Staff—Research/Writer
Beth Anderson, EPA—EPA Project Manager
Laurie Case, WMRC—Layout and Desktop Publishing
NEWMOA welcomes users of this manual to cite and reproduce sections
of it for use in providing assistance to companies. However, the Association
requests that users cite the document whenever reproducing or quoting so
that appropriate credit is give to original authors, NEWMOA and U.S. EPA.
NEWMOA thanks you for cooperating with this request.
Northeast Waste Management Officials' Association
The Northeast Waste Management Officials' Association (NEWMOA) is a non-profit,
nonpartisan, interstate governmental association. The membership is composed
of state environmental agency directors of the hazardous waste, solid waste,
waste site cleanup and pollution prevention programs in Connecticut, Maine,
Massachusetts, New Hampshire, New York, Rhode Island, and Vermont.
NEWMOA's mission is to help states articulate, promote, and implement
economically sound regional programs for the enhancement of environmental
protection. The group fulfills this mission by providing a variety of support
services that facilitate communication and cooperation among member states
and between the states and EPA, and promote the efficient sharing of state
and federal program resources.
NEWMOA was established by the governors of the New England states as
an official interstate regional organization, in accordance with Section
1005 of the Resource Conservation and Recovery Act (RCRA). The organization
was formally recognized by the U.S. Environmental Protection Agency (EPA)
in 1986. It is funded by state membership dues and EPA grants.
NEWMOA established the Northeast States Pollution Prevention Roundtable
(NE P2 Roundtable) in 1989 to enhance the capabilities of member state
environmental officials to implement effective source reduction programs.
The NE P2 Roundtable's program involves the following components: (1) managing
a regional roundtable of state pollution prevention programs; (2) publishing
a newsletter; (3) managing a resource center of books, reports, case studies,
fact sheets, notices of upcoming meetings and conferences, and a list of
P2 experts; (4) organizing training; and (5) conducting research and publishing
reports and other documents. The resource center provides pollution prevention
information to state and local government officials, the public, industry,
and others. Funding for the NE P2 Roundtable is provided by the NEWMOA
member states and the U.S. EPA. For more information contact: Terri Goldberg,
NEWMOA, 129 Portland Street, 6th floor, Boston, MA 02114, (617) 367-8558
x302 (Phone); (617) 367-0449 (Fax); newmoa@aol.com (e-mail).
About This Manual
The Northeast Waste Management Officials' Association (NEWMOA) designed
this manual to provide environmental assistance staff with a basic reference
on the metal coatings process. The purpose of the manual is to enable assistance
providers to rely on a single publication to jump start their research
on pollution prevention for companies with which they are working. The
manual is explicitly designed to be useful to assistance professionals
with experience working with metal coating operations and those who have
never before encountered this process. The U.S. Environmental Protection
Agency Pollution Prevention Division funded this manual as a model of a
comprehensive packet of pollution prevention (P2) information on a single
industry.
The Northeast Waste Management Officials' Association designed this
manual to provide information on P2 methods for paints and coatings processes.
Specifically, the manual focuses on P2 methods for reducing volatile organic
compounds (VOCs) emitted during the coating of metal substrates. This manual
stresses the use of low-VOC paints and coatings (i.e., high-solids, waterborne
and powder coatings that contain lower solvent concentrations than conventional
paints) as well as techniques that can increase transfer efficiency (i.e.,
the percentage of paints actually put on the part compared to the amount
of paint used/sprayed). Methods for reducing the amount of solvents used
during other stages of the coatings process, particularly surface preparation
and equipment cleaning, also figure prominently.
NEWMOA collaborates with state and local environmental assistance programs
in the Northeast; these programs have requested this manual to help them
provide more efficient and effective help to the numerous companies with
metal coating operations. Assistance providers have reported frustration
with having to search databases for materials only to obtain a list of
citations and case studies that they have to spend considerable time finding
in order to provide information to their client companies. In addition,
these officials rarely have the opportunity to check the accuracy of the
information they find in databases to determine whether the material is
still current. To avoid duplicating efforts and to ensure that the information
companies receive is up-to-date and accurate, NEWMOA developed this manual
as a model "synthesized" information packet that includes an exhaustive
compilation and synthesis of existing materials on P2 for the metal coatings
process.
To compile this manual, NEWMOA reviewed many books, articles, fact sheets,
reports and guides on P2 for metal coatings operations. NEWMOA staff also
sent a draft of the manual to more than 15 expert reviewers for their comments
and suggestions. The result is an up-to-date compilation of information
on P2 options for metal coatings. However, pollution prevention is a rapidly
changing field, and all users should check with the various centers identified
in Appendix A to determine whether any new information is available. |