Traditionally, coating removal activities were performed using chemical or dry abrasive techniques. Due to the use of toxic solvents, the generation of large amounts of solid waste, and the environmental, health, and safety concerns associated with these conventional processes, alternative coating processes are being investigated. One such alternative is the FLASHJET^® system.

The FLASHJET^® process is a fully automated process that uses manipulator robotic assembly to strip the coatings from large and small components. The stripper head contains a xenon flashlamp that produces pulsed light energy to break the molecular bonds of the coating. Upon the breaking of the molecular bonds, the coating is changed into a near gaseous state through a process known as "ablation." Simultaneously, as the coating is being broken up and the ablation process is occurring, a dry ice pellet stream is sweeping away the residue while cooling and cleaning the surface. The paint that is removed is vacuumed away by an effluent capture system, which consists of high efficiency particulate air (HEPA) filters and activated charcoal. The effluent capture system separates the ash from the organic vapors by processing the ash through HEPA filters and the organic vapor through the activated charcoal. The only wastes produced by this process are the spent HEPA filters, which are tested for hazardous waste and disposed accordingly.
The system has a stripping rate of approximately 270 square feet per hour, and the xenon lamp is guaranteed for 500,000 flashes, which is directly dependent on the power level at which the lamp is operated (typically, 1 million flashes are obtained.)

Use of the FLASHJET^® can decrease the amount of hazardous waste generated at a facility. The decrease in hazardous waste helps facilities meet the Resource Conservation and Recovery Act (RCRA) waste minimization requirements applicable to generators of hazardous waste, found at 40 CFR 262. Lower levels of hazardous waste generation may also help facilities reduce their generator status and lessen the number of applicable regulatory requirements, such as those covering recordkeeping, reporting, inspections, transportation, accumulation time, emergency prevention and preparedness, and emergency response.

In addition to hazardous waste reduction, the FLASHJET^® generates no airborne contaminants. The elimination of volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) that are associated with traditional solvent-based stripping techniques may allow a facility to avoid regulation under the National Emission Standards for Hazardous Air Pollutants (NESHAPs) (40 CFR 63). A facility utilizing FLASHJET^® may also be able to avoid related air pollution regulations at the federal, state, and local levels, including requirements under the Clean Air Act Title V Operating Permit Program (40 CFR 70 and 71). .

Furthermore, use of the FLASHJET^® may reduce a facility's SARA Title III reporting requirements (40 CFR 355, 370, and 372; and EO 13148) and reduce the potential for a release of hazardous substances in reportable quantities (40 CFR 110 and 302).

The Compliance Benefits listed here are only meant to be used as a general guideline and are not meant to be strictly interpreted. Actual Compliance Benefits will vary depending on the factors involved, e.g., the amount of workload involved.

No materials compatibility issues were identified.

Caution must be exercised with the equipment, as high voltages from the xenon lamp are a potential danger.

Since the process is used to remove potentially hazardous materials, proper personal protective equipment (PPE) must be worn and other safety practices must be employed. The required PPE includes an ultraviolet (UV) curtain, UV goggles, and ear protection.

Consult your local industrial health specialist and your local health and safety personnel prior to implementing this technology.

Table 1. Annual Operating Costs for De-Painting Technologies

Cost Category	Input Parameter	Current PMB	Alternative FLASHJET
Labor	Operational	$391,116	$220,916
	Maintenance	$12,000	$36,000
	Inspection	---	$12,810
	Waste management	$4,100	$3,075
Materials	Media	$651,147	$52,577
	Misc. material	$37,660	$5,345
	Equipment upkeep	---	$37,725
Health & safety	Personal protection	$1,925	$1,200
	Medical exams	$100	$50
Utilities	Electricity	$5,950	$27,578
	Compressed air	$100	---
Waste Management	Haz waste disposal	$134,117	$2,458
	Solid waste disposal	$4,395	$1,000
Total		$1,242,610	$400,734

To implement a FLASHJET^® system instead of a PMB process at a facility currently without a de-painting process: 0.95 years, using a 15-year analysis and 10% discount rate.

A summary of the financial implications for two scenarios is provided in Table 2. The first results column addresses replacing a PMB process with a FLASHJET^® system. The next two columns compare the economic impact associated with installing a coating system at a facility that currently does not operate a de-painting process. Based on the findings, the FLASHJET^® system is more economical. The 15-year NPV and IRR, as well as the payback period are also listed in Table 1.

Table 2: Financial Implications of Using a FLASHJETâ System Vs. a PMB System

Category	Financial Analysis Results
	Replace PMB system	Install FLASHJETâ	Install PMB system
Investment Required	$3,271,000b	$3,271,000b	$2,548,680b
Discounted Payback Period (year) a	5.17 years	0.95 years	N/A
NPV a	$3,144,760	$5,681,704	N/A
IRR a	24.8%	116%	N/A

a	This value was calculated with Pollution Prevention Financial Analysis and Cost Evaluation System (P2/FINANCE). This software is proprietary and copyrighted by Tellus Institute of Boston, Massachusetts. A 15-year analysis, and 10% discount rate were assumed.
b	This number is based on the cost of the equipment, installation, and other contributing one-time fees related to the process.

Approval is controlled locally, and the technology should be implemented only after engineering approval has been granted. Major claimant approval is not required.

NSN_MSDS

Milissa A.B. Pavlik
Concurrent Technologies Corporation
100 CTC Drive, Johnstown, PA 15904
Phone: (814) 269-2545

Dean Hutchins
U.S. Army Enviromental Center
Aberdeen Proving Ground, MD 21010
Phone: (410) 436-6855

The Boeing Corporation
P.O. Box 516
St. Louis, MO 63166

Boeing is the manufacturer of the FLASHJET^® system.

Concurrent Technologies Corporation. Tri-Service Demonstration and Validation of the FLASHJET^® Process for Military Applications. CH-53 Off-Aircraft Component Economic Analysis. September 17, 1999.

Schematic/photo of the FLASHJET^® system.