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.)

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 reporting requirements under SARA Title III (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 general guidelines 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.

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, your local health safety personnel, and the appropriate MSDS prior to implementing this technology.

• Does not release hazardous or toxic emissions.
• Removes paint from surfaces quicker than conventional chemical or mechanical means.
• Operator friendly.
• Generates little annual waste.
• Capable of selective stripping.

• Large capital cost investment.

Assumptions:

• Parts are from a CH-53 helicopter, and 100 aircraft units would be stripped annually.
• Labor is $40 per hour for a PMB system, and $60 per hour for a FLASHJET® system.
• Seam stripping, also referred to as spot stripping, is assumed to be the same for both processes.
• Waste associated with the FLASHJET® process is considered hazardous for this analysis. The status of this waste is directly associated to the type of paint being stripped. Therefore, this waste stream can be either hazardous or non-hazardous.
• Final stripping results (95-99%) are the same for both processes.
• Breakdown of the cost categories is shown in the following table.

Table 1. Annual Operating Costs for De-Painting Technologies

Cost Category	Input Parameter	PMB Process	FLASHJET® Process
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

Economic Analysis Summary: 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 2.

• Annual Savings for FLASHJET®: $841,876
  
• Capital Cost for FLASHJET®: $3,271,000, which includes equipment, installation, permit exemption, setup, and training.
  
• Payback Period for Investment in Equipment/Process: 5.17 years, using a 15-year analysis and 10% discount rate. 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.