Coatings & VOC Emission - 海上技術安全研究所...Coatings & VOC Emission Target Emission...

Coatings &VOC Emission

Marc Jan GiesselinkSigmaKalon

ISST2007Osaka – September 7th, 2007

Introduction into Solvent Emission Legislation

Possible Emission Savings

Coatings & VOC Emission

22 Kdwt Bulk Carrier

Current and Future Legislation in Europe

SED Solvent Emission Directive- Directive 99/13/EC in force from 31-10-05 (sooner for new processes)- Emission controls tightened from 31-10-07- Directive 2004/42/CE in force from 01-01-07

NEC National Emission Ceilings- National Emission Ceilings fixed from 2010- NECs tightened up to 2020 – actual limits under review

CAFÉ Clean Air For Europe- Clean Air For Europe – Thematic Strategy due July 2005- EC Data (IIASA Report) suggests large reductions beyond SED- Current 2020 Target for Industrial Paints is 279KT

IIASA report suggests reducing this to 141KT (further 49% reduction)


Target Emission Values

Total Mass of Solids x 0.37

i.e. <27gmVOC/100gm paint>15 TonnesLarge installations

Total Mass of Solids x 0.6

i.e. <37.5gmVOC/100gm paint5 – 15 TonnesMedium installations

None<5 TonnesSmall installations

Target EmissionExisting facilities from 31-10-07, and New/ Changed facilities from 31-10-04

SOLVENT USAGE PER ANNUM

Solvent Emission Directive

How to be compliant with it?Two ways to do:

1. Monitoring emissions and fugitive emissions

2. Reduction scheme




This would be rather elaborative, since a lot of measuring will be required

2. Reduction scheme




This would be rather elaborative, since a lot of measuring will be required

2. Reduction scheme

a. Possibility is have specifications evaluated on presence of

solvents (% and/or absolute amount)

b. Also, companies could be requested/instructed to

administer the amount of solvents (within products;

thinners) used at the facility


What is the general situation in the major Asian NB countries:

There is not much legislation for the Marine (New Building) industry.If existing, the legislation tends to be focused like in Europe on the Deco industrial coatings

Brief situation in the major New Building countries:

CHINA no clear regulation, other than DECO






KOREA no clear regulationIndividual shipyards already start to set limits (70%)






KOREA no clear regulationIndividual shipyards already start to set limits (70%)

JAPAN in 2010 to achieve a 30% reduction of VOC emission compared to 2000 for the individual industries (10% by law; 20% by industry commitment).


Introduction into Solvent Emission Legislation

Possible Emission Savings



New Building situationM&R situationSea Stock – Maintenance At Sea

New BuildingBetween SHIPYARD and PAINT SUPPLIER

M&RBetween OWNER and PAINT SUPPLIERInvolvement of M&R shipyard (the shipyard may/will be forced by local legislation)

Sea Stock (Maintenance At Sea)Between OWNER and PAINT SUPPLIER (the owner may be forced by IMO)


New Building situationM&R situationSea Stock – Maintenance At Sea

Concentrate on some major products Waterborne ShopprimersSolvent Free Epoxy CoatingsWaterborne products

Fouling Release


To envisage what the contribution of variation in products could mean, use is made of a typical coating requirement for a 22 Kdwt Bulk Carrier

The amount of paint required:80,000 litres paint

4,000 litres of thinner (5%)

Typical average volume solids:paint: 60 % (32,000 litres solvents)thinners: 0 %

hence: emission of 36,000 litres of solvents



WATERBORNE SHOPPRIMERSSOLVENT FREE EPOXY COATINGSWATERBORNE PRODUCTS

FOULING RELEASE



9,500 litres of shopprimer requiredTypical volume solids of shopprimers: 30%

Solvent emission from shopprimer application is roughly 6,500 litresThis to be a reduction of 18% a reduction of 18% of the total solvent emission solvent emission to coat this vessel

NB – Waterborne Shopprimers


Roughly 110,000 m2 of steel plate to beblasted & coated with shopprimer

Application and dry to handle

As seen from earlier presentation, the paint industry is in the final stages of developing waterborne shopprimers. These to become truly replacement of the existing solvent based shopprimers.




Bending of shopprimed steel Fast rain resistance

As seen from earlier presentation, the paint industry is in the final stages of developing waterborne shopprimers. These to become truly replacement of the existing solvent based shopprimers.




Bending of shopprimed steel Fast rain resistance

Point of attention regarding waterborne shopprimers:1. The temperature has to be at least 5˚C to have the water evaporated

2. Additional ventilation will be required to reduce the relative humidity

at/near the shopprimer application

The steel plates will have to be heated up to some 25˚C (not really different from

present shopprimer application)

WATERBORNE SHOPPRIMERSSOLVENT FREE EPOXIESWATERBORNE PRODUCTSFOULING RELEASE



Typical areas that could be coated with solvent free epoxiesWater Ballast TanksExternal hull (excluding tiecoats for AF and the anti foulings)DecksSuperstructureCargo HoldsCargo TanksFresh Water Tanks

NB – Solvent Free Epoxy

Solvent free in WBT’sSolvent free in Cargo Holds


Solvent free for decksSolvent free on external hull

Typical areas that could be coated with solvent free epoxies

Total amount of solvent borne that could be replaced by Solvent Free Epoxy:50,000 litres of solvent borne paints containing approx. 17,500 litres solvents

The solvent borne coating would need some 2,500 litres thinners.

The total reduction of solvent emission would be 20,000 litres which would represent in this example a reduction of 54% reduction of 54% of the total solvent emission.solvent emission.


Solvent free for decks

Solvent Free Epoxy

Total amount of solvent borne that could be replaced by Solvent Free Epoxy:54,000 litres of which approx. 19,300 litres is solvent

Also some 2,700 litres lesser thinners required.The total reduction of solvent emission that could be achieved would be 22,000 litres which would represent in this example some 61% of the total solvent emission.

Points of attention regarding solvent free products:1. Normal spray equipment can be used (no need for hot twinfeed)

2. The substrate temperature to be at least 5˚C (generally 10° is preferred)

3. The viscosity cannot be adjusted by adding of thinners – adjustment

has to be achieved by adjustment of temperature & pump pressure

and/or pump size


No shrinkage – no cracking

Solvent Free Epoxy



Nevertheless, big advantage:1. Improved safety in confined spaces

2. No real limitation on maximum DFT; no shrinking

3. Very good edge covering

Solvent free product

Typical STARTING conditionafter chemical cleaning, before surface preparation

Solvent Free Epoxy also in repair

Typical FINISHING conditionafter paint application, before being in service


Arrival condition after 5 years in serviceafter discharging


Arrival condition after 5 years in serviceafter discharging – cleaning the surface with kerosine



Solvent free for decksSolvent free on external hull

Solvent Free Epoxy



Additional comment:Maximum overcoating interval is always considered a limitation, but products have been available in the market for many years with maximum overcoating intervals that are similar to solvent based products.Some products even with maximum overcoating interval up to 2 months @

20°C

WATERBORNE SHOPPRIMERSSOLVENT FREE EPOXY COATINGSWATERBORNE PRODUCTSFOULING RELEASE

Waterborne Products


Typical areas that could be coated with waterborne productsInside superstructure

Either full waterborne systems,or waterborne products combined with e.g. Solvent Free epoxy

Total amount of solvent borne that could be replaced by Solvent Free and/or waterborne products:5,000 litres of solvent borne paints containing approx. 2,500 litres solvents.This could result in a reduction of 7% reduction of 7% of the total solvent emission.solvent emission.

Waterborne Products


Typical areas that could be coated with waterborne productsInside superstructure

Depending on quality required the minimum temperatures are 5°C (acrylic)or 10°C (epoxy)Humidity has to be 75% or less

VOCAcrylic primer: 35g/kg or 50g/ltrAcrylic pmr/ctg: 19g/kg or 25g/ltrAcrylic coating: 13g/kg or 20g/ltrAcrylic finish: 12g/kg or 14g/ltrEpoxy primer: 5g/kg or 6g/ltrEpoxy coating: 5g/kg or 6g/ltr

Waterborne Products


Points of attention regarding solvent free products:1. The substrate temperature to be at least 5˚C

2. Relative Humidity below 75%; good ventilation recommended

WATERBORNE SHOPPRIMERSSOLVENT FREE EPOXY COATINGSWATERBORNE PRODUCTSFOULING RELEASE

Fouling Release Products

Fouling release products beside no leaching of (co-)biocides and potential fuel savings

But from a VOC Emission point of view, these products are also interesting.

1. Higher volume solids

2. Lower Dry Film Thickness (5 years systems)

3. Prolonged life time


Typical 5 years system for conventional system:3x 125 microns 50% volume solids

requires 3,600 litres of paint 1,800 litres solvent

5% thinner 180 litres thinner

1,980 litres

2x 150 microns 78% volume solids

requires 2,400 litres of paint 550 litres solvent


680 litres



Typical 5 years system for conventional system:3x 125 microns 50% volume solids

requires 3,600 litres of paint 1,800 litres solvent


1,980 litres

2x 150 microns 78% volume solids

requires 2,400 litres of paint 550 litres solvent


680 litres



This could result in a reduction of 3% reduction of 3% of the total solvent emission.solvent emission.

Consequences for New Building Shipyards

Consequences for NB shipyards

CONSEQUENCES FOR NEW BUILDING YARDS

More control of the application conditions requiredThis may result in a need to have application done indoors

1. To reduce the fluctuations in application conditions2. To optimise the coating application & curing3. Special equipment may be required (extra investment required)


CONCLUSIONS

Introduction of some of the existing products discussed have been slowly accepted by the market. This due to reasons like: Cost (more expensive); Production (longer production time); more complicated application (e.g. fouling release; hot-twinfeed for Solvent Free products)

However, technology is available, but may have impact on the coating application and production


CONCLUSIONS

Introduction of some of the existing products discussed have been slowly accepted by the market. This due to reasons like: Cost (more expensive); Production (longer production time); more complicated application (e.g. fouling release; hot-twinfeed for Solvent Free products)

However, technology is available, but may have impact on the coating application and production

• Legislation will limit the use of lower volume solids paints

• The paint industry has solutions to be in line with the expected legislations

• Curing of waterborne and solvent free paints requires more time & effort; this will require investments


Questions???


Coatings & VOC Emission - 海上技術安全研究所...Coatings & VOC Emission Target Emission...

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