vocs in marine coatings a technical regulatory overview ... 11:… · vocs in marine coatings – a...
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All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
VOCs in Marine Coatings – A Technical
Regulatory Overview David Mather IPPIC Nov 2012
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
1. VOC legislation and why it is needed
2. Why VOC (solvent) is required in marine coatings
3. Challenges of low VOC
• Waterbased
• High Solids/Solvent Free
4. Prognosis for further VOC reductions
Agenda
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
1. VOC legislation and why it is needed
2. Why VOC (solvent) is required in marine coatings
3. Challenges of low VOC
• Waterbased
• High Solids/Solvent Free
4. Prognosis for further VOC reductions
Agenda
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Why are VOCs a problem?
• VOC’s are lost from the coating during drying and rise
into the air.
- Other sources – Industry, forests…
• VOC’s mix with other air pollutants in the atmosphere
• Other pollutants
from vehicle exhausts and
factory stacks etc
- Oxides of Nitrogen (NOx)
- Oxides of Sulphur (SOx)
• React together in presence of sunlight
NOx + SOx + VOC’s →UV→ → O3
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Why are VOCs a problem?
• At high enough concentrations, low level ozone causes
health problems in humans such as asthma.
• Also damages vegetation e.g. agricultural crops and forests.
O3 + Particulates → SMOG
In 2008 this was a big
problem for China when
they hosted the Olympics in Beijing. It occurs in many large
cities which have high industry and high average sunlight.
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
SMOG…
London 1952
London - after
Los Angeles
China- Beijing
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
VOC legislation – 2 methods favoured by regulators
• USA approach
• Well defined coating categories with maximum
VOC limits
• Up to paint manufacturers to make sure coatings
they supply are compliant for customers
• Compliance can be challenging for paint
manufacturer
• EU Approach
• Averaging approach
• Up to shipyard to demonstrate compliance
• Compliance less challenging
• Combination of high and low VOC containing
coatings
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
VOC legislation impacting Marine Coatings
Averaging
Categories and Limits
USA
EU
Hong Kong
China
1
So Korea
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are subject to our Standard Terms and Conditions.
USA – Categories and levels
Marine Vessels Bay Area
Rule 8-43
Mohave
Desert Rule
1106
San Diego
Rule 67-18
South
Coast
Rule 1106
Ventura
County
Rule 74.24
USEPA
NESHAPS
Main
Categories
Status Last
Revised
Oct 16,
2002
Last
Revised
Oct 23, 2006
Last
Revised
May 15,
1996
Last
Revised
Jan 13,
1995
Last Revised
Nov 11, 2003
CTG Aug
1997
Anti-foulant 400 400 400 400 400 400
General coating (air-
dried) 340 340 -- 340 340 340
High gloss (air-dried) 340 340 420 340 420 420
Inorganic zinc coating 340 340 340 (650 air
dried)
340 340
Organic zinc coating -- 360 340 -- 340 360
Military exterior
specialty topcoat 340
340 340 -- 340 340
Specialty interior 340 340 340 -- 340 340
Weld-through
preconstruction
primer
-- 340 -- -- -- 650
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Option 1 – Capture/Filter
Fugitive
emissions
Emissions
in waste gases
Stack
material purchased
recovered
ship stores
spillages
waste
>15Tonnes VOC/annum. Target Emission
<27.3% Average VOC in wet paint
EU – Averaging Industrial Emissions Directive 2010/75/EU
Option 2 – Solvent Reduction Scheme
OR
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
1. VOC legislation and why it is needed
2. Why VOC (solvent) is required in marine coatings
3. Challenges of low VOC
• Waterbased
• High Solids/Solvent Free
4. Prognosis for further VOC reductions
Agenda
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Why is VOC (solvent) required in marine coatings?
• Reduce viscosity to aid application through standard
equipment
• Aid manufacture eg control rheology such as sag resistance
• Aid film forming properties (flow and levelling)
• Can effect drying time
• For 2pack systems, controls reactivity
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are subject to our Standard Terms and Conditions.
Shipyard Requirements (vary….)
Korea
• Limited space for construction of new shipyards or
expansion of existing facilities
• High labour rates
• Biggest driver is production efficiency
• Fast drying
• Rapid access
• Short recoat windows
• Winter workable
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Climatic Conditions – MinimumTemperatures
0
5
10
15
20
25
30
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Te
mp
ara
ture
/ º
C
Month
Average Daily Minimum Temperature
Houston
Newcastle
Busan
Shanghai
Singapore
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Climatic Conditions – Maximum Temperatures
0
5
10
15
20
25
30
35
40
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Te
mp
ara
ture
/ º
C
Month
Average Daily Maximum Temperature
Houston
Newcastle
Busan
Shanghai
Singapore
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Climatic Conditions – Average Humidity
0
10
20
30
40
50
60
70
80
90
100
JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
Rela
tive
Hu
mid
ity %
Month
Average Relative Humidity
Houston
Newcastle
Busan
Shanghai
Singapore
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
1. VOC legislation and why it is needed
2. Why VOC (solvent) is required in marine coatings
3. Challenges of low VOC
• Waterbased
• High Solids/Solvent Free
4. Current technologies
• Universal primers
• Biocidal Antifoulings
• Finishes
5. Prognosis for further VOC reductions
Agenda
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are subject to our Standard Terms and Conditions.
Key Challenges for Water Based Coatings for
Marine applications
Issue Commentary
Environmental
conditions
Temp, RH, & airflow all affect use of WB coatings
Typical usable conditions: T +10oC to +40oC; RH 20-80%; min
airflow >0.1 ms-1
Underwater resistance Full immersion is currently a challenge for Water Based
Early Water Resistance Development of fast early water resistance
Cost vs Performance vs
VOC Attaining customer confidence from Water Based coatings
VOC Water Based not necessarily solvent free
Coalescing solvents = VOC
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Key Challenges for Solvent Free Coatings
for Marine applications
Issue Commentary
Environmental
conditions Minimum application temperature often 5-10ºC
Environmental
conditions
Use of low MWt amines lead to carbamation under high RH
conditions
Application
Equipment Specialist equipment often needed eg twin feed, heated lines
Thickness Control Difficult to achieve 1x125µm wft
H&S Issues Use of low MWt resins generally have higher risk profiles
Drying Times Drying times often long, reduction in productivity
Pot life Dissipation of heat more difficult w/o solvent - exotherms
Flexibility High resin content, more brittle, potential to crack
O/C Intervals Overcoating intervals often short
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are subject to our Standard Terms and Conditions.
Pot Life – Dry Time Conundrum
• Fast reactions required to compensate for slower drying in high solids
• For 1K application need to manipulate the chemistry
Time
Exte
nt
of
reacti
on
High solids
Fast reacting
↓ Short pot life
Rapid dry
Twin feed
Low solids
conventional system
↓ Long pot life
Slow reaction
Solvent provides lacquer dry effect
Ideal high
solids system
↓ Long pot life
Rapid dry
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
1. VOC legislation and why it is needed
2. Why VOC (solvent) is required in marine coatings
3. Challenges of low VOC
• Waterbased
• High Solids/Solvent Free
4. Prognosis for further VOC reductions
Agenda
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
1. VOC legislation and why it is needed
2. Why VOC (solvent) is required in marine coatings
3. Challenges of low VOC
• Waterbased
• High Solids/Solvent Free
4. Prognosis for further VOC reductions
Agenda
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Universal Primers – typical information
• 80% VS - maintain properties to allow efficient application
• Overthickness has less effect on drying time for HS systems
• >90% - compromises needed
60% 70% 80% >90%
Resin Type Solid or
Semisolid
Semisolid or
Liquid
Liquid or Liquid
& diluent
Liquid &
diluent
Curing
mechanism
Vitrification &
curing
Vitrification &
curing Curing Curing
Typical D/T @
5ºC 8hrs 10 hrs 14 hrs 46 hrs
Typical Max
O/C 14 days 14 days 14 days 5-10 days
Typical Pot life
@25ºC 2½ hrs 1½ hrs 1 hr ½ hr
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Universal primer
• Coatings which have lower VOC content but adequate
pot life under development by industry
• Any new developments likely to have increased cost
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Biocidal Antifoulings
• Based on high molecular weight, non-crosslinked thermoplastic
polymers... solvent required for usable solution viscosites
• Biocides generally solid pigments and large proportion of the
paint volume...solvent required to disperse effectively and reduce
paint viscosity
• Application critical low hull roughness low emissions
...solvent required to give good application properties
• 400g/L is possible
Further reductions lead to restriction in application properties
• Large reductions possible only with change in technology and
production methods
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Finishes
• Based on relatively old technology – solids generally ~50%
• Finishes have different performance requirements
• Application critical aesthetic requirement (good flow
and levelling)
• solvent required to give good application properties
• Unlike Antifoulings, no fuel savings – purely aesthetic
• Many owners do not want to pay more for better
performance
• Newer technologies can achieve high solids, but generally
also high performance and therefore higher cost
• Low VOC target for finishes will make yards uncompetitive
with current technologies
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Conclusion
• Two approaches regulators choose to restrict VOC
content of marine coatings
• USA approach - categories and limits
• EU approach – averaging
• VOC content still required in marine coatings of the
future
• Application aid
• Drying in cold temperatures
• Water based technology facing challenges
• Solvent free technology introduces application, stability,
drying problems
• Legislators will set future VOC targets on best
available technology
• Products still have to be acceptable to the market
Marine & Protective Coatings All products supplied and technical advice or recommendations given
are subject to our Standard Terms and Conditions.
Questions……