Coatings & VOC Emission

Transcription

1 Coatings & VOC Emission Marc Jan Giesselink SigmaKalon ISST2007 Osaka September 7 th, 2007

2 Coatings & VOC Emission Introduction into Solvent Emission Legislation Possible Emission Savings 22 Kdwt Bulk Carrier

3 Coatings & VOC Emission Current and Future Legislation in Europe SED NEC Solvent Emission Directive - Directive 99/13/EC in force from (sooner for new processes) - Emission controls tightened from Directive 2004/42/CE in force from National Emission Ceilings - National Emission Ceilings fixed from NECs tightened up to 2020 actual limits under review CAFÉ Clean Air For Europe - Clean Air For Europe Thematic Strategy due July 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)

4 Solvent Emission Directive Target Emission Values SOLVENT USAGE PER ANNUM <5 Tonnes Small installations 5 15 Tonnes Medium installations Target Emission Existing facilities from , and New/ Changed facilities from None Total Mass of Solids x 0.6 i.e. <37.5gmVOC/100gm paint >15 Tonnes Large installations Total Mass of Solids x 0.37 i.e. <27gmVOC/100gm paint

5 Coatings & VOC Emission How to be compliant with it? Two ways to do: 1. Monitoring emissions and fugitive emissions 2. Reduction scheme

6 Coatings & VOC Emission How to be compliant with it? Two ways to do: 1. Monitoring emissions and fugitive emissions This would be rather elaborative, since a lot of measuring will be required 2. Reduction scheme

7 Coatings & VOC Emission How to be compliant with it? Two ways to do: 1. Monitoring emissions and fugitive emissions 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

8 Coatings & VOC Emission 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

9 Coatings & VOC Emission 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 KOREA no clear regulation, other than DECO no clear regulation Individual shipyards already start to set limits (70%)

10 Coatings & VOC Emission 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 KOREA JAPAN no clear regulation, other than DECO no clear regulation Individual shipyards already start to set limits (70%) in 2010 to achieve a 30% reduction of VOC emission compared to 2000 for the individual industries (10% by law; 20% by industry commitment).

11 Coatings & VOC Emission Introduction into Solvent Emission Legislation Possible Emission Savings 22 Kdwt Bulk Carrier

12 Coatings & VOC Emission New Building situation M&R situation Sea Stock Maintenance At Sea New Building Between SHIPYARD and PAINT SUPPLIER M&R Between OWNER and PAINT SUPPLIER Involvement 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)

13 Coatings & VOC Emission New Building situation M&R situation Sea Stock Maintenance At Sea Concentrate on some major products Waterborne Shopprimers Solvent Free Epoxy Coatings Waterborne products Fouling Release

14 Coatings & VOC Emission 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 22 Kdwt Bulk Carrier

15 Coatings & VOC Emission WATERBORNE SHOPPRIMERS SOLVENT FREE EPOXY COATINGS WATERBORNE PRODUCTS FOULING RELEASE 22 Kdwt Bulk Carrier

16 NB Waterborne Shopprimers Roughly 110,000 m 2 of steel plate to be blasted & coated with shopprimer 9,500 litres of shopprimer required Typical volume solids of shopprimers: 30% Solvent emission from shopprimer application is roughly 6,500 litres This to be a reduction of 18% of the total solvent emission to coat this vessel Application and dry to handle 22 Kdwt Bulk Carrier

17 NB Waterborne Shopprimers Roughly 110,000 m 2 of steel plate to be blasted & coated with shopprimer 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 22 Kdwt Bulk Carrier

18 NB Waterborne Shopprimers Roughly 110,000 m 2 of steel plate to be blasted & coated with shopprimer Point of attention regarding waterborne shopprimers: As seen from earlier presentation, the paint industry is in the final stages of 1. The temperature developing waterborne has to be at shopprimers. least 5 C to These have to the become water truly evaporated replacement of the existing solvent based shopprimers. 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) Bending of shopprimed steel Fast rain resistance 22 Kdwt Bulk Carrier

19 Coatings & VOC Emission WATERBORNE SHOPPRIMERS SOLVENT FREE EPOXIES WATERBORNE PRODUCTS FOULING RELEASE 22 Kdwt Bulk Carrier

20 NB Solvent Free Epoxy Typical areas that could be coated with solvent free epoxies Water Ballast Tanks External hull (excluding tiecoats for AF and the anti foulings) Decks Superstructure Cargo Holds Cargo Tanks Fresh Water Tanks Solvent free in Cargo Holds Solvent free in WBT s

21 NB Solvent Free Epoxy 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% of the total solvent emission. Solvent free on external hull Solvent free for decks

22 NB Solvent Free Epoxy Solvent Free Epoxy Points of attention regarding solvent free products: Total amount of solvent borne that could be replaced by Solvent Free Epoxy: 54,000 litres of which approx. 19,300 litres is solvent 1. Normal spray equipment can be used (no need for hot twinfeed) Also some 2,700 litres lesser thinners required. 2. The substrate temperature to be at least 5 C (generally 10 is preferred) 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 3. The viscosity solvent emission. cannot be adjusted by adding of thinners adjustment has to be achieved by adjustment of temperature & pump pressure and/or pump size Solvent free for decks

23 NB Solvent Free Epoxy 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 Nevertheless, big advantage: 1. Improved safety in confined spaces Also some 2,700 litres lesser thinners required. The total reduction of solvent emission that could be achieved would be 2. No real limitation on maximum DFT; no shrinking 22,000 litres which would represent in this example some 61% of the total solvent emission. 3. Very good edge covering No shrinkage no cracking Solvent free product

24 Solvent Free Epoxy also in repair Typical STARTING condition after chemical cleaning, before surface preparation

25 Solvent Free Epoxy also in repair Typical FINISHING condition after paint application, before being in service

26 Solvent Free Epoxy also in repair Arrival condition after 5 years in service after discharging

27 Solvent Free Epoxy also in repair Arrival condition after 5 years in service after discharging cleaning the surface with kerosine

28 NB Solvent Free Epoxy Solvent Free Epoxy Additional comment: Total amount of solvent borne that could be replaced by Solvent Free Epoxy: 54,000 litres of which approx. 19,300 litres is solvent Maximum overcoating interval is always considered a limitation, but products have been available in the market for 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. many years with maximum overcoating intervals that are similar to solvent based products. Some products even with maximum overcoating interval up to 2 20 C Solvent free on external hull Solvent free for decks

29 Waterborne Products WATERBORNE SHOPPRIMERS SOLVENT FREE EPOXY COATINGS WATERBORNE PRODUCTS FOULING RELEASE 22 Kdwt Bulk Carrier

30 Waterborne Products Typical areas that could be coated with waterborne products Inside 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% of the total solvent emission. 22 Kdwt Bulk Carrier

31 Waterborne Products Typical areas that could be coated with waterborne products Inside superstructure Points of attention regarding solvent free products: 1. The Depending substrate on temperature quality required to be the at minimum least 5 Ctemperatures are 5 C (acrylic) or 10 C (epoxy) 2. Relative Humidity Humidity has to be below 75% or 75%; lessgood ventilation recommended VOC Acrylic primer: 35g/kg or 50g/ltr Acrylic pmr/ctg: 19g/kg or 25g/ltr Acrylic coating: 13g/kg or 20g/ltr Acrylic finish: 12g/kg or 14g/ltr Epoxy primer: 5g/kg or 6g/ltr Epoxy coating: 5g/kg or 6g/ltr 22 Kdwt Bulk Carrier

32 Fouling Release Products WATERBORNE SHOPPRIMERS SOLVENT FREE EPOXY COATINGS WATERBORNE PRODUCTS FOULING RELEASE

33 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

34 Fouling Release Products 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 2x 150 microns 78% volume solids 1,980 litres requires 2,400 litres of paint 550 litres solvent 5% thinner 130 litres thinner 680 litres 22 Kdwt Bulk Carrier

35 Fouling Release Products 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 2x 150 microns 78% volume solids 1,980 litres requires 2,400 litres of paint 550 litres solvent 5% thinner 130 litres thinner 680 litres This could result in a reduction of 3% of the total solvent emission. 22 Kdwt Bulk Carrier

36 Consequences for NB shipyards Consequences for New Building Shipyards

37 Fouling Release Products CONSEQUENCES FOR NEW BUILDING YARDS More control of the application conditions required This may result in a need to have application done indoors 1. To reduce the fluctuations in application conditions 2. To optimise the coating application & curing 3. Special equipment may be required (extra investment required)

38 Coatings & VOC Emission 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; hottwinfeed for Solvent Free products) However, technology is available, but may have impact on the coating application and production

39 Coatings & VOC Emission 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; hottwinfeed 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

40 Coatings & VOC Emission Questions???