New UV/Color Stable Spray
Aliphatic Polyurea CoatingTechnology
Albemarle Corporation

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

1Company Overview – Who We Are
Albemarle provides innovative development, manufacturing and marketing of complex
chemistry solutions and services that create exceptional customer value while maximizing
shareholder wealth.
Diversified mix of solution-based products and custom services sold to a wide range ofcustomers and end markets.
• Over 3400 customers, 100 countries• Operate 45 facilities, encompassing production, research & development
facilities, and administrative offices in North and South America, Europe,
the Middle East and Asia
• Over 4000 employees around the world2010 Net Sales

Catalysts
38%

Polymer Solutions
38%

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

Fine Chemistry
24%2

Scale and Scope

Amsterdam,
The Netherlands
Bergheim, Germany
St. Jakob/Breitenau, Austria

South Haven, MI, USA

Beijing, China

Moscow, Russia

Avonmouth, UK

Weifang City, China
Seoul, Korea

Louvain-la-Neuve, Belgium
Twinsburg, OH, USA
Magnolia, AR, USA
Pasadena, TX, USA

Tokyo, Japan

Budapest, Hungary

Osaka, Japan,Safi, Jordan

Tyrone, PA, USA

Houston, TX, USA
Bayport, TX, USA

Niihama, Japan
Orangeburg, SC, USA

Al-Jubail, Saudi
ArabiaBaton Rouge, LA, USA

Dubabi, UAE

Shanghai, China
Ningbo, China

Corporate Headquarters(Baton Rouge, LA, USA)

Zhejiang Province, China
Singapore

Regional/Sales OfficeNanjing, China

Manufacturing
Joint Venture

Doncaster East VIC,
Australia

Santa Cruz, Brazil

R&D

2010 Net Sales

Americas42%Europe
34%

Asia
24%
3

PDA Europe 2011 Annual Conference –The Hague, 14-16 NovemberDifferentiated by Our Innovation
Research and process development expertise that allow us to bring innovative technologies
to the market more quickly and at a lower capital cost than our competitors.
$700
New Products Sales

$600
$500
$400
$300$200$100$0
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

We provide innovative development, production and service for the application of complex
chemistry to create exceptional customer value.
PDA Europe 2011 Annual Conference –The Hague, 14-16 November

4Polyurea Spray Coatings• Two component solventless coatings (zero VOC)
– A Side: Isocyanate prepolymer– B Side: Resin blend containing• Amine Curative hard segment• Polyetheramine soft segment• Systems are fast reacting– Quick return to service– Need to moderate reactivity for cure rate control andsmooth surface• Most systems are aromatic (MDI and Ethacure 100)and thus lack UV/color stability.
PDA Europe 2011 Annual Conference –The Hague, 14-16 November

5Ethacure® 90• New aliphatic amine curative
commercialized in 2011 (TSCAregistration in US in February).
• Chemical structure designed toprovide moderate cure speed.
• Allows formulation of robust fully
aliphatic spray polyurea
systems.
• Global registration underway.
HNNH

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

6

Aliphatic Polyurea Coatings• The aliphatic polyurea coating system in thispresentation is based on an HDI
polyisocyanurate.
• Screening of formulations involved:– Mixing resin side components in a Speedmixer– Providing a 1:1 volume ratio with a dual cartridge
syringe– Mixing iso and resin through a static mixer
equipped with an air spray nozzle.

• Gel times were obtained by measuring time
until the material no longer flowed whensprayed on a vertical surface
PDA Europe 2011 Annual Conference –The Hague, 14-16 November

7Ethacure 90 gives significantly longer gel times
with HDI than other aliphatic secondary amines.

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

8Formulation Flexibility

25Gel Time (sec)882020151410286516250030.7

41.1

1009080706050403020100% Elongation

Addition of PEA D-400 Provides Allows Cure Rate
Control as well as Increasing Elongation

49.6

Level of PEA D-400
PDA Europe 2011 Annual Conference –The Hague, 14-16 November

9Base Formulations and Coating Properties
Iso-side wt%
HDI 19.4% NCO

Formula 1100

Formula 2100

Resin-Side, wt %E9047.643.9PEA D-400

17.6

23.4

PEA D-2000

23.3

21.2

IPDA

6.5

6.5

TiO2

55Index

1.10

1.10

Gel time, sec

8<6Physical Properties
Thickness, mils

69105

Hardness Shore A

94

95

Tensile Strength, psi

1920

2260

Elongation, %6890

Tear Strength, pli

520

460

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

10Comparison of Aliphatic vs. Aromatic
Spray Polyurea Coating Systems
1. Aliphatic System: HDI-based spray aliphatic
coating cured with Ethacure 90
2. Aromatic System: MDI-based spray aromatic
coating
3. Aromatic/Topcoat System: MDI-based sprayaromatic coating with aliphatic (polyaspartic)
topcoatPDA Europe 2011 Annual Conference –The Hague, 14-16 November

11New E90-based One Coat All Aliphatic• Taber Abrasion and QUV (Weathering) TestingIn 2-coat system,
topcoat was abraded
off allowing coating
discoloration.

Yellowing
throughout in all
aromatic system.

No yellowing in
E90-based all
aliphatic system.
1-Coat: E90based All
Aliphatic

2-Coat: Aromaticwith Polyaspartic
TopcoatPDA Europe 2011 Annual Conference –The Hague, 14-16 November

1-Coat: All
Aromatic
12

WVTR (Water Vapor Transmission Rate)following ASTM E 96-05
New aliphatic coating has 2-2.5 X lower moisturetransmission rate than aromatic systems.
WATER VAPOR TRANSMISSION RATE (PERMS)

2.0
ALIPHATIC-0.84

y = 32.25x
R2 = 0.98

1.5

AROMATIC WITH TOPCOATAROMATIC

1.00.5y = 12.79x-0.84-0.91

2y = 33.87x
R2 = 0.90

R = 0.95
0.0020

4060

80

100

120

140160

THICKNESS (MIL)
13PDA Europe 2011 Annual Conference –The Hague, 14-16 NovemberNew aliphatic technology provides same moisturebarrier protection at much lower coating thickness.

Required Coating Thickness for low MVT Rate (0.55 Perms)
140

COATING THICKNESS (MIL) REQUIRED120100806040200
ALIPHATICAROMATIC WITH TOPCOATPDA Europe 2011 Annual Conference –The Hague, 14-16 November

AROMATIC

14

2011 Applications• New Ethacure 90-HDI based polyurea coating on theconcrete below an amusement park ride.

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

15

Discovery Channel’s Storm Chaser vehicle
The tough, new aliphatic spray coating protected the Discovery Channel’s
Storm Chaser vehicle from the severe tornado season of spring 2011.

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

16Decorative Coatings• Aliphatic system allows the colorful coating on thisamusement park ride.

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

17Conclusions• The commercialization of Ethacure 90 in 2011 provides anew slow aliphatic diamine for formulators, allowing theformulation of robust fully aliphatic spray polyurea systems.
• The cure rate is slow enough to allow one to formulate withfaster primary amines like PEA D-400 and IPDA.
• The WVTR of the aliphatic polyurea is less than half of thatof the aromatic polyurea systems.
• The improved moisture barrier performance allows
application of a thinner aliphatic polyurea coating,significantly improving the system economics.
• Global rollout and registrations in 2011-2012.

PDA Europe 2011 Annual Conference –The Hague, 14-16 November

18Special thanks to co-authors: Paul Wiggins (Albemarle), Terry Pe (Line-X
Performance Coatings), Thalan Burris (Albemarle), and Dustin Le (HORN)

For more information regarding Albemarle’s curatives,
please visit www.curatives.com
PDA Europe 2011 Annual Conference –The Hague, 14-16 November

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