United States Air and Energy Engineering

Environmental Protection Research Laboratory

Agency Research Triangle Park, NC 27711

E AP Project Summary

Proceedings: Pollution Prevention

Conference on Low- and No-VOC

Coating Technologies

Research and Development EPA/600/SR-94/022 April 1994

The report documents a conference

that provided a forum for the exchange

of technical information on coating

technologies. It focused on improved

and emerging technologies that result

in fewer volatile organic compound

(VOC) and toxic air emissions than traditional coating emissions. Among the

new products and improvements focused on were an electrophoretic urethane coating, a zero-VOC house paint,

and developments involving such inorganic polymers as zinc silicates and

silicones. Coatings for such substrates

as metal (aerospace), wood (furniture),

plastic, foil, and concrete were also discussed.

This Project Summary was developed

by EPA’s Air and Energy Engineering

Research Laboratory, Research Triangle Park, NC, to announce key findings of the research project that is fully

documented in a separate report of the

same title (see Project Report ordering

information at back).

Introduction

Surface coating operations release approximately 19% of stationary area source

volatile organic compound (VOC) emissions. Many of these sources cannot be

impacted by add-on controls at a reasonable cost due to their small size and/or

the difficulty of capturing emissions. The

reduction of solvent emissions from architectural and other coatings continues to

rely on prevention technologies, such as

the replacement of VOC with water or

nonphotochemically reactive solvents, the

use of high solids coatings, or improvement of the efficiency of transfer of the

coating to the coated surface. In current

practice, reformulation with nonphotochemically reactive solvents may lead to

other environmental problems, such as

increased toxicity, greater stratospheric

ozone depletion potential, and worsened

multimedia effects.

A conference, “Pollution Prevention Conference on Low- and No-VOC Coating

Technologies,” was held May 25–27, 1993,

in San Diego, CA. The conference was

sponsored by the U.S. Environmental Protection Agency (EPA), Research Triangle

Institute (RTI), and the American Institute

for Pollution Prevention (AIPP). The conference provided a forum for the exchange

of technical information on coating technologies. Specifically, the conference focused on improved and emerging technologies that result in fewer VOC and

toxic air emissions than traditional coating

systems.

Approximately 230 people attended the

conference: about 50% were from industry, 40% from government, and 10% from

consulting firms and universities. There

were three registrants each from Taiwan

and the United Kingdom; and one each

from Sri Lanka, Norway, and the Philippines. Conference registrants are listed in

Appendix A of the proceedings.

Approximately 40 technical papers were

presented at the conference, divided into

11 sessions focusing on such topical areas as coating technologies, specific coating applications and case studies, application equipment, and pollution prevention concepts. Several papers focused on

new products and improvements in these

areas, such as an electrophoretic urethane

coating, a zero-VOC house paint, and deColeen M. Northeim and Ella Darden
2

velopments involving inorganic polymers

such as zinc silicates and silicones. Coatings for substrates, such as metal (aerospace), wood (furniture), plastic, foil, and

concrete, were also discussed.

Conference Program

Portions of the conference program follow, including the session topics, paper

titles, and authors. The project report

includes copies of the presented papers

that were submitted for inclusion in the

proceedings.

Conference Scope

The purpose of this conference is to

provide a forum for the exchange of technical information on coating technologies.

One of the primary objectives of the conference will be the presentation and discussion of improved coating technologies

that result in fewer volatile organic compound (VOC) and toxic air emissions. The

conference is designed to benefit coating

manufacturers and users and representatives of government, academia, environmental groups, and other research and

development organizations. Research and

case studies will be presented that are

specifically applicable to the architectural

and industrial maintenance (AIM), aerospace, automotive, wood furniture, and

printing industries. The sessions will consist of technical paper presentations and

are planned to allow for discussion periods and active participation by all attendees.

Tuesday, May 25

Session 1: Opening Session, Moderator–Coleen M. Northeim, RTI

8:15 a.m.

Welcome by Richard J. Sommerville,

Air Pollution Control Officer, San Diego

County Air Pollution District, San Diego,

CA

8:30 a.m.

Keynote by Paul Eisele, Director of

Health Safety & Environmental Affairs,

Masco Corporation, Taylor, MI

9:00 a.m.

Coating Research in the U.S. EPA’s

Organics Control Branch, Michael

Kosusko, U.S. Environmental Protection

Agency, Air and Energy Engineering

Research Laboratory, Research Triangle

Park, NC

9:20 a.m.

Using Life-Cycle Analytical Techniques

to Assess Alternative Coating Systems,

Keith A. Weitz and John Warren

(Speaker), Research Triangle Institute,

Research Triangle Park, NC

Session 2: Technologies, Moderator–

Robert McCrillis, U.S. EPA/AEERL

10:00 a.m.

Radiation Curing Technology: Ultraviolet and Electron Beam Processing, Richard Stowe, Fusion UV Curing Systems, Rockville, MD

10:30 a.m.

Environmental Compliant Thermoplastic Powder Coating, David F. Ellicks,

Department of the Air Force, Air Force

Corrosion Program Office, Robins AFB,

GA

11:00 a.m.

Supercritical Fluid Spray Application of

Low-Pollution Coatings for Plastic Substrates, Wayne Miller and Kenneth

Nielsen, Union Carbide Corporation,

South Charleston, WV, and Tom

Morrison, Red Spot Paint & Varnish,

Evansville, IN

11:30 a.m.

Utilizing Dispersion Resins with

Inorganci Solids in a New Formulary

Blending Process to Achieve Synergistic Results of Performance (Expanded

Abstract), Philip W. Coscia, Resources

Conservatory International, Gustine, CA

Session 3: Powder Coatings,

Moderator–Richard Sayad, Dow

Chemical Company

1:15 p.m.

Advantages of Powder Coating, Albert

Holder, Naval Surface Warfare Center,

Annapolis, MD

1:45 p.m.

Aerospace Applications for Powder

Coating at Hughes Aircraft Company,

Larry Brown, Hughes Missile Systems

Company, Tucson, AZ

2:15 p.m.

Fluoropolymer Coatings for Architectural,

Automotive and General Industrial Applications, David M. Grafflin, Evodex

Powder Coatings, Birmingham, AL

Session 4: Federal Programs,

Moderator–John Warren, RTI

3:00 p.m.

US Navy Compliance to Shipbuilding

and Ship Repair Environmental Regulations, Alex Kaznoff, Naval Sea Systems

Command, Arlington, VA

3:30 p.m.

Low-VOC Coatings Developed by DOE

for Environmentally Conscious Manufacturers, Mark D. Smith, Allied Signal,

Inc., Kansas City, MO

4:00 p.m.

The Precedent-Setting Use of a Pollution Prevention Project in an EPA Enforcement Settlement, David Nelson,

EnviroSearch International, Salt Lake

City, UT, and James J. Periconi,

Donovan Leisure Newton and Irvine,

New York, NY

4:30 p.m.

Army Pollution Prevention Success Stories, Jack Hurd, Army Acquisition Pollution Prevention Support Office, Alexandria, VA, and Mark W. Ingle, Ocean

City Research Corporation, Arlington, VA

Wednesday, May 26

Session 5: Encouraging Pollution

Prevention, Moderator–Coleen

Northeim, RTI

8:00 a.m.

Pollution Prevention Opportunities in

Coatings: Educating Those who are

Responsible for This Task, Robert B.

Pojasek, GEI Consultants, Inc.,

Winchester, MA

8:30 a.m.

Economic Incentives to Stimulate the

Development and Diffusion of Lowand No-VOC Coating Technologies,

Brian Morton, Research Triangle

Institute, Research Triangle Park, NC,

and Bruce Madariaga, U.S. Environmental Protection Agency, Office of Air

Quality Planning and Standards,

Research Triangle Park, NC

9:00 a.m.

Pollution Prevention in the Wood

Refinishing Industry, Azita Yazdani,

Pollution Prevention International, Inc.,

Brea, CA

9:30 a.m.

The Importance of Product Stewardship and its Impact on Pollution

Prevention, Richard Sayad, Dow

Chemical Company, Midland, MI

Session 6: Inorganic Coatings,

Moderator–Vic Young, Waste

Reduction Resource Center
3

10:15 a.m.

Long-Term Corrosion Protection With

Single-Coat, High-Ratio Zinc Silicate,

Parke Schaffer, Jr., Inorganics Coatings, Inc., Malvern, PA

10:45 a.m.

Two Surprises From an Inorganic ZincRich Silicate Coating, C. William

Anderson, Marine Environmental

Research, Inc., Morehead City, NC

11:15 a.m.

A New Inorganic Coating for Magnesium Alloys With Superior Corrosion

Resistance, Alex J. Zozulin, Technology Applications Group, Inc., Grand

Forks, ND, and Duane E. Bartak,

University of Northern Iowa, Cedar

Falls, IA

11:45 a.m.

Inorganic Chemistry as an Option for

Formulating High Solids, Low- and

Zero-VOC Architectural and Industrial

Maintenance Coatings, Christine L.

Stanley and Raymond Foscante,

Ameron, Brea, CA

Session 7: High Solids & Water Based

Coatings, Moderator–Wade Ponder,

U.S. EPA/AEERL

1:30 p.m.

The Development of Practical ZeroVOC Decorative Paints, Richard

Tuckerman and David W. Maurer,

Glidden Company, Cleveland, OH

2:00 p.m.

New Environmentally Acceptable Metal

Coating Systems, Peter C. Ryder,

Hawking International Limited, United

Kingdom, and Peter Hope, LVH

Coatings Limited, United Kingdom

2:30 p.m.

Water-Reducible Polyurethane

Coatings for Aerospace Applications,

Patricia B. Jacobs and David C.

McClurg (Speaker), Miles, Inc.,

Pittsburgh, PA

Concurrent Sessions

Session 8: Applications 1, Moderator–

Kevin Dick, Nevada Small Business

Development Center

3:15 p.m.

Water Based and UV-Cured Coatings

for Plastics, Edwin C. Laird, Coatings

Resource Corporation, Huntington

Beach, CA

3:45 p.m.

Waterborne Lacquers for Aluminum

Foil, William Marwick, Alcan International Limited, England

4:15 p.m.

Lower-VOC Coating System Conversion Costs for Wood Furniture Industry, Mary-Jo Caldwell, Midwest

Research Institute, Cary, NC

4:45 p.m.

Development of Ultra-Low VOC Wood

Furniture Coatings, Eddy W. Huang,

Center for Emissions Research &

Analysis, Larry Watkins, South Coast

Air Quality Management District, and

Robert C. McCrillis, EPA/AEERL

Session 9: Aerospace Applications,

Moderator–Robert B. Pojasek, GEI

Consultants, Inc.

3:15 p.m.

Replacement of Chromated Epoxy

Primers for Ground Support Equipment

and Flight Hardware, Marke E.

Lindsay, Locheed Missiles & Space

Company, Inc., Sunnyvale, CA

3:45 p.m.

An Investigation of Flexibility Test

Methods for Low-VOC Aerospace

Coatings, Angela J. Brown, Boeing

Defense & Space Group, Seattle, WA

4:15 p.m.

Waterborne Maskant, Mark Jaffari,

Malek, Inc., San Diego, CA

4:45 p.m.

Low-VOC Organic Coatings for

Commercial Aircraft Application, T.D.

Leland and C.M. Wong, Boeing

Commercial Airplane Group, Seattle,

WA

Thursday, May 27

Session 10: Auxiliary Systems,

Moderator–Michael Kosusko, EPA/

AEERL

8:00 a.m.

Low Volatility Surface Preparation: A

Hybrid Approach, Joseph A. Lucas,

Inland Technology Incorporated,

Tacoma, WA

8:30 a.m.

Transfer Efficiency and VOC Emissions of Spray Gun Technologies in

Wood Finishing, Leslie SnowdenSwan, Pacific Northwest Laboratory,

Richland, WA, and Pamela Worner,

Pacific Northwest Pollution Prevention

Research Center, Seattle, WA

9:00 a.m.

You Can’t Always Judge a Paint Spray

Gun Cleaning System By Its Cover,

Michael J. Callahan and John P. Kusz,

Safety-Kleen Corporation, Elgin, IL

Session 11: Applications 2, Moderator–Jack Kowal, Coors Brewing

Company

9:45 a.m.

Priority Manufacturing and Environmental Issues at Military Industrial

Facilities, John W. Adams, Richard S.

Goldman, and Jerry R. Hudson,

Concurrent Technologies Corporation,

National Defense Center for Environmental Excellence, Jamestown, PA

10:15 a.m.

Low-VOC Dual-Cure Aerospace

Topcoat, Kevin E. Kinzer and Steven

J. Keipert, 3M Company, St. Paul, MN

10:45 a.m.

UV Pollution Prevention Technology in

Can Manufacturing, Erik Donhowe,

Coors Brewing Company, Golden, CO

Pollution Prevention Opportunities in

the Manufacture of Paint and Coatings,

Paul M. Randall, U.S. Environmental

Protection Agency, Risk Reduction

Engineering Laboratory, Cincinnati, OH
4

• •

United States

Environmental Protection Agency

Center for Environmental Research Information

Cincinnati, OH 45268

EPA/600/SR-94/022

Official Business

Penalty for Private Use $300

BULK RATE

POSTAGE & FEES PAID

EPA

PERMIT No. G-35

C. Northeim and E. Darden are with Research Triangle Institute, PO Box 12194,

Research Triangle Park, NC 27709.

Michael Kosusko is the EPA Project Officer (see below).

The complete report, entitled “Proceedings: Pollution Prevention Conference on

Low- and No-VOC Coating Technologies,” (Order No. PB94-152246/AS;

Cost: $61.00; subject to change) will be available only from:

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22161

Telephone: 703-487-4650

The EPA Project Officer can be contacted at:

Air and Energy Engineering Research Laboratory

U.S. Environmental Protection Agency

Research Triangle Park, NC 27711