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AIIMilCHI
COATI]IGS
]OB
]ITW
APPIIGAIIO]IS
IIew
formulations
allow industries
to
euolue,
and
reduce
lahol
costs and environmentalconcerns
hanging
markets
and new
ap-
plications
are
putting
more
de-
mands on
the
protective
coat-
ings
industry
than ever before.
While
developing
enüronmentally
friendlier
and less
labor-intensive
corrosion-
and
chemical-resistant
paints
and
coatings
is
always
a
major
goal,
new formulations
are needed
to
address
the
coating
challenges
pre-
sented
by today's changing
chemical
process
industries
(CPI),
as
well
as
modern
construction
and other engi-
neering
capabilities.
'Reduction
of VOCs
[volatile
or-
ganic
compoundsl
and labor
costs
will
always
be
sought
afl,er
goals
in
the
prot€ctive
coatings
industry
but
we are
begianing
to see additional
needs
emerge
as
there is an increase
in operating
temperatures
in
many
applications,
especially in
oil-and-
gas
and chemical
processing,
as well
as more
and more
astounding
feats
of engineering
cropping
up,"
says
Jerry Witucki.
associate
coating
sci-
entist with
Dow
Coming
(Midland,
Mich.;
www.dowcorning.com).
applications
"Enormous structures,
such
as
mega
s\iscrapers
and
wind turbine
farms,
those
in
the
middle
of
the
not
only
have
the
initial
chal-
performance
requirements,
also,
the
owners
don't want
to
someone
up
or out
to
rcpaint
Witucki.
"They need
protective
coating
that
will
last
for
which
is
placing
demands
coatings
that
simply haven't
ex-
in
the
past."
In
addition, he
says, even
every-
applications,
such as
chemical-
processing
equipment and bridges
require
more from coatings
than
ever before
because
shutting
down
a
process
or
bridge to
paint
is
be-
coming
cost
prohibitive
in today's
competitiveeconomicenvirónment.
And,
in
many industries,
tempera-
tures
are
increasing,
which
piles
on
additional
demands.
*People
want
to
operate
their lines
faster,
so
they
heat up the oven
to
higher
temperatures
or,
for
better
emis-
sion control,
they
may
tum up
the
heat
in
a catallic
converter
to
en-
sure
complete
combustion,
so
theyare looking
for
coatings
that
pro-
vide
longerJasting performance
at
higher
temperatures,"
says
Witucki.
"It
costs
a
lot
in
lost
production
time
and
labor
to
have someone
re-
paint,
so
between
labor
costs,
shut
dow¡r costs
and
environmental
costs,
the
actual
cost
ofthe
paint
or
coating
is
no
longer
the
primary
consider-
ation fo¡
the
end
user,"
says Witucki.
"They
are
willing to
absorb
the
cost
ofa
more
expensive
paint
ifit
means
it
wont
have to be
applied
as
oÍten."
He
says. in [he
past,
organic
resins
were
the "go-to" coating for
many
ofthese applications,
but
with
more
demanding
criteda, the
exist-
ing
formulations
were not working
as well,
so
coatings
manufacturers
started
seeking
new
ingredients
and
additives
that would
boost
the
durability
and
life
of
their
coatings.
Dow
Coming,
s
ays
Witucki,
strives
to
create materials,
such
as
silicone-
organic hybrids,
which
possess
greater
thermal stability
and
better
chemical
resistance
when
added to
coating
formulations.
"We've
seen
a steady
increase
in the number
of
FIGURE l.
Slvance's
C1008 is
a
s¡l¡cone
curative that improves the
durable
flexlbllity
of
epoxy
polyslloxane protective
topcoats ¡n
mar¡ne
and ¡nfrastfucture appllcatlons
U.S.
patents
using silicone-organic
hybrids,
to the
point
where
107o of
all U.S.
paint
parenrs
as
of2013 in-
corporated silicone-organic
hybrid
technology," notes
Witucki.
Jeff
Jones,
business development
director with
SiVance,
LLC,
a
sub-
sidiary
of Milliken
&
Co.
(Gaines-
ville, Fla.;
www.sivancellc.com),
agrees
that
new
ingredients
are the
key to developing
better
coatings
for
changing applications.
"In
the
oil-
and-gas industry
especially, they
are seeking
protective
coatings that
are more
durable to higher
tempera-
tures. higher
pressuues
and nastier
mixes of
chemicals
at
those
higher
temperatures
than ever before," he
says.
"In
these applications,
they
were finding
a
lot
of the
coatings
they
had
been
using for tank
and
pipe
linings
were
just
not
durable
enough for
the
higher
temperatures
and new
mixtures
ofchemicals
they
are
seeing
today."
One
ofthe
reasons
is that
the
products
resulting
from
hydraulic
fiacturing
are
very
differ-
ent and more corrosive
than
the
tra-
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ditional
products.
Another
example
is in deep-sea oil drilling
where,
as
the
oil-and-gas
industry is
forced
to dig deeper,
the environment
be-
comes
morc harsh.
"They
need coat-
ings
that
pedorm better under
these
ncw
conditions,"
says Jones.
As an
ingredient supplier to the
protective
coatings industry,
he
says, it was
SiVance's
job
to
de-
termine what was
causing
failure
under new operating conditions and
adjust the chcmistry
accordingly to
avoid those
failures. The
company
started by examining the
issues
ex-
hibited
by
structural
coatings.
'1Ve
are
a silicones
producer
and
we
realized
that
many
ofthe
protec-
tive
coatings
for structural
applica-
tions were
epoxy-based
because
epoxy
provides
excellent
adhesion
and
corosion resistance
at a low
cost. However, silicones are
out-
standing for
weatherability,
fl
exibil-
ity
and
thermal stability,
which
are
needed
to
increase
the durability
of
protective
coatings used
in
these
applications. We decided
to combine
the
best of
both
worlds
and deviscd
a
silicone material
that
coatings
produccrs
could easily
formulate
into their existing epoxy
system,"
says Jones.
"What
we developed
al-
lows them to create an
cpoxy
that
acts a
bit Iike a
silicone
to
give
their
coalings
a boosi in the
properlies
that
can help increase
durability."
The ñrst
product
introduced
by
SiVance
was
its C1008
(Figure
1),
a
silicone
curative that
improves
the
durable flexibility
of
epoxy
polysiloxane
prolecr
ive
topcoats
in
marine
and
infiastructure
applica-
tions, without sacrificing
weather-
ability.
The
curalive
solves a major
challenge common
to
cpoxy
polysi
loxanes:
bdttleness
and cracking
that can
develop
over time as the
coating continues to
cure.
The
curative
is
designed
fbr
use
i¡
coatings
applied to
piping,
bridges,
wind
turbines, offshorc
platforns,
tarrk
exteriors,
stnrctual steel
and
heav)
eqüpmenL.
lt
uses a
propri-
etary
molecular
structure
that
pro-
üdes
enhanced
compatibility
in
epoxy
systems.
The
product
is
firlly
miscible
with hydrogenated
bisphenol
-A-epoxy
resir:s. The compaúbility ol C1008
in
other
epoxy
resins
is
possible
with the
24 CHEMICALENGINEEBING WWW,CHEIVENGONLINE,COI\,1
DECEIUBER2014
FIGUBE
2,
Ser¡es
391 Tank Armor from Tnemec ¡s
a chem¡cal-res¡stant
formulation
for use
in
severe
chem¡cal-¡mmers¡on env¡ronments
use
ofsolvents
or
reactive
diluents.
Jones
says
the company
is
prepar-
ing to
lau:rch a
second
product
that
will
provide
rnore
compatibility
with
the
epoxy
coatings
most
comrnonly
used
in the
oil-and-gas
industry
where the
need for
higher-performing
coatings continucs
to
grow
due to the
challenges
presented
by
hydrauLic
fracturing and
deep-sea oi1
drilling.
Good
for the environment
Formulators
are
also
faced
with
the
challenge
of
providing
more
du-
rable
protective
coatings
for
today's
oi1-and-gas
industry that are
more
environmcntally
Íiiendly,
says
Gary
Zinn, director
of sales
-
industrial
markcts,
with Tnemec
Co.
(Kansas
Clty,
Mo.; www.tnemec.com).
"In
the
past, a
1ot
of
the tankJining
mate-
rials contained
solvents and VOCs.
Today's
technology
needs
to
be 1007¿
solids
with
little to
no
VOCs
or sol-
vents,
yet
still
provide
excellent
t
ransfer, high-build
charact
eristics
and
protection
from
today s heavier
and
higher-sulfur-content
crude."
In
response, Tnemec,
introduced
a I00% solids epoxy
liner
lor
use
in
transpofl tanks
containing
chemi-
cal blends
or
acids used
in
hydrau-
1ic
fracturing
(Figure
2).
Series
391
Tank
A¡mor is
a
chemical-resistant
lormulation
for
use
in
severc
chemi-
cal-immersion environ
ments.
"Series
391 Tank
Armor
meets
the require-
ments of customers
in
thc oil and
gas
service industries,
such
as
rapid
rcturn
to service,
one-coat applica-
tion,
fast-cure, high-build
capabili-
ties,
ease
of application
arrd
physical
propcrties
for long-tenn durability,"
says
Zinn.
"It
also offers
excellent
corrosion
protection
against
hyüo-
chloric acid
and selected chemical
combinations,
along
with
toluene
and xylene blends,
which
may also
be
used for well-ser-vice
treatment,"
Environmental
liiendliness
isn't
jusl
a trend
in
the oil-and-gas
in-
dustry.
It
is
a
requirement in
almost
every
industry, and,
as
laws and
regulations
become
more
stringent,
the
protective
coatings
industry
is responding to these
needs
with
kinder,
gentler products
and appli-
cation
processes.
One such development
is the
Co-
Cure coating
process
from
Hen-
kel Corp.
(Rocky
Hill, Conn.; www.
henkelna.com).
This
unique
process
reduces
the environmental
impact
because
it laycrs
Henkel's
coatings
with
a topcoat and
"co-cures"
them
together in a single
oven, which
reduces
energy consumption
and
waste-treatment costs.
"The chemistry
in
the
frrst layer
allows us to dehydrate
thc coating
without
having
the
need
to
ful1y
cure
it
at high
tcmperatures
for
long du-
rations,"explains OmarAbu-Shanab,
technical director with
Henkel. "The
second
layer
is
applied
and both
lay-
ers are Co-Cured
and chemically
8/9/2019 Advanced Coating for New Applications
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crosslinked in
a
single oven."
"This
ptocess
is
unique
to
our coat-
ings," says Mike
Berger,
business
development
manager
with
Henkel.
"Many other
coatings
reqüre
users
to
wholly
cure the
primer
before
the
top
coat can be applied,
which
re-
quircs
two
ovens
and much
longer
durations
of
time at higher tempera-
tures.
In
new applications,
end
users
can employ
a shorter
oven,
which
results
in lower
equipment
costs.
In
existing lines, thev
can tu¡n
down
the
oven temperature
and reduce
the
time
and
save
energy."
The
Co-Cure
process
carr
be
used
Bonderite
M-PP
930
Autodepo-
sition
Coating. The coating
delivers
conosion
pedormance
in
such
as
vehicle
frames
chassis
components, construc-
equipment and appliances
(Fig-
ure 3).
The
enüronmentally
sustain-
coating
contains no toxic
heavy
and is very
low
in
VOCs.
addition
to its
environmentally
proEle
and application
FIGUBE
3. Bonderite M-PP 930 Autode-
position
Coatlng from Henkel
delivers
enhanced
coros¡on
performance
ln ap-
pl¡qat¡ons
such as vehicle
rrames and
chassls
components
process,
the
coating
was
developed
for
use
on
difficult-to-coat
reactive
substrates
where traditional
pro-
tectants
could
not
provide
a
uni-
form
coating,
which
often
resulted
in
exposure
to
corrosion
through
microscopic
pinholes.
Bonderite
M-PP
930C
'addresses
issues appli-
cators
face
when coating
cast
sub-
strate
by
eliminating
surface voids
and outgassing,
which
contribute
to
improved
corrosion
properties.
Be-
cause
Bonderite
M-PP
930
provides
uniform
coverage
with
lower
main-
tenance
requirements
-
there
is no
FIGURE
4. Cortec's
Ecoson¡c
Confomal
Coatlng
powered
by Nano.Vpcl
for
use as a
c¡rcu¡t-board
conformal
coat¡ng comblnes
molsture-intrus¡on
preventlon
and
corrosion
res¡stance wiih
the company's
Vapor-phase
Corroslon lnhibitor
(VpCl)
technology
ultraflltration,
no ¡ectiñers,
no
elec-
trodes
and fewer
stages
-
the coat-
ing is
expected
to last
5
to 10
years
under ext¡eme
corrosion
conditions,
says
Henkel's
Abu-Shanab. This
combination
ofthe shorter
cure
time
and the reduction
in
maintenance
results
in
lower
labor
costs,
says
Berger,
which is another
demand
on
toda¡/s
protective
coatings.
Cortec
Corp.
(St.
Paul,
Minn.;
www.corteccvci.com)
also
saw
an
opportuniry
to improve
several
pro-
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