Advanced Coating for New Applications

8/9/2019 Advanced Coating for New Applications

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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-

CHEMICAL ENGINEERING

WWWW,CHEI\,4ENGONLINE,COMI\,4

DECEIVBER2OI4

23



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



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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Advanced Coating for New Applications