VOC Controls 1/66 © Copyright Training 4 Today 2001 Published by EnviroWin Software LLC VOLATILE ORGANIC COMPOUNDS CONTROLS CUSTOMIZED ENVIRONMENTAL TRAINING

VOC Controls 1/66 © Copyright Training 4 Today 2001 Published by EnviroWin Software LLC

VOLATILE ORGANIC COMPOUNDS CONTROLS

CUSTOMIZED ENVIRONMENTAL TRAINING


INSTRUCTOR

Insert Instructor Name Here


Define Ground Level Ozone.

Define VOCs.

Discuss VOC Content.

Discuss Transfer Efficiency (TE).

Discuss Different Types of Sprayers.

Discuss Operator Training.

Discuss Capturing Fugitive Emissions.

Discuss Destroying Fugitive Emissions.

Recommend Handling, Storage, and Disposal Procedures for VOCs.

OBJECTIVES


GOALS

Understand the Definition Ground Level Ozone.

Understand the Definition of VOCs.

Understand What VOC content is.

Understand Transfer Efficiency.

Be Familiar With The Different Types of Sprayers.

Understand the Importance of Operator Training.

Understand the Importance of Capturing Fugitive Emissions.

Understand the Importance of Destroying Fugitive Emissions.

Be Familiar With Recommend Handling, Storage, and

Disposal Procedures for VOCs.


BACKGROUND

In 1998, 61,234 industries reported a total of 7.3 billion pounds of hazardous chemicals released to the air, land and water in the United States.

EPA estimates that 85,300 tons of toxic emissions from solvents are released to the atmosphere annually

Solvents contain Volatile Organic Compounds (VOCs) that have been found to contribute to the formation of smog and ozone

Fugitive Air Emissions Containing VOCs can have a Detrimental Impact on Human Health and the Environment.


Supervisors

Facility Engineers

Maintenance Personnel

Department Managers

Building Occupants

Process Specialists

Environmental and Safety Committees

LEARNERS


The goal of this course is to provide supervisors with the tools needed to help control Volatile Organic Compounds (VOCs) from becoming fugitive emissions. It recommends practical, actions that can be carried out by facility management, maintenance personnel and building occupants. The course will help you to integrate good VOC control management activities into your existing organization and identify which of your staff have the necessary skills to carry out those activities.

OVERVIEW


WHAT THIS COURSE DOES NOT DO

The course is not intended to provide information to install, repair, calibrate equipment or remove VOC control devices. Nor is it intended to provide alternative technologies or products that do not contain VOCs. These specialties required training beyond the intended scope of this course. Where this expertise is needed, outside assistance should be solicited.


CLEAN AIR ACT AMENDMENTS (CAAA)

CAAA of 1990 - One of the 189 hazardous air pollutants that has been identified is Volatile Organic Compounds (VOCs).


FEDERAL REGULATIONS

Pertinent Regulations:

40 CFR 59—National Volatile Organic Compound Emission Standards For Consumer and Commercial Products 40 CFR 63 Subpart D—National Volatile Organic Compound Emission Standards for Architectural Coatings 40 CFR 63 Subpart KK - National Emission Standards for the Printing and Publishing Industry 40 CFR 60 Subpart RR - Standards of Performance for Pressure Sensitive Tape and Label Surface Coating Operations 40 CFR 60 Subpart FFF - Standards of Performance for Flexible Vinyl and Urethane Coating and Printing


GROUND LEVEL OZONE

Ground level ozone, commonly referred to as "smog," is the single most serious air quality challenge for most urban areas In 1990, six out of every ten Americans were living in an areas where ozone levels exceeded EPA's air quality standards This was the number 1 urban pollutant


GROUND LEVEL OZONE

Ground level ozone is a complex problem that is difficult to control in part because it is not emitted directly by specific sources It forms in the air when there are chemical reactions between two other pollutants nitrogen oxides (NOx) and volatile organic compounds (VOCs) -- in the presence of heat and sunlight Hotter temperatures accelerate ozone formation Ozone at ground level is a major health and environmental problem Ozone is beneficial substance in the stratosphere where it shields the earth from the sun's harmful ultraviolet radiation


WHAT ARE VOCs?

VOCs* (volatile organic compounds); smog-formers VOCs are released from burning fuel solvents, paints glues and other products used at work or at home VOCs, in addition to ozone (smog) effects, can cause serious health problems such as cancer and other effects In addition to ozone (smog) effects, some VOCs such as formaldehyde and ethylene may harm plants and animals


WHAT ARE VOCs?

All VOCs contain carbon (C), the basic chemical element found in living beings Carbon-containing chemicals are called organic Volatile chemicals escape into the air easily Many VOCs are also hazardous air pollutants, which can cause very serious illnesses EPA does not list VOCs as criteria air pollutants, but they are included in this list of pollutants because efforts to control smog target VOCs for reduction


REDUCING VOCs

Non-attainment areas must reduce VOC emissions by 3% per year, until the standard is attained The base year of measuring is 1990. All but Marginal areas must reduce VOC emissions by 15% by 1996 After that point, the areas must continue to reduce VOC emissions by 3% annually


REDUCING VOCs

Purchase products with the lowest VOC concentrations Ensure there are high transfer efficiencies of the product to reduce waste and fugitive emissions Collect and destroy fugitive VOC emissions


VOC CONTENT

Coatings consist of solids and solvents Solvents lower the viscosity and act as the carrier for the solids Solvents also are used to dissolve the solid resin Solvents evaporate from the coating before, during and after application Solvents include VOCs, water, and exempt solvents


VOC CONTENT

The VOC concentration does not change if you increase the volume of mixed paint used, however, the VOC concentration does increase when adding VOC solvents such as thinners or reducers Manufacturers are currently being required by federal regulations to formulate paint to certain VOC specifications, that when used, according to the manufacturer’s recommendations, will meet VOC content limits The VOC content is generally stated on the label or on the manufacturer’s paint specification sheet


CALCULATING VOC CONTENT

Information is from a Material Safety Data Sheet for this coating: If the coating weighs 10.4 pounds/gallon, and it contains the following VOCs:Xylene 2% x 10.4 lb/gal = .21 lb/galToulene 2% x 10.4 lb/gal = .21 lb/galMEK 6% x 10.4 lb/gal = .63 lb/galMixed Aliphatics 10% x 10.4 lb/gal = 1.04 lb/galTOTAL 20% x 10.4 lb/gal = 2.09 lb/gal

2.09 lb/gal x 119.8 (g/L) (gal/lb) = 250 grams/Liter


TRANSFER EFFICIENCY

Transfer efficiency rates the ability of spray equipment to put a coating on the parts being coated rather than allowing it to escape as overspray or in other forms of waste If you spray 10 pounds of coating on uncoated parts and those parts gain two pounds as the result of being coated, you've achieved 20% transfer efficiency (TE) In selecting new spray-painting equipment, 85% of industrial consumers rated transfer efficiency as extremely or moderately important


SPRAYING

The major types of spray equipment in use today are as follows: Conventional Air-Atomize Guns Airless and Air-Assisted Airless Guns High-Volume, Low-Pressure Spray Equipment Electrostatic Spray Equipment Plural-Component Spray Equipment


CONVENTIONAL SPRAY GUNS

They have been around since the early part of this century They emit a stream of coating from a small opening in a fluid nozzle The coating is broken up into tiny droplets by compressed air emerging from jets adjacent to the fluid nozzle Relatively high air pressures at low volumes will quickly atomize large amounts of coating



Advantages In the hands of a skilled operator, produces smooth, reflective finishes Can be used to coat almost any shape Can apply paint at high production rates on parts hanging from fast-moving conveyors Are "user friendly." Most spray painters are experienced in using them



Disadvantages Very poor transfer efficiency Wastes paint, increases cleanup costs, emits more VOCs


AIRLESS SPRAY GUNS

Similar to a garden hose Airless paint guns pressurize coatings to 900-1200 psi (or higher) and forces it through a nozzle Unlike conventional air spray, there are no jets of atomizing air to break up the paint and propel it to the surface Atomization is dependent upon high fluid pressure


AIRLESS SPRAY GUNS

Advantages In the absence of atomizing air, less overspray and better transfer efficiency Can apply paint at high flow rates, resulting in ability to meet high-production speeds


AIRLESS SPRAY GUNS

Disadvantages Inability to break up paint into very fine droplets, thus producing a coarser spray and a rougher finish Nozzle wear from high velocities cause abrasive pigments in paints to wear nozzle openings more rapidly as they travel through the nozzle. Danger of airless-injection injury


AIR-ASSISTED AIRLESS SPRAY

A hybrid of airless spray and conventional air-atomize spray, this kind of gun uses fluid pressures higher than those used in conventional air-atomize guns but lower than those employed in normal airless spray Unlike normal airless guns, these guns do have compressed air jets that supply atomizing air, but the air pressure is far lower than that used in conventional air-atomize guns In operation, air-assisted airless guns provide atomization much better than is normal with airless spray Danger of airless injection is lessened, as is wear of fluid nozzles


AIR-ASSISTED AIRLESS SPRAY

The main reason for considering use of air-assisted airless spray is better transfer efficiency Its softer spray also makes it easier to spray into recesses Both air-assisted and pure airless spray operate at high fluid pressures and thus can use smaller-diameter fluid lines This translates into paint and solvent savings


HVLP SPRAY

High-Volume Low-Pressure (HVLP) Spray is a variation of conventional air-atomize spray The difference is that these guns are designed to atomize coatings using a high volume of air delivered at low pressure The lower pressure results in far less overspray and "bounce-back"


HVLP SPRAY

Advantages Better transfer efficiency results in less coating waste and lower cleanup costs The exact TE depends upon the circumstances in your installation the booth design, spray techniques, the mix of parts, etc. Operators used to conventional guns generally find it easy to learn how to use HVLP


HVLP SPRAY

Disadvantages Atomization may be insufficient to meet the strictest requirements for smooth, fine finishes May be difficult to atomize coating at sufficiently high rates to meet very high-production requirements


HVLP SPRAY

Disadvantages continued Some problems in achieving proper atomization with HVLP may be caused by "starving" the spray gun for air Causes of this problem include use of air hoses that are too long or too small in diameter; use of too many "quick-disconnect" fittings; and use of low-performance air compressors and air regulators Any one of these factors may result in too little air being delivered to the air cap, causing poor atomization from the gun


ELECTROSTATIC PAINTING

Electrostatic painting begins with a spray gun or other device to atomize a coating The atomizing principle could be any of those previously discussed conventional air-atomize, HVLP, or airless The difference is that an electrostatic application device is equipped with a means of electrically charging the particles of a coating A common method is to build in an electrode near the point where a coating is atomized Parts are grounded, usually by hanging them on a conveyor securely connected to a ground



The result is that fewer of the coating particles are propelled into space as overspray and more are electrostatically guided to the surfaces of the parts being coated Sprayed particles will even turn the corner and be attracted to the back side of a part if the velocity of the particles causes them to initially travel past the parts being painted Transfer efficiency is greatly improved with electrostatic spray



Advantages Higher transfer efficiency Coverage of edges Uniformity of film thickness Productivity - Electrostatic guns mounted on reciprocators are widely used to paint long runs of parts in high-production installations producing lower labor costs



Disadvantages Electrostatically charged particles seek out the nearest grounded surface, if that happens to be the ridge area of a sculptured part, the valley may be difficult to reach For this reason, manual touchup with non-electrostatic guns may be necessary Changes appearance of metallics that are electrostatically charged



Disadvantages continued Fire hazard - there is danger that a spark can occur, igniting paints containing flammable solvents Safety - If operators are not careful to follow set-up directions, they can be electrically shocked Ergonomics - Operators may find some guns more difficult and more tiring to handle



Disadvantages continued Cleanliness - It's mandatory in order to achieve the benefits of electrostatic application Some coatings may require reformulation because some solvents are more conductive than others


ELECTROSTATIC ROTATIONAL ATOMIZERS

Rotary atomizers utilize centrifugal force rather than compressed air or fluid pressure to atomize coatings Discs It is a spinning flat round disc with a hole in the center Feed coating through a hose so that it overflows through the hole and onto the spinning disc Centrifugal force propels coating over the surface of the spinning disc until it flies off the edge The coating atomizes as it is propelled through the atmosphere Parts on hangers travel around the periphery of the disc in an "omega loop," housed by a circular spray booth



Bells Electrostatic bells are similar in principle, except that in this case the paint is fed through a hole at the closed end of the spinning bell-shaped atomizer Centrifugal force propels paint from the edges of the bell Bells may be mounted on reciprocators or on hand-held guns.



Higher-Speed Rotational Devices The latest bells and discs utilize higher rotational speeds, producing finer atomization, the ability to apply higher-solids and waterborne coatings, and high transfer efficiency These devices are often mounted on reciprocators in very-high-production installations Less operator time is required in the disc application But high-speed discs and bells also may have problems in reaching into deep recesses Some of the labor conserved by their use may be required to hand-spray reinforce the areas of parts not properly covered by the automatic spray


VOLTAGE-BLOCK SYSTEMS

Voltage-Block Systems Waterborne coatings are widely used to lessen the VOC content of coating materials To oversimplify, if water replaces some or all of the organic solvents used in paints, the resultant coating material contains less VOC Electrostatically applying waterborne coatings can be a problem To circumvent this, manufacturers have developed increasingly sophisticated "voltage-block" systems Switching to waterbornes is now easier because of the new technologies available in voltage-isolating systems


PLURAL-COMPONENT GUNS

Plural-Component Guns Some coatings, principally urethanes, are supplied as two components They are often referred to as "catalyzed" since the "catalyst" causes a reaction that leads to curing of the coating An advantage is that low temperatures are sufficient to cure the coating and thus plastic parts that cannot tolerate high temperatures can be coated The coatings also exhibit unusual durability in certain applications and require less solvent for thinning, thus improving VOC control


PLURAL-COMPONENT GUNS

Plural-Component Guns continued If the two components are mixed before entering a paint pump or pressure pot, the mixed material must be sprayed promptly It is said to have limited "pot life" For this reason, spray guns have been developed that bring each of the two components into the spray gun through separate feed lines This remedies the "pot-life" problem, since mixing occurs only at the moment before application


CO2 SPRAY

CO2 Spray The most recent development in spray application equipment is built to spray coatings formulated with heated, compressed carbon dioxide Carbon dioxide is a liquid and can be used as a coating thinner Since carbon dioxide is naturally present in the atmosphere and is not considered hazardous The system was developed and patented by Union Carbide under the trade name "Unicarb"


HYBRIDS

Hybrids There are numerous combinations of the technologies for spray painting Such technologies as HVLP and air-assisted airless, already more efficient in raising TE, can be equipped with electrostatics to further improve TE and lessen VOCs But you have to test any system that appears to meet your requirements in YOUR plant, while painting YOUR mix of parts


PAINT HEATERS

Paint Heaters Heat reduces the viscosity of paint Heating paint before it is atomized makes it possible to spray more viscous paint Paint heaters are a well-established, viable means of lowering VOCs If the coating formulation permits use of a paint heater, it will keep viscosity more constant, improve TE, lower wear of equipment and improve finish quality and consistency


CONVERTIBLE AIR-SPRAY GUNS

Convertible Air-Spray Guns Some conventional air-spray guns can be converted to HVLP By inexpensively changing a few components of these guns, one can move to HVLP without buying a whole new gun


OPERATOR TRAINING

Training operators of spray equipment has always been important, but it becomes even more so when one considers how operators' techniques can influence TE Operator training and annual re-training may be the best investment you can make Knowledgeable operators with good spray techniques can measurably improve TE without changing equipment


OPERATOR TRAINING

Pressures Operators sometimes perceive that they can increase air and fluid pressures to improve speed or reduce orange peel Had they used the right air caps and fluid tips they might have applied a smoother finish at lower fluid and air pressures As much as 20% of a coating applied can be wasted by too-high fluid and air pressures Use the lowest pressures consistent with finish quality and productivity


OPERATOR TRAINING

Exhaust Rates In trying to improve transfer efficiency plant engineers must set air-exhaust rates in spray booths to the lowest consistent with operator safety and comfort Too-high rates can pull more coating onto air-exhaust filters than is being applied on parts being coated OSHA regulations specify minimum flow rates and you should aim to be close to these rates


OPERATOR TRAINING

Gun Handling A well-trained operator holds the gun perpendicular to the surface being coated, at a distance of six to eight inches Avoid "arcing" (holding the gun at less than a 90-degree angle to the surface) Good operators move the spray gun toward the surface to be coated before triggering As they reach the end of the surface being coated, they release the trigger to stop coating flow


OPERATOR TRAINING

Gun Handling continued Manufacturers of equipment have been paying much more attention to ergonomic design Companies using ergonomically designed guns report not only greater worker satisfaction and higher-quality finishes, but actual improvements in TE A competent operator learns how to overlap his strokes to apply a smooth finish without excessive thickness Your equipment and coating suppliers can help you with operator training and tell you where to find training courses for your operators


FUGITIVE VOC EMISSIONS

State permits will often dictate either "capture efficiency," "overall VOC reduction efficiency," or both VOC Reduction can be expressed in the following way: VOC Reduction = VOC Capture x VOC Destruction VOC Capture = % of the VOC emissions that is exhausted to the VOC controlVOC Destruction = % of the VOC emissions that is exhausted to VOC control that is destroyedExample: VOC Destruction for Control Device = 95%VOC Capture Rate = 90%VOC Reduction = 0.95 x 0.90 = 0.855 or 85.5%


TOTAL ENCLOSURE

EPA Guidelines for "TOTAL ENCLOSURE" 1. VOC sources not close to indraft openings.2. Minimum openings in room of less that 5% of total enclosure surface area.3. Minimum indraft air velocity of 200 fpm.4. Access doors and windows closed during routine operation.5. All exhaust points must be directed to a control device.

With "total enclosure," EPA will assume 100% of total capture under these guidelines.


CAPTURING FUGITIVE VOC EMISSIONS

The kinds of equipment needed to capture and convey the waste gas to a control device are:

(1) hoods - used to capture the emissions at the source

(2) ductwork- to convey them to the control device

(3) stacks - to disperse them after they leave the control device

(4) fans - to provide the energy for moving them through the control system


CONTROL DEVICES

The principle devices are: Thermal Oxidation Catalytic Oxidation Condensation Carbon Adsorption


THERMAL OXIDATION

Thermal oxidizers are control devices in which solvent-laden air is preheated and then passed to a combustion chamber In the combustion chamber, volatile organics in the inlet air stream are ignited and combusted to carbon dioxide and water The two main types of thermal oxidizers are recuperative and regenerative Thermal oxidizers device efficiencies range from 98 to 99 percent


CATALYTIC OXIDATION

Catalytic oxidizers, like thermal oxidizers, are control devices in which solvent-laden air is preheated and then passed to a combustion chamber In the combustion chamber, volatile organics in the inlet air stream are ignited and combusted to carbon dioxide and water In the presence of a catalyst, combustion will take place at a lower temperature than that required for thermal oxidizers The catalysts, supported on ceramic or metallic substrates, are metal oxides or precious metals Catalytic oxidizers can achieve control device efficiencies of 95 to 99 percent


CONDENSATION

Condensation is a control technique in which one or more volatile components of a solvent-laden air stream are separated from the remaining vapor through saturation followed by a gas-to-liquid phase conversion (i.e., condensation) The recovered organic components can be reused or sold Refrigeration is often employed to obtain the low temperatures required for acceptable removal efficiencies Removal efficiencies obtained by condensers usually range from 50 to 90 percent.


ADSORPTION

Adsorbers typically use activated carbon as the adsorptive material Adsorber beds are typically operated in parallel so that when the adsorption capacity of one bed is exhausted, it can be removed from service and a second adsorber bed can be put into service Carbon adsorption systems can achieve control device efficiencies between 95 and 99 percent.


HANDLING, STORAGE AND DISPOSAL OF VOCs

Handling – Reduce spills and clean up spills immediately During atomized cleaning of a spray gun, the cleaning solvent must be directed into a waste container fitted with a capture deviceStorage - Store all VOCs and materials impregnated with VOCs in closed containersDisposal - Handle used VOCs as hazardous waste and always keep waste VOCs in closed containers


Remember, You Control Your Facility or Area!

Review Procedures With Them Before Starting the

Job!

Ensure They Are Properly Trained!

Determine Their Environmental Compliance Record!

Determine Who Is in Charge of Their People!

Determine How They Will Affect Your Facility’s

Environmental Compliance!

TIPS FOR USING CONTRACTORS


ELEMENTS OF A SUCCESSFUL UST PROGRAM

1. DETAILED WRITTEN VOC CONTROL INSPECTION

GUIDELINES

2. DETAILED WRITTEN VOC CONTROL BEST

MANAGEMENT PRACTICES

3. EXTENSIVE EMPLOYEE TRAINING PROGRAMS

4. PERIODIC REINFORCEMENT OF TRAINING

5. SUFFICIENT DISCIPLINE REGARDING IMPLEMENTATION

6. PERIODIC FOLLOW-UP


THE IMPORTANCE OF A CLEAN ENVIRONMENT

“I would ask all of us to remember that protecting our environment is about protecting where we live and how we live. Let us join together to protect our health, our economy, and our communities -- so all of us and our children and our grandchildren can enjoy a healthy and a prosperous life.”

Carol Browner Former EPA Administrator

Documents

VOC Controls 1/66 © Copyright Training 4 Today 2001 Published by EnviroWin Software LLC VOLATILE ORGANIC COMPOUNDS CONTROLS CUSTOMIZED ENVIRONMENTAL TRAINING