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METAL SURFACE COATING 1/66
Copyright Training 4 Today 2001 Published by EnviroWin Software LLC.
INSTRUCTOR
Insert Instructor Name Here
OBJECTIVES
Discuss Hazardous Materials Used in Metal Coating and Coating Removal. Define VOC and Explain How to Calculate VOC Content. Discuss the Types of Metal Coatings. Discuss Transfer Efficiency. Give an Overview of Application Technology. Give an Overview of Coating Removal Technology.
GOALS
Understand the Hazardous Materials Used in Metal Coating and Coating Removal. Understand VOC and Understand How to Calculate VOC Content. Be Familiar With the Types of Metal Coatings. Understand How to Improve Transfer Efficiency. Understand Some of the New Available Application Technologies. Understand Some of the New Available Coating Removal Technologies. Be Familiar With Required Logs and Records.
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.
Fugitive Air Emissions, Water Emissions from Poorly Treated Rinsewater, and Solid Waste Generated from Coating and Coating Removal Operations can have a Detrimental Impact on Human Health and the Environment.
LEARNERS
Supervisors
Facility Engineers
Maintenance Personnel Department Managers
Building Occupants
Process Specialists Environmental and Safety Committees
OVERVIEW
The goal of this course is to provide supervisors with the tools needed to help reduce hazardous waste from metal surface coating operations. It recommends practical, actions that can be carried out by facility management, maintenance personnel and building occupants. It also gives an overview of new technology in coating application and removal. The course will help you to integrate good surface coating management activities into your existing organization and identify which of your staff have the necessary skills to carry out those activities.
METAL SURFACE COATING 7/66
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FEDERAL LAWS
Clean Water Act addresses wastewater effluent requirements. RCRA addresses hazardous waste used in metal finishing, including minimization Clean Air Act Amendments address harmful air emissions in coatings EPAs Toxic Release Inventory (TRI) requires businesses to disclose toxic materials at facilities
FEDERAL REGULATIONS
Pertinent Regulations:
40 CFR Part E413 The Effluent Guidelines and Standards for Electroplating 40 CFR Part 59 National Volatile Organic Compound Emission Standards for Consumer and Commercial Products
CADMIUM
Cadmium is a common plating material that has properties superior to other metal coatings in some applications. It displays excellent corrosion resistance and is valued for its natural lubricity or smoothness. It exhibits good corrosion resistance, and meets the salt-spray test requirements of the automotive industry. It can be soldered readily and is toxic to fungus and mold growth. In the past, numerous military specifications have specified the use of cadmium. The major cadmium complex used in electroplating baths is cadmium cyanide, or Cd(CN-24).
METAL SURFACE COATING 14/66
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CYANIDE SOLUTIONS
Sodium and potassium cyanide are used in electroplating bath formulations for the deposition of copper, zinc, cadmium, silver, gold, and alloys such as brass, bronze, and alballoy (copper-tin-zinc). Electroplating baths may also utilize cyanide compounds of the metal being plated, such as copper cyanide, potassium gold cyanide, or silver cyanide. In a well-designed wastewater treatment system, most cyanides can be destroyed through oxidation. Cyanides used in stripping solutions, especially those for stripping nickel, are similarly resistant to oxidation and typically must be disposed of in bulk at a high cost.
COPPER/FORMALDEHYDE SOLUTIONS
Electroless copper deposits are frequently used to apply a conductive base to non-conductive substrates such as plastics. A thin copper deposit provides a base for an additional decorative or functional coating of copper, nickel, etc. One important application is in the coating of printed circuit boards. Formaldehyde, a water pollutant and a suspected carcinogen, is used as the reducing agent in electroless copper baths. Caustic mists resulting from hydrogen evolution and air sparging in the baths present an additional hazard.
CHROMIUM
Decorative chromium plating is almost always applied
over a bright nickel plated deposit, which in turn can be easily deposited on steel, aluminum, plastic, copper alloys, and zinc die castings. Functional chromium plating is normally not applied over bright nickel plating, although in some cases, nickel or other deposits are applied first to enhance corrosion resistance. The main ingredient in all hexavalent chromium plating solutions is chromium trioxide (CrO3). Hexavalent chromium has been linked to cancer in humans following prolonged inhalation, and is toxic to aquatic life at relatively low concentrations.
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WASTEWATER GUIDELINES
The Effluent Guidelines and Standards for Metal Finishing (40 CFR Part 433) are applicable to wastewater generated by any of these operations: Electroplating Electroless Plating Anodizing Coating Chemical Etching and Milling Printed Circuit Board Manufacturing. Discharges from 40 additional processes, including: painting, cleaning, polishing, shearing, hot dip coating, solvent degreasing etc.
METAL SURFACE COATING 18/66
Copyright Training 4 Today 2001 Published by EnviroWin Software LLC.
WASTEWATER GUIDELINES
Chemicals to be monitored include: Cadmium Chromium Copper Silver Zinc Cyanide Total Toxic Organics (TTOs) Oil and Grease TSS pH
METAL SURFACE COATING 19/66
Copyright Training 4 Today 2001 Published by EnviroWin Software LLC.
WASTE HANDLING
Physical processes such as abrasive blasting, grinding, buffing, and polishing do not contribute as much to hazardous waste generation as chemical and electrochemical processes. The most common hazardous waste sources are rinse water effluent and spent process baths. These systems in turn generate solid and liquid wastes that are regulated under the provisions of RCRA.
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Copyright Training 4 Today 2001 Published by EnviroWin Software LLC.
AIR EMISSIONS
The air emissions from many metal finishing processes must be controlled using scrubbing or filtering equipment. These can generate further wastes that must also be treated, disposed, or recycled. Some of the processing solutions used in metal finishing have a finite life, especially conversion coating solutions, acid dips, cleaners and electroless plating baths.
VOC CONTENT
Coatings consist of solids (resin, pigments, extenders, additives) and solvents. Solvents lower the viscosity (reduce or thin), 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 means pounds of VOCs per gallon of coating (lb/gal) or grams of VOCs per liter of coating (G/L), minus water and exempt solvents (exempt solvents do not contain volatile organic compounds).
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 manufacturers recommendations, will meet VOC content limits. The VOC content is generally stated on the label or on the manufacturers paint specification sheet.
TYPES OF COATINGS
Water Borne - Water is the major solvent and includes water reducible and emulsions. These coatings usually include VOCs as co-solvents. UV Curable Coating - Liquid resin and pigment which uses UV light to cure the coating. High Solids - Coatings that contain greater than normal resin and pigment (70 - 80% by volume). Powder - Dry finely ground coating which is usually sprayed dry on an electrically charged surface and is later heated to its melting point so that the powder can flow together (3% VOCs by volume).
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TYPES OF COATINGS
Exempt Solvent based - Coatings that contain exempt solvents, primarily 1,1,1 TCA. These coatings usually include VOC as stabilizers and co-solvents. Electrodeposition - Dip coating process where water borne coatings are electrically "plated-out". Autodeposition - Dipcoat plating process without electrical charge. Catalyzed Coatings - Two or three component coatings which are mixed together prior to application.
PHOTOCHEMICALLY REACTIVE
A photochemcially reactive is any solvent with an aggregate of more than 20% of its total volume composed of chemical compounds classified below: a. A combination of hydrocarbons, alcohols, aldehydes, esters, ethers, or ketones having an olefinic or cycle- olefinic type of unsaturation: 5%. b. A combination of aromatic compounds with eight or more carbon atoms to the molecule except ethylbenzene: 8%. c. A combination of ethylbenzene, ketones having branched hydrocarbon structures, trichloroethylene or toluene: 20%.
TRANSFER METHODS
Coatings and agents containing high VOC concentrations can be applied using the following high transfer efficiency methods: High-Volume, Low-Pressure coating system Electrostatic application Flow coat application Dip coat application Brush coat application Pre-packaged aerosol can application Roll coat application
TRANSFER EFFICIENCY
Transfer efficiency is the percentage of paint solids deposited on the surface of your product. The cost savings in paint consumption when using high transfer efficiency guns is significant. If you achieve 30% transfer efficiency, then 30% of the paint solids sprayed have adhered to the product, and 70% of the paint solids are on your floor, booth walls, and exhaust filters. You can get more paint to stay on the product if you use application methods with transfer efficiencies in excess of 65%, and you buy less paint.
WASTING PAINT
High transfer efficiency saves paint and decreases emissions, thus lowering your costs. High transfer efficiency decreases your booth filter purchases, decreases your booth cleaning expenses, and may decrease your waste disposal costs. Train your painters to maximize their efficiency. Consider racking parts to make overspray land on a part. Make sure automatic spray lines spray the parts and not empty hooks. Spray corners of parts first so overspray hits uncoated areas of the part.
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STORING
Tightly seal all containers of coatings and solvents.
Cans and drums should be equipped with tight fitting lids and should remain closed between uses to prevent evaporation. Large drums should have screw caps to cover the bung holes and should be opened only to empty or fill the drum. Use a pump or funnel when filling and make sure to close the drum completely when you are finished. Use new funnels that screw into the bung of drums and have a lid that clamps down on top of the funnel for a tight seal.
SURFACE PREPARATION
Preparing a surface may entail using a solvent degreaser. Alternatives to solvent degreasing include using abrasives, water with surfactants, exempt solvents, alkaline washes, or acid etches. Switching from solvent cleaners to other surface preparation methods can save money and reduce disposal costs.
CLEANING UP
VOCs from your facility can be reduced significantly by cleaning your spray guns and other equipment properly. Never clean your lines by spraying solvents into the air or into the filters. Always direct the clean-up solvents, using minimal pressure, into containers to prevent evaporation. Remove atomization tips, soak and/or use a brush to clean the tip, then flush solvent through the gun (without the tip) into a container which is immediately sealed. Soak spray guns in closed containers and avoid the use of VOCs for clean-up whenever possible.
LOGS
Keep detailed records of the coatings applied at your facility. Monthly logs should detail the products purchased, including the name and number of the product, and the amount of product purchased, with the appropriate unit indicated (i.e., gallon, quart, pint). Remember that inspectors look for accurate records. One proven method of record keeping involves the use of job tickets and a summary log. Many facilities instruct the operator to record coating information for each job on a production ticket at the booth. The job tickets are then summarized nightly by the supervisor.
APPLICATION TECHNOLOGY
Non-Cyanide Copper Plating Non-cyanide copper plating is an electrolytic process similar to its cyanide-based counterpart. Operating costs for the bath itself are higher for the non-cyanide process than the cyanide process. Non-cyanide copper plating benefits: Greatly reduces safety risks to workers. Greatly reduces the costs and complexity of treating spent plating solutions. Smaller risk to hydrogen cyanide exposure. Plating solution does not have to be treated for carbonates.
METAL SURFACE COATING 41/66
Copyright Training 4 Today 2001 Published by EnviroWin Software LLC.
APPLICATION TECHNOLOGY
Zinc-Alloy Electroplating Both zinc and zinc-alloy electroplating processes are very common and have a long history in the electroplating industry. Recently these processes have been considered as possible replacements for cadmium coatings. Benefits of zinc and zinc-alloy Eliminates workplace exposure to cadmium and cyanide. Corrosion resistance as good as cadmium. Better wear resistance than cadmium. Zinc-cobalt deposits show good resistance to atmospheres containing SO2.
APPLICATION TECHNOLOGY
The Blackhole Technology Uses an aqueous carbon black dispersion at room temperature for preparing through-holes in printed wire boards for subsequent copper in the through-holes. Benefits of Blackhole Technology Process Simplification - requires fewer process steps as well as associated chemicals and rinses. Contamination Reduction - does not use formaldehyde. Ease of Implementation - uses existing equipment in an electroless copper process line. Acceptable Product Quality - accepted under MIL-P-5511OD. Lower Operating Costs
APPLICATION TECHNOLOGY
Ion Vapor Deposition of Aluminum (IVD) In IVD, the coating metal is evaporated and partially ionized before being deposited on the substrate. A typical IVD system consists of a steel vacuum chamber, a pumping system, a parts holder, an evaporation source, and a high-voltage power supply. Benefits of this technology Health and safety risks can be greatly reduced when IVD is used in place of cadmium electroplating. The greatest advantage of aluminum IVD is that the process significantly reduces the generation of hazardous wastes, and potentially eliminates the need for special pollution control systems.
APPLICATION TECHNOLOGY
Physical Vapor Deposition (PVD) A thoroughly cleaned workpiece is placed in a vacuum chamber, and a very high vacuum is drawn. The chamber is heated to between 400o and 900o F. A plasma is created from an inert gas such as argon. The workpiece is first plasma-etched to further clean the surface. The coating metal is then forced into the gas phase by either evaporation, sputtering or ion plating. Benefits of PVD PVD results in a thin, uniform coating that is much less likely to require machining after application. PVD titanium nitride coatings have already gained wide acceptance in the cutting tool industry.
APPLICATION TECHNOLOGY
Chromium-free Surface Treatments for Aluminum and Zinc Chromium-free surface treatments for aluminum and zinc are relatively new. One of the few commercially proven, non-chromate surface treatments for aluminum is an inorganic conversion coating based on zirconium oxide. A recent chrome-free post-rinse process has been developed for use on phosphated steel, zinc, and aluminum surfaces prior to painting. The new rinse, known as Gardolene VP 4683, contains neither hexavalent or trivalent chrome. It contains only inorganic metallic compounds as the active ingredient.
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Copyright Training 4 Today 2001 Published by EnviroWin Software LLC.
APPLICATION TECHNOLOGY
Metal Spray Coating Molten Metal -The metal is heated by some suitable means (either resistance heating or a burner) and then supplied to the atomizing source in molten form. Fuel/Oxidant - Oxygen/acetylene flames are typically used. The metal melts as it is continuously fed to the flame in the form of a wire or powder. Electric arc - In this method an electric arc is maintained between two wires that are continuously fed as they melt at the arc. These technologies for thermal spraying of metals are well developed, but they tend to have their own market niche and are not typically thought of as a replacement for electroplating.
RECORDKEEPING
Accurate recordkeeping helps to ensure that you operate in daily compliance. Daily recordkeeping has several other advantages as well. Your records tell you how much paint you use each day. You will have an accurate record of production expenses which can enable you to cut costs. If you have an approved Notice of Construction, it may include a limitation on annual coating usage. Do not paint more than you are allowed. Modify your production schedule to avoid penalties. Be careful with multiple shifts. If you cannot modify your daily production, contact your air district.
SELF- INSPECTIONS
1. If your facility coats light duty automobiles, do the coatings used have the appropriate/compliant VOC levels? ___Yes ___No ___NA
2. Does your facility only apply coatings with less than 0.1% lead and hexavalent chromium? ___Yes ___No ___NA 3. If you coatings contain more than 2.1 Lb/Gal or 250 G/L VOC, do you only use approved application methods as outlined in your air districts regulations (i.e. HVLP gun)? ___Yes ___No ___NA
SELF- INSPECTIONS
4. Does all surface coating take place in a booth or room equipped with a particulate control system capable of capturing all visible overspray? ___Yes ___No ___NA 5. Does your paint booth or room exhaust through an unobstructed vertical stack (no caps, elbows, etc.)? ___Yes ___No ___NA
6. Is your spray gun totally enclosed during clean-up, or is solvent flushed through the gun into a container which is immediately sealed? ___Yes ___No ___NA 7. Are all coating and solvent containers tightly sealed when not in use? ___Yes ___No ___NA
SELF- INSPECTIONS
8. Are all solvent containing wastes stored in tightly sealed containers until disposal? ___Yes ___No ___NA
9. Are solvent rags kept in tightly sealed containers when not in use? ___Yes ___No ___NA
10. Are spills of solvent containing material cleaned up upon discovery? ___Yes ___No ___NA
11. Are the most current MSDS kept for materials used, and are they available upon request? ___Yes ___No ___NA 12. Are records of purchases/usages and waste disposal kept for the previous 24 months of operations and available on site? ___Yes ___No ___NA
SELF- INSPECTIONS
13. Are fugitive emissions from prep work controlled? ___Yes ___No ___NA
14. Are you properly operating your pressure drop gauge (i.e., is it checked to insure that it is zeroed before the booth is turned on)? ___Yes ___No ___NA 15. Are filters seated in filter housing such that there are no gaps between the filter and the housing? ___Yes ___No ___NA
16. If you operate a water wash booth, is the water level maintained to adequately filter exhaust air? ___Yes ___No ___NA
SELF- INSPECTIONS
17. If you operate a water wash booth, is the water curain continuous all the way across the booth wall with no flow inconsistencies or gaps? ___Yes ___No ___NA
18. Are visible emissions and overspray NOT observed from the exhaust stack? ___Yes ___No ___NA 19. Are you performing pressure drop readings, filter changes, visual observations of filter media condition, and other manufacturer-recommended booth maintenance? ___Yes ___No ___NA 20. Are all maintenance activities recorded on a maintenance log? ___Yes ___No ___NA
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