The coatings and polymer industry requires continuous innovation to enable sustainable and environmentally friendly materials processes and coating systems. Providing continuous improvement in sustainability requires the development and implementation of new science and technologies to minimize waste, save energy, lower VOC, reduce hazardous waste, incorporate nonhazardous materials to replace questionable items, use renewable raw materials where possible and minimize water and air pollution. Advances in Smart coatings, Nano coatings and heavy metal free alternatives to hexavalent chrome has fueled many of these advances along with the development and implementation of biobased renewable materials. In multiple cases, new technologies provide a triad of economic, environmental and social benefits.
Economic Sustainability
Examples of economic sustainability possible through the use innovative coatings and materials to provide energy savings, and/or improve the life expectancy of the coated object include:
- Energy savings through the use of solar reflective coatings to reduce solar absorption and reduce air conditioning costs by as much as 15%.
- Superhydrophobic Aerospace primers and topcoats provide self-cleaning, icephobicity coupled with enhanced corrosion resistance without the use of Hexavalent chrome in the primer. This extends the lifetime of the coating and the exterior painted surface of the aircraft.
- Icephobic coatings utilizing nano materials on wind mill blades reduce the resistance to erosion and improve operating efficiency.
- Long Life Coatings (automotive, building products, aerospace) provide longer lasting film integrity and thus material and labor savings over the lifetime of the product or building. Advances in visible and UV light stabilizers and antioxidants coupled with innovations in polymer and pigment technologies have made this possible.
- Hydrophobic and Superhydrophobic coatings using nanomaterials for application on structural steel, and oil rigs to delay the onset of corrosion by limiting the migration of moisture and soluble salts to the metal surface. These coatings reduce the need for more frequent repainting which in turn reduces volatile emissions.
Environmental Sustainability
Environmental sustainability involves the use of materials that reduce the impact on health and safety, reduction in emissions, recyclability of paint/materials, use of renewable energy, conservation of water and alternatives to the dependency on fossil fuels that minimize hazardous emissions from fossil fuels. Lastly, the use of eco-friendly paints as well as bio-based renewable materials together provide a sustainable environment. Some of these initiatives are described below.
- Environmental Health and Safety concerns include alternatives to the use of PFAS (polyfluoroalkyl substances) in paints which are used in a wide variety of applications in paint due to their properties which include longevity, low surface tension, fire repellency and inertness. The US has multiple laws and regulations concerning PFAS, the latest went into effect in April 2024 (National Primary Drinking Water Regulations) and in February 2024 the US FDA announced that manufacturers are no longer selling certain substances containing PFAS for food contact use. There are also regulations contained in REACH as well as in Canada.
From a historical standpoint, these materials are used in a wide variety of applications including surfactants, catalysts, defoamers, polymers and solvents. However, their inertness and stability results in their classification as “forever chemicals” as PFAS can accumulate in the blood and organs of people and animals and is thought to be linked to increased cholesterol, and changes in hormone and the immune system, increased risk of certain cancers and decreased fertility. Some materials that are touted to be acceptable replacements in polymers include polydimethylsiloxane and TMS-PDMS as well as a range of other low surface tension additives for improved leveling, defoaming and improved wetting. Silanes which contain long alkyl side chains offer the advantage of low surface tension properties and provide hydrophobicity and offer another viable alternative to PFAS substances.
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Antimicrobial Coatings possess antibacterial, antiviral, and antifungal properties to eliminate bacteria, viruses, molds and fungi. These coatings are used on an increasing basis especially in the health care, medical and hospital settings. These coatings are used in a variety of applications including HVAC systems and for mold control, food and beverage, packaging, automotive and appliance.
Reduction in emissions is obtained through multiple initiatives including:
- Conversion to lower or zero VOC paints such as waterborne, powder, UV/LED and EB, higher solids and 100% solids coatings.
- Emission control
- Regenerative Thermal Oxidizers (RTOs) that destroy VOCs at elevated temperature. Incineration of volatiles.
- Adsorption, Absorption or Condensation to capture VOCs
- Utilize VOC exempt solvents listed by the US EPA include acetone, dimethyl carbonate, methyl acetate, T-butyl acetate, Propylene carbonate, 2-amino-2-methyl-1-propanol (AMP) and parachlorobenzotrifluoride. EPA Exempt solvents are determined to have low photochemical reactivity based on approved test methods which would have a limited local and regional effect on ozone pollution. As reported in my first Sustainability article in February 2024, for waterborne formulations, Eastman Optifilm™ Enhancer 300 or 400 contribute little or no VOC as a coalescent solvent. Their low VOC is attributed to a very low volatility (low vapor pressure and a boiling point >700° F for Optifilm™ Enhancer 400 and 537.8° F for Optifilm™ Enhancer 300). These materials can be used in multiple applications including Architectural finishes, Can and Coil coatings, General Industrial, Maintenance and Wood coatings.
- Please see the first article “The synergy between Economic, Environmental and social Considerations” released in Prospector in February, 2024 for details and examples of renewable and biobased materials derived from multiple renewable plant-based sources can provide solvent, oil and other building blocks for utility as biobased solvent or monomer and polymer synthesis for acrylic, alkyd and polyester synthesis.
Social Sustainability – Implementing responsible Environmental and Economic sustainable processes ensures prolonged availability of our natural resources, less emissions, cleaner water, improved health, slowing climate change, fewer and less severe natural disasters and less loss of biodiversity.
Resources
- UL Prospector – Sustainability Part 1 Article Feb. 2024 – The synergy between Economic, Environmental and social Considerations.
- UL Prospector – Smart Coatings, The intelligent Choice
- ACA 2024 Sustainability Report
- PCI – Biobased Polymers for Sustainable Coatings
- GOOGLE and AI Internet Search for Sustainability and Biobased Materials
- EPA – Cool Roofs to Reduce Heat Islands
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