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The versatility of powder coatings
FOCUS ON P O W D E R C O AT I N G S A MONTHLY REPORT FROM SID HARRIS
THE VERSATILITY OF POWDER COATINGS
MAY 2012 In this issue
TECHNICAL
2
Thermal spraying of thermoset powder coatings
INDUSTRY NEWS
2-4
BASF’s Coatings Division launches a new website Ecology Coatings enters into a licence agreement with BASF Coatings Cytec announces price increase for powder coating resins in the Americas, Europe, the Middle East and Africa
NEW PRODUCTS
4-5
Oxford Advanced Surfaces unveils its new technology BASF patents colour effect materials Dupont-Mitsui Fluorochemicals patents non-stick coating
MARKETS
AN INTERNATIONAL NEWSLETTER MONITORING TECHNICAL AND COMMERCIAL DEVELOPMENTS IN POWDER COATINGS ISSN 1364–5439
5-8
Dow Corning Coatings plans further business growth in Middle East-Africa region (MEA) through Univar distribution agreement expansion Surfactants update
In the early nineteen seventies, when we were seeking to establish thermosetting powder coating as a viable contender to existing industrial coatings, there was little evidence at that time to support its technical qualities, and it would take many years for this new concept to achieve maturity. The European Community was also in its infancy as a free trade agreement zone between contributing countries, and an offshoot of this collaboration was closer attention to health and safety matters within this community. Increasing awareness of the steady growth in global air pollution and the citing of industrial coatings as the second largest air polluter gave powder coatings the boost of legislation support as the prime non-polluter of volatile organic compounds (VOCs). It has taken forty years, during which the technical maturity of powder coatings was achieved by the end of the old century, to provide powder producers with a level playing field to meet the competition of alternative industrial coatings. No-one could have predicted the severe economic pressures of the first decade of the new century; price increases in energy and raw materials, plus the added pressures of global warming and waste disposal charges that are often higher than the initial cost of
the waste material. These factors have had a similar effect on powder coatings. However the recent developments of low temperature curing thermoset powders and the introduction of UV curable powder systems, offering reduced process times and energy savings, coupled with the almost 100% utilisation of applied powder coatings and little or no waste, have now given powder coatings attractive cost savings compared to other coatings technologies. Global demand has ensured that our economic future will continue to suffer from increasing application costs, which will favour the growth of powder coatings. There is also evidence in the industry literature that liquid coatings are being asked to further reduce their VOC levels and the emission of decomposition products during ageing. In Dubai, it is reported that paint and coatings on buildings are to be subjected to tests to ensure that they are safe for human health and meet green building standards (p 4). The pressure on liquid coatings is never-ending! The capability to spray thermosetting powder coatings to large components and structures on-site has long been a prime objective because of the excellent chemical and corrosion resistance of these materials and the
POWDER COATINGS POWDER COATINGS POWDER COATINGS POWDER COATINGS
FOCUS potential for applying thick protective films in one coat. There have been a number of field trials in the past, particularly for protecting the welded seams of pipelines after the factory precoated lengths of pipe are connected on-site, and for repairing welded sections in chemical plant construction, but the major problem has been to ensure that the applied coating is uniformly cured. Solvent resistant tests on thick coatings have proved to be unreliable as a nondestructive method for assessing cure on these items. The abstracted article in this issue (p 2) offers the possibility that this might be achieved by flame spraying application methods if the process parameters can be optimized by computer simulation techniques. Is there no end to the versatility of powder coatings? Sid Harris
TECHNICAL Thermal spraying of thermoset powder coatings Thermal spraying is a widely used technique for the on-site coating of large components and structures with thermoplastic coatings, but little attention has been given to applying thermoset powder coatings. A team drawn from several London UK universities has now published the results of its recent work, which examines the possibility of thermal spraying of thermosetting powder coatings. If this is possible, then the feedstock particles will have to melt in the flame without degradation, and the coating must be cured by the end of the deposition process. Particle residence time in the flame during deposition is less than 0.01 seconds and thermosetting powder coatings invariably need both high temperatures and residence time 2
ON
POWDER
to achieve satisfactory cure. It is, however, possible that the deposited thermoset coating will receive additional heat from the scanning flame during deposition. Since this would be a variable factor, the researchers have examined the interactions between the flame, coating and the substrate. They used computer simulations aimed at controlling the temperature profiles of the thermosetting powder deposits to ensure that adequate cure can be obtained. They developed computer software to simulate flame scanning and post heat treatment, and they also applied commercial software to simulate steady-state infrared heating. It was found that process parameters have a critical effect on coatings properties and these can be optimized by the use of computer simulations. The thermal conductivity of the polymers is much lower than that of the metal substrates. Epoxy, nylon and steel have thermal conductivities of 0.19, 0.24 and 51.9Wm-1K-1 respectively, which results in slower heat flow from the hot surface and higher temperatures at the surface of the polymer particles during flame application, making it difficult to maintain temperature of the polymer below its decomposition temperature. Another consequence of the thermal gradient within the thermoset polymer is non-uniform curing that would drastically affect film properties. A possible solution could be post heating after application by flame scanning or infrared irradiation. An interesting and well presented paper in which the effect of substrate thickness and heating power were simulated so that the temperature of both coating and substrate can be controlled to provide adequate curing of the thermoset powder coating. Article entitled “Process Modelling of Thermal Spraying for Thermoset Coatings”. Original Source: Progress in Organic Coatings, Feb/Mar 2012, 73 (2-3), 225-231 (Website: http://www.sciencedirect.com) © Elsevier BV 2012
C O AT I N G S
INDUSTRY NEWS BASF’s Coatings Division launches a new website BASF’s Coatings Division has unveiled a redesigned website at www.basfcoatings.com. The userfriendly website provides detailed information on the firm’s paints and coatings. Original Source: Coatings World, Feb 2012, 17 (2), 10 (Website: http://www.coatingsworld.com/) © Rodman Publishing 2012
Ecology Coatings enters into a licence agreement with BASF Coatings GmbH Ecology Coatings Inc has inked a licence agreement with German firm BASF Coatings GmbH. Under the deal, BASF has a nonexclusive licence to use Ecology Coatings’ EP 1 723 180, US 7,323,248, US 7,153,892 and US 7,498,362 patents covering novel UV-curable coatings. In exchange, BASF will give Ecology Coatings a royalty fee of 0.5% of the net sales value of products using EP 1 723 180 sold in Europe, and a royalty fee of 2.5% of the net sales value of products sold outside of Europe. Original Source: Coatings World, Feb 2012, 17 (2), 16 (Website: http://www.coatingsworld.com/) © Rodman Publishing 2012
Cytec announces price increase for powder coating resins in the Americas Cytec Industries Inc and its affiliated companies have announced to customers a selling price increase on all powder coating resins (Crylcoat powder resins, Additol powder resins additives, Modaflow additives and resins and Uvecoat powder resins) sold in North America and Latin America. The increase will be between $0.10/lb- $0.12/lb and will be effective for shipments on MAY 2012
THE VERSATILITY OF POWDER COATINGS
MAY 2012 In this issue
TECHNICAL
2
Thermal spraying of thermoset powder coatings
INDUSTRY NEWS
2-4
BASF’s Coatings Division launches a new website Ecology Coatings enters into a licence agreement with BASF Coatings Cytec announces price increase for powder coating resins in the Americas, Europe, the Middle East and Africa
NEW PRODUCTS
4-5
Oxford Advanced Surfaces unveils its new technology BASF patents colour effect materials Dupont-Mitsui Fluorochemicals patents non-stick coating
MARKETS
AN INTERNATIONAL NEWSLETTER MONITORING TECHNICAL AND COMMERCIAL DEVELOPMENTS IN POWDER COATINGS ISSN 1364–5439
5-8
Dow Corning Coatings plans further business growth in Middle East-Africa region (MEA) through Univar distribution agreement expansion Surfactants update
In the early nineteen seventies, when we were seeking to establish thermosetting powder coating as a viable contender to existing industrial coatings, there was little evidence at that time to support its technical qualities, and it would take many years for this new concept to achieve maturity. The European Community was also in its infancy as a free trade agreement zone between contributing countries, and an offshoot of this collaboration was closer attention to health and safety matters within this community. Increasing awareness of the steady growth in global air pollution and the citing of industrial coatings as the second largest air polluter gave powder coatings the boost of legislation support as the prime non-polluter of volatile organic compounds (VOCs). It has taken forty years, during which the technical maturity of powder coatings was achieved by the end of the old century, to provide powder producers with a level playing field to meet the competition of alternative industrial coatings. No-one could have predicted the severe economic pressures of the first decade of the new century; price increases in energy and raw materials, plus the added pressures of global warming and waste disposal charges that are often higher than the initial cost of
the waste material. These factors have had a similar effect on powder coatings. However the recent developments of low temperature curing thermoset powders and the introduction of UV curable powder systems, offering reduced process times and energy savings, coupled with the almost 100% utilisation of applied powder coatings and little or no waste, have now given powder coatings attractive cost savings compared to other coatings technologies. Global demand has ensured that our economic future will continue to suffer from increasing application costs, which will favour the growth of powder coatings. There is also evidence in the industry literature that liquid coatings are being asked to further reduce their VOC levels and the emission of decomposition products during ageing. In Dubai, it is reported that paint and coatings on buildings are to be subjected to tests to ensure that they are safe for human health and meet green building standards (p 4). The pressure on liquid coatings is never-ending! The capability to spray thermosetting powder coatings to large components and structures on-site has long been a prime objective because of the excellent chemical and corrosion resistance of these materials and the
POWDER COATINGS POWDER COATINGS POWDER COATINGS POWDER COATINGS
FOCUS potential for applying thick protective films in one coat. There have been a number of field trials in the past, particularly for protecting the welded seams of pipelines after the factory precoated lengths of pipe are connected on-site, and for repairing welded sections in chemical plant construction, but the major problem has been to ensure that the applied coating is uniformly cured. Solvent resistant tests on thick coatings have proved to be unreliable as a nondestructive method for assessing cure on these items. The abstracted article in this issue (p 2) offers the possibility that this might be achieved by flame spraying application methods if the process parameters can be optimized by computer simulation techniques. Is there no end to the versatility of powder coatings? Sid Harris
TECHNICAL Thermal spraying of thermoset powder coatings Thermal spraying is a widely used technique for the on-site coating of large components and structures with thermoplastic coatings, but little attention has been given to applying thermoset powder coatings. A team drawn from several London UK universities has now published the results of its recent work, which examines the possibility of thermal spraying of thermosetting powder coatings. If this is possible, then the feedstock particles will have to melt in the flame without degradation, and the coating must be cured by the end of the deposition process. Particle residence time in the flame during deposition is less than 0.01 seconds and thermosetting powder coatings invariably need both high temperatures and residence time 2
ON
POWDER
to achieve satisfactory cure. It is, however, possible that the deposited thermoset coating will receive additional heat from the scanning flame during deposition. Since this would be a variable factor, the researchers have examined the interactions between the flame, coating and the substrate. They used computer simulations aimed at controlling the temperature profiles of the thermosetting powder deposits to ensure that adequate cure can be obtained. They developed computer software to simulate flame scanning and post heat treatment, and they also applied commercial software to simulate steady-state infrared heating. It was found that process parameters have a critical effect on coatings properties and these can be optimized by the use of computer simulations. The thermal conductivity of the polymers is much lower than that of the metal substrates. Epoxy, nylon and steel have thermal conductivities of 0.19, 0.24 and 51.9Wm-1K-1 respectively, which results in slower heat flow from the hot surface and higher temperatures at the surface of the polymer particles during flame application, making it difficult to maintain temperature of the polymer below its decomposition temperature. Another consequence of the thermal gradient within the thermoset polymer is non-uniform curing that would drastically affect film properties. A possible solution could be post heating after application by flame scanning or infrared irradiation. An interesting and well presented paper in which the effect of substrate thickness and heating power were simulated so that the temperature of both coating and substrate can be controlled to provide adequate curing of the thermoset powder coating. Article entitled “Process Modelling of Thermal Spraying for Thermoset Coatings”. Original Source: Progress in Organic Coatings, Feb/Mar 2012, 73 (2-3), 225-231 (Website: http://www.sciencedirect.com) © Elsevier BV 2012
C O AT I N G S
INDUSTRY NEWS BASF’s Coatings Division launches a new website BASF’s Coatings Division has unveiled a redesigned website at www.basfcoatings.com. The userfriendly website provides detailed information on the firm’s paints and coatings. Original Source: Coatings World, Feb 2012, 17 (2), 10 (Website: http://www.coatingsworld.com/) © Rodman Publishing 2012
Ecology Coatings enters into a licence agreement with BASF Coatings GmbH Ecology Coatings Inc has inked a licence agreement with German firm BASF Coatings GmbH. Under the deal, BASF has a nonexclusive licence to use Ecology Coatings’ EP 1 723 180, US 7,323,248, US 7,153,892 and US 7,498,362 patents covering novel UV-curable coatings. In exchange, BASF will give Ecology Coatings a royalty fee of 0.5% of the net sales value of products using EP 1 723 180 sold in Europe, and a royalty fee of 2.5% of the net sales value of products sold outside of Europe. Original Source: Coatings World, Feb 2012, 17 (2), 16 (Website: http://www.coatingsworld.com/) © Rodman Publishing 2012
Cytec announces price increase for powder coating resins in the Americas Cytec Industries Inc and its affiliated companies have announced to customers a selling price increase on all powder coating resins (Crylcoat powder resins, Additol powder resins additives, Modaflow additives and resins and Uvecoat powder resins) sold in North America and Latin America. The increase will be between $0.10/lb- $0.12/lb and will be effective for shipments on MAY 2012