AIIMilCHI COATI]IGS

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IIew formulations allow industries to euolue,
and reduce lahol costs and environmentalconcerns
hanging markets and new applications are putting more demands on the protective coatings industry than ever before.
While developing enronmentally

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 presented by today's changing chemical

process industries (CPI), as well as
modern construction and other engi-

neering capabilities.

'Reduction of VOCs [volatile organic compoundsl and labor costs

will always be sought afl,er goals in
the protctive 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 scientist with Dow Coming (Midland,
Mich.; www.dowcorning.com).

New applications
"Enormous structures, such as mega
s\iscrapers and wind turbine farms,
especially those in the middle of the
ocean, not only have the initial challenging performance requirements,
but also, the owners don't want to
send someone up or out to rcpaint
them," explains Witucki. "They need
a protective coating that will last for
decades, which

is placing demands

on coatings that simply haven't existed in the past."

In addition, he says, even everyday 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 becoming cost prohibitive in today's
competitiveeconomicenvirnment.
And, in many industries, temperatures 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 emission control, they may tum up the FIGURE l. Slvance's C1008 is a slcone
curative that improves the durable flexlbllity
heat in a catallic converter to en- of epoxy polyslloxane protective
topcoats n
sure complete combustion, so they marne and nfrastfucture appllcatlons
are looking for coatings that provide longerJasting performance at U.S. patents using silicone-organic
higher temperatures," says Witucki.
hybrids, to the point where 107o of
"It costs a lot in lost production all U.S. paint parenrs as of2013 intime and labor to have someone re- corporated silicone-organic hybrid
paint, so between labor costs, shut technology," notes Witucki.
dowr costs and environmental costs,
Jeff Jones, business development
the actual cost ofthe paint or coating director with SiVance, LLC, a subis no longer the primary consider- sidiary of Milliken & Co. (Gainesation fo the end user," says Witucki. ville, Fla.; www.sivancellc.com),
"They are willing to absorb the cost agrees that new ingredients are the
ofa more expensive paint ifit means key to developing better coatings for
it wont have to be applied as oten." changing applications. "In the oilHe says. in [he past, organic and-gas industry especially, they
resins were the "go-to" coating for are seeking protective coatings that
many ofthese applications, but with are more durable to higher temperamore demanding criteda, the exist- tures. higher pressuues and nastier
ing formulations were not working mixes of chemicals at those higher
as well, so coatings manufacturers temperatures than ever before," he
started seeking new ingredients says. "In these applications, they
and additives that would boost the were finding a lot of the coatings
durability and life of their coatings. they had been using for tank and
Dow Coming, s ays Witucki, strives pipe linings were just not durable
to create materials, such as silicone- enough for the higher temperatures
organic hybrids, which possess and new mixtures ofchemicals they
greater thermal stability and better are seeing today." One ofthe reasons
chemical resistance when added to is that the products resulting from
coating formulations. "We've seen hydraulic fiacturing are very differa steady increase in the number of ent and more corrosive than the traCHEMICAL 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 becomes 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 determine what was causing failure
under new operating conditions and
adjust the chcmistry accordingly to
avoid those failures. The company
started by examining the issues exhibited by structural coatings.
'1Ve are a silicones producer and
we realized that many ofthe protective coatings for structural applica-

tions were epoxy-based

because

epoxy provides excellent adhesion

and corosion resistance at a low
cost. However, silicones are outstanding for weatherability, fl exibility 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 allows 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 rst 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 applications, without sacrificing weatherability. 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) eqpmenL. lt uses a proprietary molecular structure that prodes enhanced compatibility in epoxy
systems. The product is firlly miscible

with hydrogenated bisphenol -A-epoxy

resir:s. The compability ol C1008 in
other epoxy resins is possible with the

24

CHEMICALENGINEEBING

FIGUBE 2, Seres 391 Tank Armor from Tnemec s a chemcal-resstant formulation

for use in severe chemcal-mmerson envronments
use ofsolvents or reactive diluents.
Jones says the company is preparing to lau:rch a second product that

gas service industries, such as rapid

will provide rnore compatibility with

the epoxy coatings most comrnonly
used in the oil-and-gas industry

ties, ease of application arrd physical

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 durable protective coatings for today's
oi1-and-gas industry that are more
environmcntally iiendly, says Gary
industrial
Zinn, director of sales
markcts, with Tnemec-Co. (Kansas
Clty, Mo.; www.tnemec.com). "In the
past, a 1ot of the tankJining materials contained solvents and VOCs.
Today's technology needs to be 1007

solids with little to no VOCs or solvents, yet still provide excellent

t ransfer, high-build charact eristics
and protection from today s heavier
and higher-sulfur-content crude."

rcturn to service, one-coat application, fast-cure, high-build capabilipropcrties for long-tenn durability,"
says Zinn. "It also offers excellent
corrosion protection against hyo-

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 industry. 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 application processes.
One such development is the CoCure coating process from Henkel 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

a
transpofl tanks containing chemical blends or acids used in hydrau1ic fracturing (Figure 2). Series 391
Tank Amor is a chemical-resistant

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-

lormulation for use in severc chemical-immersion environ ments. "Series

391 Tank Armor meets the requirements of customers in thc oil and

rations,"explains OmarAbu-Shanab,
technical director with Henkel. "The
second layer is applied and both layers are Co-Cured and chemically

In

response, Tnemec, introduced

I00% solids epoxy liner lor use in

WWW,CHEIVENGONLINE,COI\,1

DECEIUBER2014

crosslinked in a single oven."

"This ptocess is unique to our coat-

ings," says Mike Berger, business

development manager with Henkel.
"Many other coatings reqre users
to wholly cure the primer before the
top coat can be applied, which requircs two ovens and much longer
durations of time at higher temperatures. In new applications, end users
can employ a shorter oven, which
results in lower equipment costs. In

existing lines, thev can tun down

the oven temperature and reduce
the time and save energy."
The Co-Cure process carr be used

with Bonderite M-PP 930 Autodeposition Coating. The coating delivers

enhanced conosion pedormance in
applications such as vehicle frames
and chassis components, construction equipment and appliances (Figure 3). The enronmentally sustainable coating contains no toxic heavy
metals and is very low in VOCs.

In addition to its environmentally

friendly proEle and application

FIGUBE 3. Bonderite M-PP 930 Autodeposition Coatlng from Henkel delivers

enhanced coroson performance ln applqatons such as vehicle rrames and
chassls components

process, the coating was developed

for use on difficult-to-coat reactive

substrates where traditional protectants could not provide a uniform coating, which often resulted

in

exposure

to

corrosion through

microscopic pinholes. Bonderite

FIGURE 4. Cortec's Ecosonc Confomal

Coatlng powered by Nano.Vpcl for use as a
crcut-board conformal coatng comblnes
molsture-intruson preventlon and corrosion
resstance wiih the company's Vapor-phase
Corroslon lnhibitor (VpCl) technology

ultraflltration, no ectiers, no electrodes and fewer stages

the coat-

ing is expected to last 5 -to 10 years

under exteme corrosion conditions,
says Henkel's Abu-Shanab. This
combination ofthe shorter cure time
and the reduction in maintenance

M-PP 930C
issues appli'addresses
cators face when
coating cast substrate by eliminating surface voids
and outgassing, which contribute to
improved corrosion properties. Be-

Berger, which is another demand on

toda/s protective coatings.

cause Bonderite M-PP 930 provides

uniform coverage with lower maintenance requirements
there is no

www.corteccvci.com) also saw an

opportuniry to improve several pro-

results

in lower labor costs,

says

Cortec Corp. (St. Paul, Minn.;

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2014 25

regarding the rnechanical removal of

old paint, corrosion, insulation and
other barricr materials," he explains.

tective coatings by making them

both more environmentally friendly
and less labor intensive. For example, the Ecosonic Conforral Coating powered by Nano-VpCI fbr use
as a circuit-board conformal coating
combines moisture-intrusion prevention and corrosion resistance

with the

"To address this issue, we developed

a novel corrosion convcrsion coating that eliminates the need to mechanically rernove corrosion in most
circumstances. This is subsequently
combined with a water-based coating system that can increase the life
of a str-rcture substantially."

companv's Vapor-phase

Corrosion Inhibito (VpCI) technology (Figure 4). It contains an optical

Cortec's VpCI CorrVerter Rust

Primer is a water-based primer for
application to msty or poo prepared steel surfaces where further
corrosion protection is rcquired and
good surfacc preparation is difficult
to achieve. The primer is formulated to penetrate rust, eliminate
rust, pcnetrate to bare metal and
stop further rtLsting.
The chemical chclating agent
modifres thc surface rust into a hydrophobic passive layer. VpCI Cor-

identifier visible with ultraviolet

light, assuring rapid and effectivc

visual confirmation of proper coating on surfaces. The coating is VOCfree, fast-drving and a single-componenl formulation. which is easier
to use than two-component coatings,
eliminating the need for special metering and mixing equipment.
Coltec sa\/ another opportunity
to help cuslomers reduce labor costs
in the area of structural restoration.
says Cliff Cracauer, vice president of
salcs with Cortec. "In tl:e restoration
industry, there are great restrictions

rVerter combines the chclating agent

with low water-vapor permeability.

The combination ofthe active chelat-

ing agent with a frlm-forming latex,

thickeners and spersant offers

a unique formulation for a primer
h protection againsl, re-rusting.
"This product eliminates the need
to mechanically treat a metal surlace using sand blasting or dry ice
w il

blasting, which meets the market

needs to reduce labor while subslanlilly increasing the life of a
structure," says Cracauer.
'As we come up with these new
environmental and labor requirements, as well as new applications

and capabilities that allow us to

build higher, dig deeper or run hotter, we have to realize that it's not
the ability to engineer the pipe or
the skyscraper that allows these
projects, it's the coating that protects the pipe or the skyscraper that
is truly the enabling technology,"
notes Dow Corning's

with a high-solids waterborne latex

Witucki. I

JoY LePree

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