for the Paint and Adhesive Application in Germany -Volume I

508 Pages·2002·2.72 MB·German

Deutsch-Französisches Institut für
Umweltforschung (DFIU)
Karlsruhe – Strasbourg
o. Prof. Dr. O. Rentz
Prof. Dr. L. Zilliox Institut Franco-Allemand de Recherche sur
l’Environnement (IFARE)
Best Available Techniques (BAT) for the Paint- and
Adhesive Application in Germany
-Volume I: Paint Application-
Deutsch-Französisches Institut für Umweltforschung (DFIU)
Universität Karlsruhe (TH)
o. Prof. Dr. O. Rentz
N. Peters, S. Nunge, J. Geldermann, O. Rentz
Karlsruhe, August 2002
Volume I: Paint Application
Volume II: Adhesive Application
Dipl. Geoök. Niels Peters (DFIU)
e-mail: [email protected]
Tel. [phone], Fax [phone]
Dipl.-Ing. Birgit Mahrwald (UBA)
e-mail: [email protected]
Tel. [phone], Fax [phone]
Contents...................................................................................1
Executive Summary ................................................................................11
Initial Position and Objective............................................................................................11
Results of the Determination of Best Available Techniques for the Industrial Paint
Application.......................................................................................................................15
Results of the Determination of Best Available Techniques of Industrial Adhesive
Application.......................................................................................................................29
Production of Tapes......................................................................................................29
Paper and Packaging Industry: Production of Compound foils......................................31
I General Information ..........................................................................33
I.1 Subject of the Document.......................................................................................33
I.1.1 Context.............................................................................................................33
I.1.2 Environmental Hazard.......................................................................................33
I.1.3 Significance of the IPPC Directive....................................................................33
I.1.4 Definition of the term “Best Available Techniques“..........................................34
I.2 Relevant German and International Environmental Legislation.............................35
I.2.1 International Commitments...............................................................................35
I.2.1.1 The Convention on Long-range Transboundary Air Pollution of the
UN/ECE and their Protocols.....................................................................................35
I.2.1.2 European Directive on National Emission Ceilings (NEC-Directive).........36
I.2.1.3 The Solvent Directive of the European Union............................................36
I.2.2 Legal Bases in Germany....................................................................................37
I.2.2.1 Laws.........................................................................................................38
I.2.2.2 Ordinances................................................................................................39
I.3 Subject of the Research Project.............................................................................40
II General Informations about solvent consuming Installations of the
Lacquer Processing.................................................................................45
II.1 Requirements of the paint system..........................................................................45
II.2 Coating materials..................................................................................................46
II.2.1 Paint systems.................................................................................................48
II.2.1.1 Solvent Based Paints.................................................................................48
II.2.1.2 Water-dilutable Paints...............................................................................48
1.2.1.1 Radiation-curing Paints.............................................................................49
1.2.1.2 Powder Coatings.......................................................................................49
II.3 Paint systems........................................................................................................50
II.4 Environmental Impacts.........................................................................................50
II.5 Paint Consumption and Emissions of paint processing installations.......................52
II.6 Industrial Activities with a high Potential of Environmental Pollution...................55
II.7 Developments for the Processing of Paints............................................................56
1 Serial Varnishing of Automotives......................................................59
1.1 General Information..............................................................................................59
1.1.1 Classification of Vehicle Types (according to the Directive 70/156/EWG)....59
1.1.2 Production and Sale Figures of the Automotive Industry...............................60
1.1.3 Emission Limits according to the Regulation for the German Transposition of
the Directive 1999/13/EG.............................................................................................61
1.1.4 Quality Requirements....................................................................................61
1.2 Applied Processes and Techniques........................................................................62
1.3 Current Consumption and Emission Values..........................................................77
1.4 Determination of the BAT Candidates...................................................................84
1.5 Proposal for the Best Available Techniques..........................................................99
1.6 New Progressive Techniques..............................................................................101
2 Other Vehicle Varnishing................................................................111
2.1 Varnishing of Commercial Vehicles....................................................................111
2.1.1 General Information....................................................................................111
2.1.2 Applied Processes and Techniques..............................................................112
2.1.2.1 Varnishing of Truck Chassis....................................................................113
2.1.2.2 Varnishing of axles for commercial vehicles............................................113
2.1.3 Present Consumption and Emission Values.................................................114
2.1.3.1 Consumption of Materials.......................................................................114
2.1.3.2 Emissions in the Atmosphere...................................................................114
2.1.3.3 Wastewater.............................................................................................115
2.1.3.4 Waste......................................................................................................115
2.1.3.5 Energy Demand.......................................................................................115
2.1.4 Selection of the BAT-candidates.................................................................116
2.1.4.1 Small Commercial Vehicles....................................................................116
2.1.4.2 Chassis, Axles and Driving Cabs.............................................................116
2.1.5 Proposal for the Best Available Techniques (BAT).....................................117
2.1.6 New Progressive Techniques.......................................................................118
2.2 Varnishing of Busses..........................................................................................119
2.2.1 General Information....................................................................................119
2.2.1.1 Quality Requirements..............................................................................120
2.2.2 Applied Processes and Techniques..............................................................120
2.2.2.1 Pre-treatment...........................................................................................122
2.2.2.2 Ground coating / dip coating....................................................................122
2.2.2.3 Underbody protection and seam sealing...................................................122
2.2.2.4 Application of filler.................................................................................123
2.2.2.5 Application of topcoat.............................................................................123
2.2.2.6 Cavity Sealing.........................................................................................123
2.2.2.7 Examples of varnishing installations for busses.......................................123
2.2.3 Present Consumption and Emission Values.................................................124
2.2.3.1 Consumption of Input Materials..............................................................124
2.2.3.2 Emissions into the Atmosphere................................................................125
2.2.3.3 Wastewater.............................................................................................126
2.2.3.4 Wastes.....................................................................................................126
2.2.3.5 Energy Demand.......................................................................................126
2.2.4 Determination of BAT-candidates...............................................................126
2.2.5 Proposal for BAT........................................................................................127
2.2.6 Conclusions and Recommendations.............................................................128
2.3 Varnishing of Agricultural- and Construction Vehicles.......................................129
2.3.1 General Information....................................................................................129
2.3.2 Applied Processes and Techniques..............................................................129
2.3.3 Present Consumption- and Emission Values................................................130
2.3.4 Proposal for the BAT-candidates.................................................................135
2.3.4.1 Pre-treatment...........................................................................................135
2.3.4.2 Solvent-free Paints and Paints with a Low Solvent Content.....................135
2.3.4.3 Improved Paint Application.....................................................................135
2.3.4.4 Waste Gas Cleaning................................................................................135
2.3.5 Proposal for the BAT..................................................................................136
2.3.6 New Progressive Techniques.......................................................................137
2.3.7 Conclusions and Recommendations.............................................................137
2.4 Varnishing of Caravans and Motorhomes............................................................138
2.4.1 General Informations...................................................................................138
2.4.2 Applied Processes and Techniques..............................................................138
2.4.3 Current Consumption and Emission Values.................................................138
2.5 Varnishing Of Planes..........................................................................................139
2.5.1 Maintenance................................................................................................139
2.5.1.1 General Informations...............................................................................139
2.5.1.2 Applied Processes and Techniques..........................................................139
2.5.1.3 Current Consumption and Emission Values.............................................141
2.5.1.4 Determination of the BAT Candidates.....................................................143
2.5.1.5 Proposal for the BAT...............................................................................143
2.5.2 Aircraft Construction...................................................................................143
2.5.2.1 Applied Processes and Techniques..........................................................143
2.5.2.2 Present Consumption and Emission Values.............................................145
2.5.2.3 Determination of BAT Candidates...........................................................147
2.5.2.4 Proposal for the BAT...............................................................................148
2.5.2.5 New Progressive Techniques...................................................................148
2.6 Varnishing of Rail Vehicles................................................................................149
2.6.1 General Information....................................................................................149
2.6.2 Applied Processes and Techniques..............................................................149
2.6.2.1 Pre-treatment of Car Bodies.....................................................................151
2.6.2.2 Ground Coat Application (onto outside areas and interior surfaces).........151
2.6.2.3 Filling......................................................................................................151
2.6.2.4 Filler Application (generally only onto outside surfaces).........................151
2.6.2.5 Topcoat Application (generally only onto outside surfaces).....................152
2.6.2.6 Underbody Protection..............................................................................152
2.6.3 Present Consumption and Emission Values.................................................152
2.6.3.4 Energy Demand.......................................................................................153
2.6.4 Determination Of BAT-candidates..............................................................154
2.6.5 Proposal for the BAT..................................................................................155
2.6.6 New Progressive Techniques.......................................................................156
2.6.7 Conclusions and Recommendations.............................................................156
2.7 Varnishing of Ships.............................................................................................158
2.7.1 General Information....................................................................................158
2.7.2 Applied Processes and Techniques for the Varnishing of Merchant Ships....158
2.7.2.1 Pre-treatment...........................................................................................159
2.7.2.2 Coatings..................................................................................................161
2.7.2.3 Application of Primers.............................................................................162
2.7.3 Varnishing of Yachts...................................................................................166
2.7.3.1 Pre-treatment and Primer Application onto Shipbuilding Steel.................166
2.7.3.2 Pre-treatment and Primer Application onto Aluminium...........................166
2.7.3.3 Superstructure made of Shipbuilding Steel or Aluminium: Corrosion
Protection Paint......................................................................................................167
2.7.3.4 Filling......................................................................................................167
2.7.3.5 Filler.......................................................................................................167
2.7.3.6 Topcoating..............................................................................................167
2.7.4 Current Consumption and Emission Values.................................................167
2.7.4.1 Emissions into the Atmosphere................................................................168
2.7.4.2 Wastewater.............................................................................................169
2.7.4.3 Wastes.....................................................................................................170
2.7.4.4 Energy demand........................................................................................170
2.7.5 Determination of BAT-Candidates..............................................................171
2.7.6 Proposals for the BAT.................................................................................172
2.7.7 New Progressive Techniques.......................................................................173
3 Serial Varnishing of Plastic Workpieces.........................................177
3.1 General Information............................................................................................177
3.1.1 Special Characteristic Properties of Plastic Materials...................................177
3.2 Applied Processes and Techniques......................................................................178
3.2.1 Varnishing of Bumpers................................................................................180
3.3 Current Consumption and Emission Values........................................................183
3.3.1 Varnishing of wheel covers.........................................................................185
3.3.2 Varnishing of Steering Wheels....................................................................187
3.3.3 Varnishing of Reflectors.............................................................................187
3.3.4 Varnishing in the production of TV, hi-fi and computer housings................188
3.4 Selection of the BAT Candidates........................................................................188
3.5 Proposal for the Best Available Techniques........................................................190
3.6 New Progressive Techniques..............................................................................190
3.7 Conclusions and recommendations.....................................................................191
4 Serial Varnishing of Metal Surfaces................................................195
4.1 General Information............................................................................................195
4.1.1 Requirements for the Varnishing of Metal Surfaces.....................................195
4.2 Applied Processes and Techniques......................................................................196
4.2.1 Varnishing of Steel Furniture......................................................................196
4.2.2 Varnishing of Shelves.................................................................................197
4.2.3 Varnishing of Household Appliances..........................................................198
4.2.4 Varnishing of High Voltage Switch Cabinets..............................................199
4.2.5 Varnishing of Engine Blocks.......................................................................199
4.2.6 Varnishing of Windshield Wipers................................................................200
4.2.7 Varnishing in Mechanical Engineering........................................................200
4.2.8 Varnishing of Facade Parts..........................................................................202
4.2.9 Varnishing of Hospital Furniture.................................................................202
4.2.10 Varnishing of Heating Elements..................................................................202
4.2.11 Varnishing of Bike and Motorbike Frames..................................................202
4.2.12 Varnishing of Radiators for Passenger Cars.................................................203
4.2.13 Coating of Brake Disks...............................................................................204
4.2.14 Varnishing of Aluminium Rims...................................................................204
4.3 Selection of the BAT Candidates........................................................................206
4.4 Proposal for the Best Available Techniques........................................................208
4.5 New Progressive Techniques..............................................................................208
5 Coil Coating.....................................................................................211
5.1 General Information............................................................................................211
5.1.1 Structure of the Coil Coating Industry and Plant Locations in Germany.......211
5.1.2 Requirements for Coil Coated Products.......................................................215
5.1.3 Legal Requirements for the VOC-reduction.................................................215
5.2 Applied Processes and Techniques......................................................................215
5.2.1 Process Flow...............................................................................................216
5.2.2 Cleaning and Chemical Preparation of the Metal Surface............................217
5.2.3 Conventional Coating of Metal Surfaces.....................................................218
5.2.4 Powder Coating...........................................................................................218
5.2.5 Further Processes and Surface Post-Treatment............................................218
5.2.6 Applied Coating Materials...........................................................................219
5.3 Current Consumption and Emission Values........................................................220
5.3.1 Consumption of Raw Materials...................................................................220
5.3.2 Emissions into the Atmosphere...................................................................221
5.3.3 Wastewater.................................................................................................222
5.3.4 Wastes........................................................................................................222
5.3.5 Energy Consumption...................................................................................222
5.4 Determination of the BAT Candidates.................................................................222
5.4.1 Application of Solvent-containing Varnishes and Cleaning of Exhaust Gases....
....................................................................................................................222
5.4.2 Application of solvent-free Varnish Systems and Paints with a low Solvent
Content ....................................................................................................................223
5.5 Proposal for the Best Available Techniques........................................................223
5.6 New Progressive Techniques..............................................................................224
6 Varnishing of Packings....................................................................227
6.1 General Information............................................................................................227
6.2 Production of Beverage Cans made of Tinplate...................................................228
6.2.1 Utilised Processes and Techniques..............................................................229
6.2.2 Present Consumption- and Emission Values................................................230
6.2.3 Determination of the BAT-candidates.........................................................231
6.2.4 Proposal for the BAT..................................................................................231
6.3 Varnishing of Beverage Cans made of Aluminium..............................................232
6.3.1 Applied Processes and Techniques..............................................................232
7 Varnishing of Furniture and Wood Materials..................................235
7.1 General Information............................................................................................235
7.1.1 Structure of the Wood and Furniture Industry..............................................235
7.1.2 Emission Limits according to the 31. BImSchV..........................................236
7.2 Applied Processes and Techniques......................................................................237
7.2.1 Applied Coating Materials for Wood and Wood Materials..........................237
7.2.1.1 Pre-treatment...........................................................................................237
7.2.1.2 Ground Coat Application.........................................................................239
7.2.1.3 Top Coating............................................................................................240
7.2.1.4 Summary.................................................................................................242
7.2.1.5 Paint Application Techniques..................................................................246
7.2.1.6 Flashing off and Drying / Curing Processes.............................................247
7.2.2 Exemplary Varnishing Processes.................................................................249
7.2 Current Consumption and Emission Values........................................................254
7.3.1 Material Consumption.................................................................................254
7.3.1.1 Emissions in the Air................................................................................256
6.2.1.1....................................................................................................................256
7.3.1.2 Wastewater.............................................................................................257
7.3.1.3 Wastes.....................................................................................................257
7.3.1.4 Energy Consumption...............................................................................257
7.3.1.5 Costs.......................................................................................................258
7.3 Determination of BAT Candidates......................................................................260
7.4.1 Low-emission respective Emission-free Paints............................................260
7.4.2 Paint Application Techniques with Improved Efficiency Factors.................262
7.4.3 Paint Supply with low Material Consumption..............................................264
7.4.4 Waste Gas Cleaning....................................................................................265
7.4 Proposal for the BAT..........................................................................................265
7.5 New Progressive Techniques..............................................................................268
7.6 Conclusions and Recommendations....................................................................269
Annexes
Annex I: Possibilities of Energy Savings in the Paint Application 273
1.1 Energy Flows in Coating Installations.................................................................275
1.2 Applicable Measures for the Reduction of Energy Input .....................................276
1.2.1 Reduction of Energy Input in new Installations...........................................276
1.2.2 Applicable Measures for existing Installations.............................................277
1.3 Developements and Views into the future...........................................................278
Annex II: Overview of selected Pre-treatment Processes...................281
1 Pre-treatment of Metal Substrates..................................................284
1.1 Mechanical Processes.........................................................................................284
1.2 Degreasing Processes..........................................................................................284
1.3 Chemical Processes.............................................................................................285
1.3.1 Pickling.......................................................................................................285
1.3.2 Phosphatation..............................................................................................285
1.3.3 Chromatation..............................................................................................287
1.3.4 Passivation..................................................................................................287
2 Pre-treatment of Plastics.................................................................288
2.1 Flamming...........................................................................................................288
2.2 Corona Treatment...............................................................................................289
2.3 Plasma technology..............................................................................................289
2.4 Fluorination........................................................................................................289
3 Pre-treatment of Wood....................................................................290
Annex III: Paint Application Processes................................................293
1 Application Techniques with a high Efficiency................................295
1.1 Filling.................................................................................................................295
1.2 Rolling................................................................................................................295
1.3 Casting................................................................................................................295
1.4 Dipping...............................................................................................................296
1.4.1 Conventional Dipping.................................................................................296
1.4.2 Electrophoretic Dipping (ETL)....................................................................296
1.5 Flooding.............................................................................................................297
2 Spraying Techniques ......................................................................297
2.1 Spraying without electrostatic Charge.................................................................297
2.2 Electrostatic assisted Spraying............................................................................299
2.2.1 Electro-statically atomising Processes.........................................................300
2.2.2 Mechanically atomisation via high Rotation................................................300
2.2.3 Electrostatic-assisted compressed-air-, airless- and ,air-assisted Spraying....301
2.2.4 Electrostatic-assisted Processing of water-thinnable Paints..........................302
2.2.5 Processing of Powder Coatings...................................................................302
3 Separation resp. Recycling of Paint Overspray from Spray
Applications...........................................................................................303
3.1 Wet Separators....................................................................................................303
3.2 Dry Separation....................................................................................................303
3.3 Paint recycling....................................................................................................304
Annex IV: Drying ..................................................................................307
1 Drying via circulating Air...................................................................................309
2 Ultra-red Radiation Curing..................................................................................311
3 UV- curing..........................................................................................................313
4 Electron Beam Curing.........................................................................................316
5 Drying via Induction...........................................................................................316
6 Drying via Microwaves.......................................................................................316
7 Summary............................................................................................................317
Annex V: Secondary Emission Abatement Measures for Reduction of
VOC Emissions .....................................................................................323
1. Exhaust Gas Cleaning by Thermal Oxidation.................................327
1.1.1.1 Device Construction................................................................................329
1.1.2 Thermal Regenerative Post-Combustion......................................................330
1.1.2.1 Device Construction................................................................................330
1.1.3 Properties of the Recuperative and the Regenerative Thermal Post-combustion
Methods.....................................................................................................................332
1.1.4 Parameters..................................................................................................334
1.1.5 Investments and Operation Costs.................................................................334
1.1.6 Treatable Substances..........................................................................................335
1.2 Catalytic Post-Combustion..................................................................................335
1.2.1 Device Construction....................................................................................335
1.2.2 Treatable Substances...................................................................................337
1.2.3 Parameters.........................................................................................................337
1.2.4 Application........................................................................................................338
1.2.5 Investments and operating costs.........................................................................339
2 Adsorption.......................................................................................340
2.1 Principle of the Technique..................................................................................340
2.1.1 Device Construction....................................................................................340
Fixed-bed Adsorber................................................................................................341
Moving Bed and Fluidized Bed Adsorbers..................................................................341
Rotation Adsorbers.....................................................................................................341
2.1.2 Desorption Techniques.......................................................................................342
Steam Desorption...................................................................................................342
Hot Gas Desorption................................................................................................344
2.1.3 Adsorbents.........................................................................................................345
2.2 Treatable Substances.................................................................................................345
2.3 Critical Parameters..............................................................................................346
2.4 Application...............................................................................................................346
2.5 Investments and Operating Costs..............................................................................347
2.6 Side Effects..............................................................................................................348
3 Absorption.......................................................................................349
3.1 Description of the Technique..............................................................................349
3.1.1 Absorption..................................................................................................349
3.1.2 Regeneration (Desorption)..........................................................................350
3.2 Treatable Substances.................................................................................................351
3.3 Absorbents................................................................................................................351
3.4 Main Parameters.................................................................................................352
3.5 Application...............................................................................................................352
Advantages of the Absorption.................................................................................353
Disadvantages of the Absorption.............................................................................353
3.6 Investments and Operation Costs........................................................................353
4 Biological Processes.......................................................................354
4.1.2 Treatable Substances..........................................................................................358
4.2.1 Device Construction...........................................................................................361
4.2.2 Washing Agents.................................................................................................362
4.2.3 Treatable Substances..........................................................................................362
4.2.4 Parameters for the Applicability of Bioscrubbers...............................................362
5 Condensation..................................................................................363
6 Criteria for the Selection of Emission Reduction Measures ...........367
Annex VI: Case Studies .......................................................................377
VI.1 Case study about the Serial Coating of Passenger Cars at the Volkswagen AG...378
VI.1.1 BASIC COATING PLANT Hall 17 (Pre-treatment/KTL)...........................379
VI.1.2 Ground coating line F, hall 12 (Pre-treatment/cathodic immersion prime
coating) ....................................................................................................................387
VI.1.3 Top Coating Line (5a process, hall 9)..........................................................395
VI.2 Case Study at the BMW AG...............................................................................407
VI.3 Case Study for the Serial Varnishing of of Passenger Cars at the DaimlerChrysler
AG ...........................................................................................................................411
VI.4 Case Studie at the Dynamit Nobel Kunststoff GmbH..........................................421
VI.5 Case Study for the Varnishing of Beverage Cans................................................432
Annex VI.I: Data for the Varnishing of Steel Furniture........................457
Annex VII: Questionnaire for Data Retrieval........................................465
Audi AG Plant Ingolstadt...............................................................................................466
Opel Eisenach GmbH.....................................................................................................482
HFP Bandstahl GmbH & Co KG....................................................................................496
Plastic Omnium Automotive Components GmbH...........................................................507