Project Summary Life Cycle Assessment for Chemical Agent Resistant Coating

Transcription

1 United Sttes Ntionl Risk Mngement Environmentl Protection Reserch Lbortory Agency Cincinnti, OH Reserch nd Development EPA/600/SR-96/104 September 1996 Project Summry Life Cycle Assessment for Chemicl Agent Resistnt Coting Robin Thoms nd Dune Tolle This project ws sponsored by the Deprtment of Defense's Strtegic Environmentl Reserch nd Development Progrm (SERDP) nd conducted by the U.S. Environmentl Protection Agency's Ntionl Risk Mngement Reserch Lbortory (NRMRL). In support of SERDP's objective to develop environmentl solutions tht improve mission rediness for federl ctivities, this report ws developed to determine the optimum mterils nd equipment for pplying chemicl gent resistnt coting (CARC) to vehicles t the Army Trnsporttion Center t Fort Eustis, VA. A life cycle ssessment (LCA) ws conducted to identify the performnce, cost, nd environmentl impcts of vrious combintions of CARC mterils nd equipment. The vribles for this study were the primer, thinner, CARC topcot, nd spry ppliction equipment. Combintions of the vribles were grouped to develop five lterntives. The recommended lterntive would chnge the existing primer nd ppliction equipment, but retin the existing thinner nd topcot. This lterntive would mintin required performnce chrcteristics, chieve cost objectives, nd result in low environmentl impcts in reltion to the other lterntives. This Project Summry ws developed by EPA s Ntionl Risk Mngement Reserch Lbortory, Cincinnti, OH, to nnounce key findings of the reserch project tht is fully documented in seprte report of the sme title (see Project Report ordering informtion t bck). Introduction A life cycle inventory (LCI) of chemicl gent resistnt coting (CARC) opertions ws conducted t the U.S. Army s Trnsporttion Center t Fort Eustis, VA. The LCI provided bseline of environmentl nd utility dt for the production, use, nd disposl of spent CARC nd blst medi. These dt included the rw mterils used, wter nd energy requirements, tmospheric emissions, liquid wste, nd solid wste strems. The results of this LCI provide the bsis for life cycle environmentl evlution of CARC opertions t Fort Eustis. The dt were originlly presented in units per 1,000 gllons of CARC used, which is slightly less thn the CARC produced nd purchsed due to spills, overspry, nd discrded pint. The dt were converted to units per 1,000 ft 2 for the life cycle impct ssessment (LCIA) nd the life cycle improvement ssessment (LCImA) to ccount for the dditionl CARC required due to overspry, spills, nd discrds. Therefore, the quntities of mterils required for the process, nd the emissions relesed from ny process in the CARC cycle, re expressed reltive to functionl unit of 1,000 ft 2 of pinted surfce. The scope of the LCIA ws limited to one topcot (MIL-C-53039A, Hentzen 08605GUZ), one primer (MIL-P-53022B; Prt A, Niles N-1088A nd Prt B, Niles N-1088BM), one thinner (MIL-T-81772B, Chemicl Specilists nd Development, Thinner Aircrft Coting), one pinting technique (high volume, low pressure [HVLP] spry pinting), nd one depinting blsting medi (luminum oxide). All of these, except the thinner, were used t Fort Eustis (Fort Eustis dds two qurts of A-A-857B to every five gllons of CARC). An LCImA ws then undertken, using the results of the LCIA, to define improvement strtegies tking into ccount such fctors s cost, performnce, nd environmentl considertions.

2 Life Cycle Inventory In developing the LCI, ll of the principl ingredients used to produce the finl products were identified. The specific chemicls were identified using Mteril Sfety Dt Sheets provided by the mnufcturers. Literture reserch ws then conducted to identify the processes used to mke the principl ingredients nd to identify the rw mterils. This process ws repeted until every rw mteril ws trced bck to fundmentl precursor (i.e., one identified s coming from the erth s n ore or petroleum product). Ech process ws reviewed to determine the process inputs nd the outputs. Process inputs include rw mterils, wter, nd energy (i.e., electricl, nturl gs [s fuel], oil, nd col). Outputs include the end product tmospheric emissions, wterborne wste nd solid wste. Dt were obtined through telephone surveys to mnufcturers, published chemicl industry informtion, nd chemicl process hndbooks. Serches for reports, rticles, or other sources of informtion were undertken in n ttempt to fill remining gps in the dt. These serches sometimes yielded EPA reports, EPA-contrcted reports, or industry trde mgzine rticles. As prt of the scoping ctivity for the LCIA, it ws determined tht severl of the chemicl components in the CARC life cycle described in the drft LCI could be revised to fill in missing dt or to provide more recent dt on the mnufcturing processes. Chemicls identified s most importnt for collection of dditionl LCI dt were diponitrile, coblt chromite green, hexmethylenedimine, mgnesium ferrite, phosgene, sodium cynide, nd sodium dichromte. Second tier chemicls included butyl cette, butyl lcohol, nd methyl isomyl ketone. Additionl chemicls derived closely from the crude oil nd nturl gs refining processes were not included in this rnked system, becuse they re prt of the crude oil nd nturl gs extrction nd refining models incorported into the inventory model. This included romtic 100, crbon monoxide, hydrogen, nd propne. Emissions for the electricl production, crude oil refining, nd nturl gs production were tken from Bttelle LCI dtbses. The electricl production model clcultes pollutnt lodings for the ntionl electricl grid bsed on the frctions of power creted from col, hydrocrbons, nucler, hydropower, wind, nd other energy sources. The crude oil nd nturl gs models included dt on mny of the primry refinery chemicls. Emission dt from 1993 were cross-referenced with the 1993 Directory of Chemicl Producers to determine the mnufcturers of the chemicls of interest. The directory lso provided production tbles, which llowed direct clcultion of the emission rtes per pound of product produced for severl chemicls of interest involved in the process. Life Cycle Impct Assessment The LCIA is divided into three phses: clssifiction, chrcteriztion, nd vlution. The clssifiction step involved linking or ssigning dt from the LCI to individul stressor ctegories within the three primry stressor ctegories, which re humn helth, ecologicl helth, nd resource depletion. Stressor/impct chins were developed by considering the energy, wter, nd rw mteril input, long with the ir, wter, nd solid wste emission output from ech life cycle stge, which were then compred ginst lists of potentil impcts. The chrcteriztion step involved n evlution of the mgnitude of potentil impcts cused by individul stressors on site-independent bsis. An estimtion of the mgnitude of impcts for ech stressor ctegory ws chieved by multiplying equivlency fctors by the quntity of resource or pollutnt ssocited with functionl unit of the CARC process. The vlution step involved n evlution of the mgnitude of resource depletion impcts ssocited with the CARC life cycle. The resources included in the nlysis were wter, minerls, gs, oil, col, nd lnd. The impcts were evluted from time-metric stndpoint, which considers the time to exhustion of the resource. Economic Assessment The nnul cost to pint nd depint Army vehicles ws estimted using fctored estimted pproch. Fort Eustis ws selected s the bseline site, becuse it typified depinting nd pinting opertions t mjority of Army bses; therefore, its plnt cpcity, stffing, nd pint-, primer-, nd brsive medi-usge rtes were used to estimte typicl costs. Cpitl costs were estimted for depinting, mrking nd equipment preprtion, nd CARC ppliction opertions for new fcility tht would be of similr size nd cpcity s Fort Eustis. Ech mjor item ws identified, sized, nd costs were determined (using cost files, stndrd texts, vendor quotes, nd recent procurement informtion) to estimte the totl delivered equipment costs. Operting costs re composed of the nnul costs to operte the depinting nd pinting opertions, including rw mterils, utilities, lbor, supplies, mintennce, plnt overhed, wste disposl, insurnce, nd regultory complince chrges. These costs were estimted bsed on the costs incurred t Fort Eustis. Approprite fctors were pplied to convert the usge figures to nnul costs (i.e., 3,096 gllons of CARC multiplied by the CARC purchse price). Other chrges, such s those incurred to mintin the fcility, plnt overhed, etc., were lso estimted using fctoring pproch. Annulized costs equl the nnul operting cost plus mortiztion of the cpitl investment. The nnulized cost is then divided by the nnul quntity of CARC pinted surfce to compute costs on $/ ft 2 bsis. The nnul surfce coted (619,000 ft 2 ) ws estimted from the 1993 Fort Eustis CARC pint consumption level of 3,096 gllons nd clculted CARC usge rte of 5.0 gl/1,000 ft 2 (200 ft 2 / gl). Life Cycle Improvement Assessment Inventory Anlysis Five lterntives were evluted ginst the bseline CARC system (Tble 1): (1) lterntive primer with the bseline CARC topcot nd thinner; (2) substitution of the turbine HVLP gun ginst the stndrd HVLP gun; (3) lterntive primer with the lterntive gun; (4) lterntive thinner long with the bseline topcot; nd (5) lterntive thinner nd lterntive primer with the bseline gun. The importnce of ech individul resource or chemicl within ech impct ctegory ws determined by multiplying the equivlency fctor times the inventory vlue in pounds per functionl unit. The potentil environmentl impcts ssocited with ech of the lterntives cn be evluted by compring the normlized, fctored, impct scores for ech of the nine mjor impct ctegories. Economic ssessment ws mde by tking the bseline (Fort Eustis) ctegories of fixed cpitl investment, the nnul operting cost, nd the nnulized cost nd compring those estimtes ginst the five lterntives. A performnce evlution ws conducted for the impct ssessment, which included ppliction equipment, primers, nd thinners. Scoring rnks were ssigned for ech performnce evlution prmeter. A vlution process ws conducted in step-wise fshion, beginning with the construction of hierrchy tree nd continu- 2

3 Tble 1. CARC Systems for Evlution in LCImA CARC Systems CARC Topcot Evluted Topcot Primer b Thinner c Spry Gun d 1 (Bseline) BC BP BT BG 2 BC AP BT BG 3 BC BP BT AG 4 BC AP BT AG 5 BC BP AT BG 6 BC AP AT BG BC = b BP = c BT = d BG = Bseline CARC Topcot, MIL-C-53039A, Hentzen 08605GUZ-GD, 1-prt urethne. Bseline Primer, MIL-P-53022, Niles 2-prt epoxy, solvent thinned; AP = Alterntive Primer, MIL-P-53030, Deft 2-prt epoxy, wter thinned. Bseline Thinner, MIL-T-81772B, CSD; AT = Alterntive Thinner, Fed. Std. A-A-857B (used by Fort Eustis, but not evluted by LCI. Bseline Gun, high volume, low pressure (HVLP) spry gun (thinning of topcot required); AG = Alterntive Gun, turbine HVLP spry gun with incresed trnsfer efficiency reltive to conventionl HVLP gun. ing with the environmentl, cost, nd performnce weighting, respectively. Results nd Discussion Results of the impct chrcteriztion nd vlution process showed tht the impcts of gretest concern re ozone depletion (weight = 0.362), cid deposition (weight = 0.219), nd globl wrming (weight = 0.126). Of secondry concern (with combined normlized, weighted, fctored score) were ll forms of toxicity, including humn, terrestril, nd qutic. Results for the five lterntives evluted ginst the bseline CARC system re summrized in Tble 2. Environmentl Impct/Hzrd Chrcteriztion The CARC system with the most (7 out of 9) low scores (i.e., fewest potentil impcts) in ech impct ctegory ws lterntive 3, the lterntive primer nd lterntive spry gun option. Use of the lterntive gun decresed the use rtes of topcot, primer, nd thinner, which results in reduction of potentil environmentl impct in ll nine of the impct ctegories compred to the bseline. Alterntive 3 ws lso the most ttrctive option in the res of globl scle impct ctegories (ozone depletion, globl wrming, nd nturl resource use), nd regionl scle impct ctegories (cid deposition nd smog cretion). Although lterntive 3 ws the most vible option for two (humn helth nd terrestril wildlife) of the three toxicity impct ctegories (the third being qutic toxicity), use of this option ws worse on qutic toxicity thn the bseline system. Alterntives 2 nd 3 rted the most fvorbly with regrd to locl scle impct of lnd use. Economic Assessment Estimted fixed cpitl investments, nnul operting costs, nd nnulized costs for ech of the five lterntive systems s compred to the bseline re provided in Tble 3. Performnce Evlution The lterntive spry gun (the Cn-m system) hd trnsfer efficiency of 90%, which represents n increse in trnsfer efficiency of pproximtely 38% over the bseline system. The performnce of the two primers (Bseline: MIL-P-53022, Niles; Alterntive: MIL-P-53030, Deft) were similr, except tht some users hve reported poor dhesion using the lterntive primer. Since the lterntive primer is wter thinnble, poor dhesion in isolted cses my be due to environmentl fctors, such s humidity. Performnce of the two thinners (Bseline: MIL-T-81772B; Alterntive: Federl Stndrd A-A-857B) vried from user to user. Environmentl effects re suspected to be the reson for the differences between the two. However, the effect of the lterntive thinner on the ppernce nd performnce of the topcot ws noticeble. If the lterntive thinner is found to be uncceptble for use with the topcot, it should be considered for use in the clening of process guns nd hoses. Vlution Process The results of the weighting exercise in the three mjor dimensions ssigned 65% of the vlue to the environmentl dimension, 24% to the performnce spects, nd 11% to cost. Since the scoping process ssumed tht the threshold criteri would result in lterntives tht perform dequtely nd do not differ mrkedly in cost, the results should be reviewed considering those ssumptions. Further trcing the weighting process into the three mjor brnches indictes tht globl environmentl issues were ssigned 32% of weight, or bout hlf of the overll environmentl contribution. Regionl nd locl issues received 20% nd 13%, respectively. In the cost brnch, O&M costs were considered pproximtely three times s importnt s cpitl costs. In the performnce brnch, the primer ws considered the most importnt fctor, with the thinner nd the spry gun receiving bout equl considertion. Overll Improvement Assessment Results The score summries (lower being preferble) for the ssessment results re shown below in decresing order: Bseline Alterntive Thinner (Alterntive 4) Alterntive Primer (Alterntive 1) Alterntive Thinner nd Primer (Alterntive 5) Alterntive Gun (Alterntive 2) Alterntive Primer nd Gun (Alterntive 3) The results indicte tht use of the lterntive gun mkes the lrgest potentil improvement for n lterntive tht chnges only single fctor, nd in combintion with the lterntive primer, results in the best CARC option. Conclusions Of the five lterntives considered, two (Alterntive 2, the lterntive gun; nd Alterntive 3, lterntive primer used with the lterntive gun) demonstrte the gretest potentil for environmentl improvement; the remining three lterntives exhibit slight improvements tht re not significnt, considering the scope of the study. When cost nd performnce re considered long with environmentl fctors, Alterntive 2 nd Alterntive 3 emerge s the preferred lterntives for implementtion, but the degree of differentition reltive to the bseline is minor. Alterntive 3 is the recommended implementtion choice followed by Alterntive 2. 3

4 The full report ws submitted in fulfillment of Contrct No. 68-C4-0020, work ssignment 2-11, to Lockheed Environmentl Systems & Technologies Compny through Purchse Order Number 07PPG7 from Lockheed to Bttelle, under the sponsorship of the U.S. Environmentl Protection Agency Tble 2. Results of Alterntives Aginst Bseline System from the LCImA Inventory Anlysis Results Alterntive Increse Decrese 1 Alterntive primer used with the Smll increses for fuel, sodium chloride, Smll decrese in resource consumption bseline CARC topcot nd thinner. chlorine, nd the ilmenite nd rumenite (electricity, nturl gs, stem, wter, from production of TiO 2. Slight increses crude oil, refinery gses, oxygen, nd in chlorine nd methne. Wter dischrges minor components). Elimintion of for titnium dioxide, chlorine, nd hevy phosphte nd zinc ores. Decreses in ir metls (cdmium, led, nd chromium). emissions of CO 2, voltile orgnic Addition of new chemicls from the compounds, PM, NO x, hydrocrbons, nd production of nitroethne (cetldehyde, CO. Decreses in ODP, wter usge nd methnol, 2-nitropropne, cetone, dischrges, including reductions in mobile cetonitrile, nitric cid, mmoni). ions, sodium, chloride, oil nd grese, nd boron. Slight reduction in hzrdous solid wste. 2 Substitution of the turbine HVLP gun None. Decreses noted in resource consumption, ginst the stndrd (bseline) HVLP energy usge, nd emissions. gun. 3 Alterntive primer with lterntive gun. Mixed (both increses nd decreses) in Even lrger decreses in energy nd emissions from bseline. resource consumption thn lterntives 1 nd 2. Mixed emissions, but for those emissions common to the bseline, overll mounts decresed. 4 Alterntive thinner with bseline Slight increse in SO x in ir emissions. Decreses in resource nd energy demnds topcot. for electricity, stem, wter, crude oil, buxite, ir, residul nd distillte fuel oils. Reduced CO 2 nd hydrocrbons in ir emissions. Decreses in wter usge nd dischrge rtes. Decreses in mobile ions, chloride, oil, grese, nd minor constituents. Slight decrese in solid wste. 5 Alterntive thinner nd lterntive Increses in fuel, sodium chloride, chlorine, Decreses in resource nd energy primer with bseline gun. rumenite, ilmenite (from TiO 2 production). consumption in the res of electricity, Slight increses in minor orgnic chemicl nturl gs, stem, wter, crude oil, ir, releses. Increses in hevy metl content nd refinery gses. Decreses in mjor ir for wter usge nd emissions. Increses emissions in CO 2, VOCs, PM, NO x, in solid wstes from nitroethne hydrocrbons, nd CO. Decreses in wter production processes. usge nd overll emissions. Decreses in ODP, solid wstes (except those from the nitroethne production processes). Preferred lterntives. Tble 3. Summry of Economic Assessment for Ech of the Five Alterntives Compred to the Bseline CARC System Cost Ctegory Bseline Alterntive 1 Alterntive 2 Alterntive 3 Alterntive 4 Alterntive 5 Fixed Cpitl Investment Annul Operting 1,797 1,788 1,574 1,565 1,797 1,787 Cost 2,903 b 2,888 b 2,542 b 2,928 b 2,901 b 2,885 b Annulized Cost 1,845 1,837 1,625 1,616 1,845 1,835 2,981 b 2,966 b 2,625 b 2,611 b 2,979 b 2,963 b Numbers re in thousnds of dollrs. b Reported s $/l000 ft 2. 4

5 Robin Thoms is with Lockheed-Mrtin Environmentl, Ls Vegs, NV nd Dune Tolle is with Bttelle Columbus, Columbus, OH Kenneth R. Stone nd Johnny Springer, Jr., re the EPA Project Officers (see below). The complete report, entitled "Life Cycle Assessment for Chemicl Agent Resistnt Coting," (Order No. PB ; Cost: $47.00, subject to chnge) will be vilble only from: Ntionl Technicl Informtion Service 5285 Port Royl Rod Springfield, VA Telephone: The EPA Project Officers cn be contcted t: Ntionl Risk Mngement Reserch Lbortory U.S. Environmentl Protection Agency Cincinnti, OH United Sttes Environmentl Protection Agency Ntionl Risk Mngement Reserch Lbortory (G-72) Cincinnti, OH BULK RATE POSTAGE & FEES PAID EPA PERMIT NO. G-35 Officil Business Penlty for Privte Use $300 EPA/600/SR-96/104 5