Abstract Process Economics Program Report 242 INDUSTRIAL COATINGS (July 2002)

Transcription

1 Abstract Process Economics Program Report 242 INDUSTRIAL COATINGS (July 2002) This report broadly surveys the coatings industry status in general, based on geographic consumption, end-use industry (automotive, architectural, etc), application type (solventborne, waterborne, etc), and fundamental resin component (acrylic, urethane, etc). The effects of environmental concerns and changing regulations are also discussed. The process technology evaluations, however, require a significant narrowing of the breadth of the scope. Therefore, a single industry end-use was assumed, namely automotive, because of the relatively large production volumes involved and the breadth of technology employed. The scope was further refined to focus on coatings applied during manufacture (original equipment manufacturer, or OEM, coatings). The processes evaluated in this report include a water-based formulation for an electrodeposited coating, a solventborne base coat (color coating for base coat / clear coat technology), and a waterborne base coat. The stepwise sequences of batch operations are shown for each coating process, and manufacturing economics are developed and presented. While these processes are specific to automotive OEM coatings, and the electrodeposition coating is only applicable to electrolytically coat metal substrates, the solventborne and waterborne coatings are relatively representative of coatings industry as a whole. The resins and other ingredients may change, according to the product formulation desired, but the types of steps involved and operations used are representative of most coatings processes. PEP 00 LAC/PDP

2 CONTENTS 1 INTRODUCTION SUMMARY AUTOMOTIVE OEM COATINGS Electrodeposition Primer Technology Economics Solventborne Base Coat Technology Economics Waterborne Base Coat Technology Economics Solventborne versus Waterborne Cost Comparison Issues for Coatings Effect of Coating Properties on Economics Effect of Emissions Capture Equipment on Economics Impact of Retrofit of Application Processes Inferences INDUSTRY STATUS BASIC COMPOSITION Resins Industry Changes MANUFACTURING PROCESSES ENVIRONMENTAL ISSUES AUTOMOTIVE Suppliers of OEM Automotive Coatings Automotive Refinishes iii

3 CONTENTS (Continued) 4 AN ELECTRODEPOSITABLE PRIMER COATING CHEMISTRY REVIEW OF PROCESSES PROCESS DESCRIPTION Section 100: Preparation of Ingredients ( : Surfactant Mixture) Section 100: Preparation of Ingredients ( : the Diketimine of DETA) Section 100: Preparation of Ingredients ( : the Polyurethane Crosslinker Section 200: Production of the Cationic Resin ( : the Polyether Polyol) Section 200: Production of the Cationic Resin ( : Modified Polymer) Section 200: Production of the Cationic Resin ( : Dispersion) Section 300: Production of the Additive Resin ( : Prepolymer) Section 300: Production of the Additive Resin ( : Polymer) Section 300: Production of the Additive Resin ( : Dispersion) Section 400: Formulation of the Electrodepositable Primer PROCESS DISCUSSION Batch Size Assumptions Multiple Product Vessel Usage Holding Vessel Assumptions Campaign Size and Plant Capacity Equipment Design Assumptions Operating Labor COST ESTIMATION A SOLVENTBORNE BASE COAT FORMULATION CHEMISTRY REVIEW OF PROCESSES PROCESS DESCRIPTION iv

4 CONTENTS (Continued) Section 100: Production of the Dispersion Stabilizer ( : PHSA) Section 100: Production of the Dispersion Stabilizer ( : Mix0) Section 100: Production of the Dispersion Stabilizer ( : DSP) Section 200: Production of the Polymeric Micro Particle ( : Mix2) Section 200: Production of the Polymeric Micro Particle ( : Mix3) Section 200: Production of the Polymeric Micro Particle ( : PMP) Section 300: Preparation of Reaction Premixes ( : Mix4) Section 300: Preparation of Reaction Premixes ( : Mix5) Section 300: Preparation of Reaction Premixes ( : Mix6) Section 400: Formulation of the Solventborne Base Coat ( : EAP) Section 400: Formulation of the Solventborne Base Coat ( : PAHE) Section 400: Formulation of the Solventborne Base Coat ( : ALS) Section 400: Formulation of the Solventbourne Base Coat ( : SBC) PROCESS DISCUSSION Batch Size Assumptions Multiple Product Vessel Usage Campaign Size and Plant Capacity Equipment Design Assumptions Operating Labor COST ESTIMATION A WATERBORNE BASE COAT FORMULATION CHEMISTRY REVIEW OF PROCESSES PROCESS DESCRIPTION Section 100: Production of the Polyurethane Macromonomer ( : RM1) Section 100: Production of the Polyurethane Macromonomer ( : RM2) Section 100: Production of the Polyurethane Macromonomer ( : CM) v

5 CONTENTS (Concluded) Section 100: Production of the Polyurethane Macromonomer ( : PUM) Section 200: Production of the PUAC Dispersion ( : PM) Section 200: Production of the PUAC Dispersion ( : IM) Section 200: Production of the PUAC Dispersion ( : PUAC) Section 200: Production of the PUAC Dispersion ( : PD) Section 300: Formulation of the Waterborne Base Coat ( : APS) Section 300: Formulation of the Waterborne Base Coat ( : RCD) Section 300: Formulation of the Waterborne Base Coat ( : WBC) PROCESS DISCUSSION Batch Size Assumptions Multiple Product Vessel Usage Campaign Size and Plant Capacity Equipment Design Assumptions Operating Labor COST ESTIMATION APPENDIX A: PATENT SUMMARY TABLES... A-1 APPENDIX B: DESIGN AND COST BASES... B-1 APPENDIX C: CITED REFERENCES... C-1 APPENDIX D: PATENT REFERENCES BY COMPANY... D-1 APPENDIX E: PROCESS FLOW DIAGRAM... E-1 vi

6 ILLUSTRATIONS 3.1 US Consumption of Product Finishes, US Resins Consumption, Consumption of Acrylic Resins in Coatings, US Acrylics Consumption by Formulation, US Consumption of Alkyds, Consumption of Vinyl Coating Resins, Consumption of Urethane Resins, US Consumption of Epoxy Resins in Product Finishing, US Consumption of Epoxy Resins in Special-Purpose, Powder and Radiation Curable Coatings Epoxy Resins Used in Powder Coatings Electrodepositable Primers Batch Process Preparation of Ingredients... E Electrodepositable Primers Batch Process Cationic Resin Dispersion... E Electrodepositable Primers Batch Process Additive Resin Dispersion & Product Formulation... E Electrodepositable Primers Batch Process Batch Scheduling... E Solventborne Base Coat Batch Process Dispersion Stabilizer Steps... E Solventborne Base Coat Batch Process Polymeric Microparticle Steps... E Solventborne Base Coat Batch Process Intermediate Mixture Steps... E Solventborne Base Coat Batch Process Polymers and Product Formulation... E Solventborne Base Coat Batch Process Batch Scheduling... E Waterborne Base Coat Batch Process Polyurethane Macromonomer... E Waterborne Base Coat Batch Process Polyurethane/Acrylic Graft Copolymer... E Waterborne Base Coat Batch Process Product Formulation Steps... E Waterborne Base Coat Batch Process Batch Scheduling... E-31 vii

7 TABLES 2.1 Electrodepositable Primer Economic Comparison Solventborne Base Coat Economic Comparison Waterborne Base Coat Economic Comparison Solventborne Versus Waterborne Production Costs Estimated Sales by Coating Types Coating Sales of Leading Companies A Electrodepositable Primer-Surfactant Mixture Design Basis and Assumptions B Electrodepositable Primer-Surfactant Mixture Batch Cycle Time Estimate C Electrodepositable Primer-Surfactant Mixture Material Streams A Electrodepositable Primer-Diketimine Design Basis and Assumptions B Electrodepositable Primer-Diketimine Batch Cycle Time Estimate C Electrodepositable Primer-Diketimine Material Streams D Electrodepositable Primer-Diketimine Utility Streams A Electrodepositable Primer-Crosslinker Design Basis and Assumptions B Electrodepositable Primer-Crosslinker Batch Cycle Time Estimated C Electrodepositable Primer-Crosslinker Material Streams D Electrodepositable Primer-Crosslinker Utility Streams A Electrodepositable Primer-Polyether Polyol Design Basis and Assumptions B Electrodepositable Primer-Polyether Polyol Batch Cycle Time Estimate viii

8 TABLES (Continued) 4.4C Electrodepositable Primer-Polyether Polyol Material Streams D Electrodepositable Primer-Polyether Polyol Utility Streams A Electrodepositable Primer-Cationic Resin Design Basis and Assumptions B Electrodepositable Primer-Cationic Resin Batch Cycle Time Estimate C Electrodepositable Primer-Cationic Resin Material Streams D Electrodepositable Primer-Cationic Resin Utility Streams A Electrodepositable Primer-Cationic Resin Dispersion Design Basis and Assumptions B Electrodepositable Primer-Cationic Resin Dispersion Batch Cycle Time Estimated C Electrodepositable Primer-Cationic Resin Dispersion Material Streams D Electrodepositable Primer-Cationic Resin Dispersion Utility Streams A Electrodepositable Primer - Additive Resin Prepolymer Design Basis and Assumptions B Electrodepositable Primer - Additive Resin Prepolymer Batch Cycle Time Estimated C Electrodepositable Primer - Additive Resin Prepolymer Material Streams D Electrodepositable Primer - Additive Resin Prepolymer Utility Streams A Electrodepositable Primer - Additive Resin Modified Polymer Design Basis and Assumptions B Electrodepositable Primer - Additive Resin Modified Polymer Batch Cycle Time Estimated C Electrodepositable Primer - Additive Resin Modified Polymer Material Streams ix

9 TABLES (Continued) 4.8D Electrodepositable Primer - Additive Resin Modified Polymer Utility Streams A Electrodepositable Primer - Additive Resin Dispersion Desing Basis and Assumptions B Electrodepositable Primer - Additive Resin Dispersion Batch Cycle Time Estimated C Electrodepositable Primer - Additive Resin Dispersion Material Streams D Electrodepositable Primer - Additive Resin Dispersion Utility Streams A Electrodepositable Primer - Primer Formulated Design Basis and Assumptions B Electrodepositable Primer - Primer Formulated Batch Cycle Time Estimated C Electrodepositable Primer - Primer Formulated Material Streams A Electrodepositable Primer Plant Capacity Estimate B Electrodepositable Primer Major Equipment C Electrodepositable Primer Operating Labor Estimate A Electrodepositable Primer Utility Summary B Electrodepositable Primer Total Capital Investment C Electrodepositable Primer Production Costs D Electrodepositable Primer Raw Material Cost and Source A Solventborne Base Coat - Dispersion Stabilizer Design Basis and Assumptions B Solventborne Base Coat - Dispersion Stabilizer Batch Cycle Time Estimated x

10 TABLES (Continued) 5.1C Solventborne Base Coat - Dispersion Stabilizer Material Streams D Solventborne Base Coat - Dispersion Stabilizer Utility Streams A Solventborne Base Coat - Polymeric Micro Particle Design Basis and Assumptions B Solventborne Base Coat - Polymeric Micro Particle Batch Cycle Time Estimate C Solventborne Base Coat - Polymeric Micro Particle Material Streams D Solventborne Base Coat - Polymeric Micro Particle Utility Streams A Solventborne Base Coat - Reaction Premixtures Design Basis and Assumptions B Solventborne Base Coat - Reaction Premixtures Batch Cycle Time Estimate C Solventborne Base Coat - Reaction Premixtures Material Streams A Solventborne Base Coat - SBC Formulation Design Basis and Assumptions B Solventborne Base Coat - SBC Formulation Batch Cycle Time Estimate C Solventborne Base Coat - SBC Formulation Material Streams D Solventborne Base Coat - SBC Formulation Utility Streams Solventborne Base Coat Plant Capacity Estimate Solventborne Base Coat Major Equipment Solventborne Base Coat Operating Labor Estimate Solventborne Base Coat Utilities Summary xi

11 TABLES (Continued) 5.9 Solventborne Base Coat Total Capital Investment Solventborne Base Coat Production Costs Solventborne Base Coat Raw Material Cost and Source A Waterborne Base Coat - Polyurethane Macromonomer Design Basis and Assumptions B Waterborne Base Coat - Polyurethane Macromonomer Batch Cycle Time Estimate C Waterborne Base Coat - Polyurethane Macromonomer Material Streams D Waterborne Base Coat - Polyurethane Macromonomer Utilities Summary A Waterborne Base Coat - Polyurethane / Acrylic Copolymer Dispersion Design Basis and Assumptions B Waterborne Base Coat - Polyurethane / Acrylic Copolymer Dispersion Batch Cycle Time Estimate C Waterborne Base Coat - Polyurethane / Acrylic Copolymer Dispersion Material Streams D Waterborne Base Coat - Polyurethane / Acrylic Copolymer Dispersion Utility Streams A Waterborne Base Coat - WBC Formulation Design Basis and Assumptions B Waterborne Base Coat - WBC Formulation Batch Cycle Time Estimate C Waterborne Base Coat - WBC Formulation Material Streams Waterborne Base Coat Plant Capacity Estimate Waterborne Base Coat Major Equipment Waterborne Base Coat Operating Labor Estimate xii

12 TABLES (Concluded) 6.7 Waterborne Base Coat Utilities Summary Waterborne Base Coat Total Capital Investment Waterborne Base Coat Production Costs Waterborne Base Coat Raw Material Cost and Source A.1 Automotive Coatings Patent Summary... A-3 xiii