PREMISE: Environmental/Energy Comparative Analysis of Polymer Powder Coating Systems

该产品实现和环境制造创新系统（PREMISE）项目的技术方法涉及选择溶剂介质中的传统间歇聚合工艺，并与替代的无溶剂连续工艺进行比较。将通过考虑以下因素来比较所生产的固体粉末的应用：a）常规高温固化和B）通过UV辐射的低温固化。研究计划包括详细的工程计算;成本比较和生命周期分析（LCA）原则和环境设计（DFE）方法的应用，以确定替代系统的潜在优势，以及在连续无溶剂反应器中开发UV固化粉末配方的实验工作的启动。 聚合物粉末涂料为民用和军用应用的各种基材提供环境和腐蚀保护。与溶剂型涂料（其应用通常与显著的VOC排放相关）相比，粉末涂覆物品的生产有时被认为是“绿色”工艺。 然而，在传统粉末涂覆产品的生命周期中，从通过聚合制造粉末到其随后的应用和固化，仍然有许多元素在能量和溶剂使用方面过量。 基于在不存在溶剂的情况下的连续本体聚合工艺，随后在低温下UV引发固化的系统似乎是与常规系统相比减少能量使用和降低环境影响的优秀候选者。这项研究与涂料行业的研发重点高度相关，即降低总成本和降低固化温度沿着降低VOC和有害空气污染物（HAP）。 它也是相关的聚合物工程学术课程，将有关工业生态和环境问题的案例研究，在过程/产品设计的需求不断增长。

The technical approach in this Product Realization and Environmental Manufacturing Innovative Systems (PREMISE) project involves the selection of conventional batch polymerization processes in solvent media and comparison with alternative solventless continuous processes. Application of the produced solid powders will be compared by considering: a) conventional high temperature curing and b) lower temperature curing by UV radiation. The research plan includes detailed engineering calculations; cost comparison and application of life cycle analysis (LCA) principles and Design for Environment (DFE) methodologies to identify the potential advantages of the alternative systems as well as initiation of experimental work towards developing UV curable powder formulations in continuous solventless reactors. Polymeric powder coatings provide environmental and corrosion protection to a variety of substrates for civilian and military applications. By comparison to solvent based coatings whose application is often associated with significant VOC emissions, the production of powder-coated items is sometimes considered as a "green" process. However, there are still many elements in the lifecycle of conventional powder coated products, from manufacturing of the powder by polymerization to its subsequent application and curing, which are excessive in energy and solvent usage. Systems based on continuous bulk polymerization processes in the absence of solvents, followed by UV initiated curing at low temperatures appear to be excellent candidates for reduced energy usage and lower environmental impact versus conventional systems. This research is highly relevant to the R&D priorities of the coating industry, i.e. lower overall cost and lower curing temperatures along with low VOCs and hazardous air pollutants (HAPs). It is also relevant to the growing need in polymer engineering academic curricula to incorporate case studies related to industrial ecology and environmental issues in process/product design.