LIFE WATERBORNE BIOPAINT - An Innovative and sustainable process for the development of novel biobased waterborne paints

PROJECT DESCRIPTION

BACKGROUND

Despite the introduction of the EU REACH regulation in 2006, thousands of industrial chemicals remain in use with known or potential negative effects on human health and the environment. Within this framework, paints and coatings stand out, in spite of very stringent regulations in all European Member States. Yearly global paint production is currently estimated at 50 million tons, of which over 40% are Solvent-Borne (SB), solvents being the main source of volatile organic compounds (VOCs). In particular, of the 2.6 million tons of paints used for wood coatings, for furniture, fixtures, floorings, over 60% are SB, being dissolved in 0.8 million tons of flammable and toxic aromatics, acetates or ketones. Such VOCs also impact air quality and have a large CO2 footprint, estimated in 2.4 kg CO2/kg of paint. The most common alternatives are waterborne (WB) acrylic paint which only covers 25% of the market because of outstanding quality issues. Moreover, this kind of paint still has a CO2 footprint of 1.4 kg CO2/kg of paint, due mostly to the resin production from petrochemical sources. Further bio-based and solvent-less solutions are available but they are not suitable for most industrial applications.

OBJECTIVES

LIFE WATERBORNE BIOPAINT aims at demonstrating an innovative, highly sustainable, and efficient process to produce novel waterborne (WB) resins. The project also aims at producing paints and bio-based paints - using such WB resins so that the conventional paints currently used in wood coating (furniture, flooring, wood goods) can be substituted with more sustainable and environmentally-friendly products. The project products will be nearly VOC-free and non-hazardous, thus with lower environmental impacts in terms of VOC emissions, dangerous chemicals use, and CO2 footprint.

Specifically, the project aims to design and build a prototype pilot line with a full capacity of 2 500 tons/year, which includes a novel screw extrusion prototype pilot and ancillary systems especially developed to emulsify and dilute in water high-MW hydrophobic polymers.

The project helps implement the EU REACH regulation by replacing VOCs used as paint solvents with water, thus improving the protection of human health and the environment. The availability of new WB solutions is also expected to contribute to meeting the objectives of Directive 2004/42/CE on limiting emissions of VOCs due to the use of organic solvents in certain paints and varnishes, as well as Directive 2010/75/EU (Industrial Emissions Directive).

RESULTS

Expected results:

Production up to 20 tons of paints at project scale (2 500 ton/year at full capacity);

Reduction (90%) of VOCs release during paint application, corresponding to 9 tons not emitted at pilot scale and 1 125 ton/year at full capacity thanks to lower use (production and transport) and emissions;

Complete avoidance of VOCs release during the manufacturing process, corresponding to 4 kg at pilot scale and 500 kg/year at full capacity;

Substitution of hazardous oil-based raw materials in resins (e.g. acrylic acid, flammable, corrosive, harmful for eyes and skin and toxic for aquatic life) with safer and environmentally-friendly renewable bio-based materials (40%, corresponding to 1.6 tons at project scale, and 200 ton/year at full capacity);

Reduction of CO2 emissions (less than 0.8 kg CO2/kg of paint vs. 2.4 kg CO2/kg of paint, corresponding to 32 tons CO2 at pilot scale, and 4 000 tons CO2/year at full capacity); and

Reduction of waste generation (organic solvent) of 20 ton/year at full capacity.