Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - KEMISTATIC (New ElectroSTATIC Spraying Process of Two-Component, Solvent-Free, Fast-Curing, Liquid Resins)

Teaser

The industrial coatings market is projected to reach $130.97 billion by 2022, at a CAGR of 5.91% between 2017 and 20221. Based on the technology, the market is segmented in powder coatings, water-borne coatings, solventborne coatings, radiation-cured coatings, and others...

Summary

The industrial coatings market is projected to reach $130.97 billion by 2022, at a CAGR of 5.91% between 2017 and 20221. Based on the technology, the market is segmented in powder coatings, water-borne coatings, solventborne coatings, radiation-cured coatings, and others. Currently, solvent-borne coatings account for the major share in the market (48% in 2013) and the second in volume (41% in 2013), due to their better performance compared to other coatings. However, due to stringent regulations to reduce volatile organic compounds (VOC) emissions and consumer demands for cleaner coatings technologies, water-based coatings are replacing the solvent-based (52% share of volume and 40% in value in 2013).
Even so, water-based coatings present some performance drawbacks like poor durability and resistance to corrosion, chemicals and weather in comparison to powder coatings, that are more resistant to chipping, scratching and other such wear due to the thermal bonding process during curing. Powder coatings provide a more uniform coating with most attractive, durable and high-quality finish available. As a result, the powder coatings demand by the customers has increased in many applications, replacing the liquid coatings in the appliances segment, while architectural, automotive, ACME (mining equipment), and pipe coating applications offer promising growth opportunities. In this sense, the Global powder coatings market revenue was estimated at $7.73 billion in 2013 and is expected to grow at a compound annual growth rate (CAGR) of 7.1% between 2013 and 2020.

Economic, environmental and social benefits:
Energy saving: Powder coating needs up to 60-meter long ovens to heat up to 200°C the pieces to coat to melt the powder. Electrostatic paint systems, also need drying ovens at high temperature (150°C), therefore, the energy consumption is also high. With KEMISTATIC it is not necessary to heat the substrate, therefore KEMISTATIC can provide energy saving up to 180 k€/year and 150m3/hour of CO2 emissions.
With our system, we can give up to 15 years guarantee for corrosion protection, with a film thickness of 700μ. Lifespan of coated equipment with KEMISTATIC resin is at least doubled (before any maintenance or coating renovation is needed).
KEMISTATIC resin is approved for direct contact with potable water (A.C.S.) without Bisphenol A. However, epoxy powders have Bisphenol A in their composition, and therefore are considered harmful for the health. Many companies are looking for coatings which are a substitute to Bisphenol A14 and presently there is no coating system able to offer such a resin applied electrostatically.

kemica coatings pioneering solution: kemistatic
KEMISTATIC is our pioneering technology to respond to those needs and replace the existing powder coating methods. We have developed a new, completely solvent-free, two-component, liquid resin to be applied through an innovative electrostatic spraying method, without the need of heating the substrate, and presenting the following advantages:
- Enhanced environmental benefits (VOCs & Bisphenol-A free, zero CO2 & save up to 150m3/hour gas emissions)
- No need of heating the substrate
- Application on any type of material (wood, EPS, electrical equipment, etc.), at a thickness from 60µ up to 2 mm in one single layer with endless finishing variety (aesthetic aspect).
- No size limit.
- Better performance: High corrosion protection, resistant to chemicals, high electrical insulation, wear and abrasion strength resistant, among others.

Work performed

Equipment development :
- Prototype development : technical solution identification, component sourcing and assembly, equipment testing and set-up. End of march, the electrical generator was the only function missing on the 1st prototype.
Resin formulas development :
- Resin formulas improvement (CMR removal, conductive agent testing) in progress.
- Resin characterization for electrostatic spray : study of the variation of viscosity and conductivity Vs temperature .Done
- Certification : CEVALIA (launched), Offshore platform (launched), FCBA (preliminary documentation)
Equipment production at industrial scale :
- technical solution identification, component sourcing and integration.
Dissemination and commercialization activities
- Company visual identity renewed
- Posts published on a weekly basis on the social networks
- External newsletter created published bi-monthly
- Flyers & posters created
- Web page dedicated to Kemistatic created / Kemica Coatings homepage complete renewal launched
- Product branding and marketing actions. In progress.
- Attendance to fairs and workshops

Final results

KEMISTATIC’s main goal is to replace the existing coating methods and resins. Hence, it is primarily focused on the coating industry and especially where powder coating is used. Its great range of applications includes the coating & protection of pump, valve & pipes, EPS, wood structures (frames, doors, etc.) and industrial equipment (propellers, tanks, etc.). Regarding the corrosion protection of steel structures KEMISTATIC process can replace the steel galvanization (hot & cold), as a higher corrosion protection and a reduced cost (2-4 times) solution. For Instance, we are working with ECCS (European Convention for Constructional Steelwork) to use our technology in the aerogenerator towers in bridges to improve the steal resistant in harsh environments at reduced cost.
KEMISTATIC technology also presents a unique advantage, since it can be used on-site, for large equipments and infrastructures. Moreover, the aesthetic finishing potentials can create opportunities in new sectors, such as urban furniture; appearance of natural stone to coat phone and electrical poles or EPS panels on buildings, etc.

Opportunities :
Technical: Because of the environmental benefits, performance and durability of KEMISTATIC technology and its competitive price, we are opening new market business, specially, those addressed to some special applications (electrical insulation, nuclear energy, etc.) and substrates (wood, EPS, etc.), which because of the difficulty to coat (large equipment) and/or expensive cost that means, the manufacturers have few alternatives to fulfill their needs. For instance, the value of wood and products of wood and cork, painting materials, etc., sold in 2012 achieved €91M and for electrical equipment €222M in EU8).
Regulatory: Because we already have many certifications from our current products in the market, we don\'t need to apply for a long list of certifications that it would be required and some of our resins have been already approved by the Ministry of Health according to European positive lists for direct contact with potable liquids (water, wine, beer, e.g. EUROFIN, certification for potable water without Bisphenol A) and food equipment (cheese trays, etc., e.g. ITECh for bacteria and fungi development).
Commercial: the introduction of KEMISTATIC technology is supported by ADEME (L’Agence de l’Environnement et de la Maîtrise de l’Energie) in France that identifying the ‘’green’’ aspect of KEMISTATIC, has already confirmed their support into helping potential customers (through subsidies) to invest in our technology (See letter of support). Moreover, our solution has an A+ environmental qualification by CSTB.

Website & more info

More info: https://www.kemica-coatings.com.