1. Green Chemistry and the Automotive Supply Chain
Green Chemistry Institute
February 2, 2005

2. Green Chemistry
Green Chemistry develops products and processes that enhance performance and profitability while minimizing impacts on human health and the environment.
Green Chemistry has demonstrated achievements across industrial sectors including petrochemicals, pharmaceuticals, agriculture, electronics, aerospace, and defense.

3. Green Chemistry Institute
Founded in 1997 as an independent, nonprofit organization to promote green chemistry through research, education, information dissemination, industrial implementation, conferences and symposia
Formed an alliance with the American Chemical Society in 2001
Headquarters staff located in Washington D.C.
Worldwide network of technical expertise

4. Green Chemistry and Automotive Applications
Plastics and polymers
Foam
Adhesives and sealants
Fabrics and textiles
Paints and coatings
Refrigerants
Semiconductors and electronics

5. Plastics and polymers
Green Chemistry designs next generation polymers to minimize toxic additives (i.e., flame retardants, plasticizers, and thermal stabilizers).
These polymers can be made from biobased, renewable materials and controlled to be durable for reuse, developed to be self-healing, or degradable for beneficial disposition.

6. Foams
Foams developed using Green Chemistry principles can not only be generated from non-toxic materials and reduce or eliminate hazardous blowing agent but also provide superior performance measures.

7. Adhesives and sealants
The concerns for human health and the related to many traditional adhesives and sealants are well documents.
New Green Chemistry technologies are developing multi-functional and “obedient” sealants and adhesives for higher quality and reduced health impacts.

8. Fabrics and textiles
The fibers, dyes and colorants, surfactants, etc., that are used in textiles all play a role in determining the sustainability of the material.
By generating fabric and textile “systems”, issues of reuse, reclamation, toxicity and durability are being addressed by green chemistry practitioners.

9. Paints and coatings
One of the most active areas of development in green chemistry is in the paint and coatings field.
Through the use of nanoscience, biomimicry and cutting edge polymers, green chemistry designers are creating safer and more durable coating and paints.

10. Refrigerants
The historic challenges of refrigerants, toxicity, explosiveness, ozone depleting potential and global warming potential are all do to the molecular physical/chemical properties. Green Chemistry is developing new small molecule systems for safer and more effective refrigerants.

11. Semiconductors and electronics
In order to maximize performance while ensuring sustainability in the wide array of electronics used in automotive applications – green chemistry is allowing the use of new substances (including bird feathers), and materials integration that allows for disassembly and reuse.

12. Neutral Cleaners that Reduce Environmental and Health Impacts
Cleaning plays a significant role in metal part quality for processes like coating, plating, and bonding
ESS biodegradable, neutral pH aqueous cleaners have replaced the environmental and safety hazards of solvent and aqueous alkaline cleaners
Alkaline cleaners are composed mostly of high pH inorganic ingredients; ESS cleaners are completely organic and non-corrosive, which enhances worker safety and reduces mechanical wear
Elimination of these alkaline cleaners has a secondary impact of reducing waste, emissions, and regulatory management
By replacing alkaline and solvent cleaners in the last five years, ESS neutral cleaners have eliminated over 80 million pounds of hazardous materials from the environment
Environmentally Sensitive Solutions, Inc.

13. PreKote Surface Pretreatment (SP)
Hexavalent chromium (Cr+6), a known human carcinogen, has been a standard for corrosion protection on aluminum substrates prior to painting
PreKote SP is a proven replacement for Cr+6: significantly decreases operational costs; eliminates heavy metal waste streams; replaces toxic acids and solvents; improves worker safety and health, environmentally compliant
PreKote cleans the surface to be painted while simultaneously depositing a molecular layer that bonds to the surface of the metal
The United States Air Force’s total savings to date exceed $7.2 Million since PreKote’s commercial release in 2000
Pantheon Chemical
                                                 

14. Evapo-Rust™ Iron Oxide Specific, pH Neutral, Chelation
Use of corrosion removal solvents, limited to strong acids and caustics, is generally destructive to the material being treated and strips paints, plastic, and plating
This chemistry provides an industrial replacement product for corrosion control and iron preparation
Removes iron oxide without having any affect on plastic, acrylic and poly paint, rubber, aluminum, copper and other materials
One gallon of the product will de-rust roughly 300 pounds of steel at a cost of 4 to 6 cents per pound
Harris Labs

15. Molyphos: A Chromate-Free Alternative for Corrosion Protection of Metal Parts
Molyphos technology is an alternative to the use of hexavalent chromium for the corrosion protection of metal parts
Molyphos, a molybdenum-phosphate based conversion coating, replaces the principal reagents used in chromate conversion coatings: sodium chromate and sulfuric acid with sodium molybdate and phosphoric acid
Molyphos technology provides a significant reduction in toxicity – toxicity of chemicals used in manufacture, manufacturing waste, and treated metal parts
A significant source of chromium waste generation is metal finishing for corrosion resistance: the Toxic Release Inventory reported over 2 million pounds (1000 tons) generated or released from metal finishing facilities; Molyphos totally eliminates this hazard
Nortel Technology

16. Reducing VOC Emissions with New Color Laser Marking System
Marking or coding plastic parts is a challenge since many plastics require surface treatments before paint adheres
Printed marks and self-adhesive labels lack durability, have high scrap rates, and are environmentally unfavorable (involves use of aqueous-, UV-, or solvent-based inks and primers)
A relatively new option for decorating plastic parts is the use of industrial lasers to char a mark into the wallstock of a part
Laser marking avoids many of the environmental issues associated with printing and labeling: VOC release; special waste disposal; reduction in recyclability of scrapped parts
Estimates show that within first 2 years of use, the new color laser marking technology will replace approx. 10% of decorating processes, which would eliminate approx. 1,120 tons (2,240,000 pounds) of VOC emissions
M.A. Hanna Color

17. High Energy Efficient, Environmentally Friendly Refrigerants
Chlorofluorocarbons (CFCs) were the most widely used refrigerant working fluids for several decades; their production worldwide stopped at the end of 1995 after being implicated in stratospheric ozone depletion
Ikon refrigerants is a family of nonflammable, low toxicity, environmentally safe, medium-pressure refrigerant blends with zero ozone-depletion potential
Ikon refrigerants have been shown to have good compatibility with materials used in refrigeration systems; can be used in existing systems and designs without costly and expensive parts replacement or redesign
Ikon refrigerants significantly reduce emissions of CO2 (greenhouse gas) and NOX and SOX (pollutants)
Ikon, Inc.

18. RPS Technology for Water-Based Paints, Coatings, Adhesives, and Sealants
Reversibly Protected Silanol Technology produces ready-to-use, water-based paints, coatings, adhesives, and sealants that match the performance of solvent-based products
Reduces or eliminates the need for VOCs in many coating and adhesive applications; improves health and safety of workers regularly exposed to solvent-based products
RPS technology used alkoxysilanes that are designed to be inert during long-term storage and rapidly hydrolyze after application; this significantly reduces the amount of waste generated because of its excellent storage stability
Goodyear Tire & Rubber Company

19. Solvent-Less Manufacture of High Performance Dry Powder Coatings
The overall reduction of solvent use in manufacturing industries is contributed to the use of powder coatings rather than solvent-based paints and coatings
This technology produces dry powder coating products that can be applied to uncoated surfaces without the use of a solvent
High performance characteristics achieved by the use of crosslinkable acrylics in solventless systems by melt processing
Environmental impact: reduces levels of VOC emissions, use of naturally occurring raw materials, and energy in processing and recovery of solvents
Polymer Processing Institute, New Jersey Institute of Technology

20. NALMET Heavy Metal Removal Technology
Strict National Pollution Discharge Elimination System (NPDE) limits on metal concentrations in plant effluents impact both metal and non-metal industries
This technology consists of a liquid polymer containing a metal chelating functional group that precipitates metals and clarifies the waste stream simultaneously
Benefits of NALMET include a 25-90% reduction in sludge volumes, product overfeed is reduced, customers meet the extremely low (parts-per-billion) NPDES metals discharge limits
There are currently over 50 NALMET applications in the US and 25 globally
Nalco Chemical Company
                          

21. The end.

22. Looking ahead…

23. Green Chemistry Applications to Automotive Industry
Cleaners
Pretreatments
Rust Removal
Corrosion Protection
Plastic Parts Marking
Refrigerants
Paints
Coatings
Heavy Metal Removal