Green Chemistry and the Automotive Supply Chain Green Chemistry Institute February 2, 2005 www.acs.org/greenchemistryinstitute 202-872-6102

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.

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

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

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.

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.

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.

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.

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.

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.

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.

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.

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                                                  

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

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

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

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.

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

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

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                           

The end.

Looking ahead…

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