Mekelle University

Mekelle institute of technology

Department of chemical engineering
Team work project process I (group 3)
Title: surface coating industries

Group members Id number

1. Gebrewahd werkalem…………….mit/ur/1057/10
2. Hafte kalayu………..………….….mit/ur/1065/10
3. Haftu mehari…………………..…..mit/ur/1067/10
4. Kidane hagos ………………….….mit/ur/1086/10
5. molla hayelom……………….…….mit/ur/10100/10

Submitted to ins. Tarik Hishe

Submission date 20/04/2010e.c

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Contents
Introduction .................................................................................................................................................. 3
Surface-Coating material .............................................................................................................................. 4
Manufacturing process ................................................................................................................................. 6
Byproduct/wastes ......................................................................................................................................... 7
Application of surface coating ...................................................................................................................... 8
Environmental effect .................................................................................................................................... 9
Reference ...................................................................................................................................................... 9

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Introduction
Surface coating is an economic method for the production of materials, tools and machine parts
that require the desired surface properties such as corrosion, erosion and wear resistance.
Individuals and industry tend to focus on the wearing surface that has the greatest impact on their
own economic situations.
The surface characteristics of engineering materials have a significant effect on the serviceability
and life of a component thus cannot be neglected in design. Wear resistance of materials can be
improved through surface modification techniques. Surface coatings may improve the surface’s
resistance to corrosion, erosion, impact breaks and abrasive wear. Surface engineering can be
defined as the branch of science that deals with methods for achieving the desired surface
requirements and their behavior in service for engineering components.

The effect of surfacing on component life and performance will depend upon the surface material,
alloy, service conditions and the application. The term coatings includes paints, varnishes,
lacquers, enamels and shellacs, putties, wood fillers and sealers, paint and varnish removers, paint
brush cleaners and allied paint products. Liquid coatings contain pigments and additives dispersed
in a liquid binder and solvent mixture.

Pigments are inorganic or organic compounds that provide coating color and opacity and influence
coating flow and durability. Pigments often contain heavy metals such as cadmium, lead, zinc,
chromium and cobalt. The binder increases coating adhesiveness, cohesiveness and consistency
and is the primary component that remains on the surface when coating is completed. Binders
include a variety of oils, resins, rubbers and polymers. Additives such as fillers and extenders may
be added to coatings to reduce manufacturing costs and increase coating durability.

The types of organic solvents used in coatings include aliphatic hydrocarbons, aromatic
hydrocarbons, esters, ketones, glycol ethers and alcohols. Solvents disperse or dissolve the binders
and decrease the coating viscosity and thickness. Solvents used in coatings formulations are
hazardous because many are human carcinogens and are flammable or explosive. Most solvents
contained in a coating evaporate when the coating cures, which generates volatile organic
compound (VOC) emissions. VOC emissions are becoming increasingly regulated because of the
negative effects on human health and the environment. Environmental concerns associated with
conventional ingredients, coating application technologies and coating wastes are a driving force
for developing pollution prevention alternatives.

Most coatings are used on architectural, industrial or special products. Architectural coatings are
used in buildings and building products and for decorative and protective services such as
varnishes to protect wood. Industrial facilities incorporate coating operations in various production
processes. The automotive, metal can, farm machinery, coil coating, wood and metal furniture and
fixtures, and household appliance industries are the major industrial coatings consumers. Design
of a coating formulation depends on the purpose of the coating application. Coatings provide
aesthetics, and corrosion and surface protection. Cost, function, product safety, environmental
safety, transfer efficiency and drying and curing speed determine formulations..

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Surface-Coating material
Surface coating materials are classified into the following four major raw material categories:
I. Resins or binders
II. Pigments
III. Additives
IV. Solvents.

Resins or binders
Resins are the most important components of coatings since many important properties of dry
films, such as hardness, adhesion, chemical and solvent resistance and durability, are primarily
dependent on the nature of the resins used. After application of coatings, resins form useful films
by a variety of physical and/or chemical mechanisms that convert liquid films into a dry coating.
The term binder is frequently used to refer to a resin since one of its roles is to “bind” pigment
particles in the dry film. Resins used for paints and coatings are polymeric materials with film
forming capabilities. Resins control most of the physical, chemical and mechanical properties of
the coatings. It is important to note that while there are hundreds of types of polymers
commercially available, only a few are useful as binders for coatings because of the specific
requirements for the successful use of binders in coatings.

Pigments
Pigments are finely divided colored insoluble particles having a high refractive index, typically
greater than 1.70. Pigments, when uniformly dispersed in the resin (medium), impart color and
opacity to the cured film. Thus, color and opacity are the primary functions of pigments. In
addition, some pigments (for example, chrome pigments, zinc phosphate pigments) exhibit
functional properties such as corrosion resistance, resistance to UV light, and anti-fouling
properties. Pigments are also used to control rheology, exterior durability and mechanical
properties of the films. Pigments with high light reflectivity and specific particle size and shape
are used in special effect coatings. Pigments are classified based on their origin, whether natural
or synthetic, and on their functions as organic, inorganic, metallic, and special effect pigments.
Additives
In order to facilitate manufacturing, storage and satisfactory application and to improve durability and
performance, it is essential to incorporate special additives to coatings. Additives are compounds added
in small quantities (up to ~5 % by weight) that substantially improve or modify properties of coatings.
These compounds include wetting and dispersing agents, which help disperse the pigment particles in the
medium, driers that help faster drying of coating films, plasticizers, UV stabilizers, rheology modifiers,
preservatives, and others. Their types and amounts must be carefully selected, as they may have
unintended results when used inappropriately. For their successful performance, the coating formulator

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must have good knowledge about the role of additives and their interactions with other components of
coatings.

Solvents
Solvents are primarily used to control viscosity of the coatings for acceptable application. These
are essentially volatile compounds Anatomy of paints and coatings 27 that must evaporate from
the film after application. Solvents also affect such properties as flow and leveling, drying time,
gloss etc. A wide range of organic solvent types are used in coatings. Many of these solvents are
VOCs, which have harmful effects on human health and the environment. Over the past several
decades, there have been significant efforts in developed nations to reduce VOC emissions, and
there are increasingly stringent regulatory requirements for use of such solvents in coatings.
Waterborne coatings, which use water as the primary carrier replacing organic solvents, have
therefore significantly grown over solvent based coatings as the preferred coating types for a
number of end-use applications.

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Manufacturing process
Making the paste
Pigment manufacturers send bags of fine grain pigments to paint plants. There, the pigment is
premixed with resin one or more solvents, and additives to form a past

Dispersing the pigment

The paste mixture for most industrial and some consumer paints is now routed into a sand mill, a
large cylinder that stirs fine particles of sand or silica to grind the pigment particles, making them
smaller and dispersing them throughout the mixture. The mixture is then filtered to remove the
sand particles. Instead of being processed in sand mills, up to 90 % of the water-based latex paints
designed for use by individual homeowners are instead processed in a high-speed dispersion tank.
There, the premixed paste is subjected to high-speed agitation by a circular, toothed blade attached
to a rotating shaft. This process blends the pigment into the solvent.

Thinning the paste

Whether created by a sand mill or a dispersion tank, the paste must now be thinned to produce the
last product. Transferred to large kettles, it is stirred with the proper amount of solvent for the type
of paint desired.

Canning the paint

The finished paint product is then pumped into the canning room. For the standard 8 pint (3.78
liter) paint can available to consumers, empty cans are first rolled horizontally onto labels, then set
upright so that the paint can be pumped into them. A machine places lids onto the filled cans, and
a second machine presses on the lids to seal them. From wire that is enter into it from coils, a
bailometer cuts and shapes the handles before hooking them into holes precut in the cans. A certain
number of cans (usually four) are then boxed and stacked before being sent to the warehouse.

Quality control
Paint manufacturers uses an extensive array of quality control measures. The ingredients and the
manufacturing process undergo stringent tests, and the last product is checked to insure that it is
of the required quality. A finished paint is inspected for its density, fineness of grind, dispersion,
and viscosity. Paint is then applied to a surface and studied for bleed resistance, rate of drying, and
texture.

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In terms of the coating aesthetic components, color is checked by an experienced observer and by
spectral analysis to see if it matches a standard desired color. Resistance of the color to fading
caused by the elements is determined by exposing a portion of a coated surface to an arc light and
comparing the amount of fading to a pa surface coated that was not so exposed. The paint's hiding
power is measured by coating it over a black surface and a white surface. The ratio of coverage on
the black surface to coverage on the white surface is then determined, with .98 being high-quality
paint. Gloss is measured by determining the amount of reflected light given off a painted surface.
Tests to measure the paint's more functional qualities include one for mar resistance, which entails
scratching or abrading a dried coat of paint. Adhesion is tested by making a crosshatch, calibrated
to .07 inch (2 millimeters), on a dried paint surface. A piece of tape is applied to the crosshatch,
then pulled off; good paint will remain on the surface. Scrub ability is tested by a machine that
rubs a soapy brush over the paint's surface. A system also exists to rate settling. An excellent paint
can sit for six months with no settling and rate a ten. Poor paint, however, will settle into an
immiscible lump of pigment on the bottom of the can and rate a zero. Weathering is tested by
exposing the paint to outdoor conditions. Artificial weathering exposes a painted surface to sun,
water, extreme temperature, humidity, or sulfuric gases. Fire retardancy is checked by burning the
paint and determining its weight loss. If the amount lost is more than 10 percent, the paint is not
considered fire-resistant.

Byproduct/wastes
A recent regulation concerning the emission of volatile organic compounds affects the coating
industry, especially manufacturers of industrial oil-based paints. It is estimated that all coatings,
including stains and varnishes, are responsible for 1.8 percent of the 2.3 million metric tons of
VOCs released per year. The new regulation permits each liter of paint to contain no more than
250 grams (8.75 ounces) of solvent. Paint manufacturers can replace the solvents with pigment,
fillers, or other solids inherent to the basic paint formula. This method produces thicker paints that
are harder to apply, and it is not yet known if such paints are long lasting. Other solutions include
using paint powder coatings that use no solvents, applying paint in closed systems from which
VOCs can be retrieved, using water as a solvent, or using acrylics that dry under ultraviolet light
or heat. A consumer with some unused paint on hand can return it to the point of purchase for
proper treatment.
A large paint manufacturer will have an in-house wastewater treatment facility that treats all liquids
generated on-site, even storm water run-off. The facility is monitored 24 hours a day, and the
Environmental Protection Agency (EPA) does a periodic records and systems check of all paint
facilities. The liquid portion of the waste is treated on-site to the standards of the local publicly
owned wastewater treatment facility; it can be used to make low-quality paint. Latex sludge can
be retrieved and used as fillers in other industrial products. Waste solvents can be recovered and
used as fuels for other industries. A clean paint container can be reused or sent to the local landfill.

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Application of surface coating
The application of Industrial coatings can be found across industrial and commercial settings. The
reason why we need to coat food container is to prevent corrosion and comply with food safety
standards, whereas the reason why we need coating steel beams is to prevent corrosion that also
withstand certain fire and temperature conditions. The importance of carefully selecting the
coating and application method is to produce safer products with longer service.
The application of industrial coatings is to protect materials and components ranging from
infrastructural piping to machinery to floors and other surfaces. We apply coatings by spray, brush,
or dipped, with each application type requiring carefully crafted formulating. Your company’s
application method of choice should give you gratitude your production capabilities and create
efficiencies rather than bottlenecks.
Other than protecting form corrosion industrial coatings have applications
. Varieties of coating materials can:

 Prevent parts from heavy wear, physical impact damage, and/or heat and fire
 Give non-slip or non-stick surface friction on floors, handles, and machining surfaces.
 push dirt, grease, and contaminants with a nonporous topcoat
 Popular applications include:

 Building Materials: Architectural products and engineered roofing and decking

systems
 Construction: Tools, heavy equipment, and infrastructure parts
 Consumer Packaged Goods: Canning, commercial containers, plastics
 Manufacturing: Industrial machinery, walking

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 Environmental effect
We report on the effect of surface charge and the ligand coating composition of CdSe/ZnS
core/shell quantum dot nanoparticles on human keratinocyte toxicity using fluorescent
microscopy, flow cytometry, transmission electron microscopy. Two commonly reported positive
charged (cysteamine, polyethylenimine) and two negative charged (glutathione, dihydrolipoic
acid) ligands were studied.
The QDs were fully characterized by UV-vis absorption spectroscopy, fluorescence emission
spectroscopy, dynamic light scattering and zeta potential. Differences in surface coatings and
charges were evaluated against cellular uptake, ROS generation, cytotoxicity, and mitochondrial
targeting. Results show that the negative charged QDs coated with GSH exhibit excellent water
solubility, high quantum yield and low cytotoxicity.
Ligand composition is more important in ROS generation than surface charge whereas surface
charge is an important driver of cytotoxicity. Most importantly we observe the selective
accumulation of glutathione coated QDs in vesicles in the mitochondria matrix. This observation
suggests a new strategy for developing mitochondria-targeted nanomaterials for drug/gene
delivery.

Reference
 Mannari | Patel Understanding Coatings Raw Materials
 BBI2421 PJJ - Lecture Notes 4 (Paragraph Sample)
 http://vujz.speedlager-cup-wedel.de/surface-coating-pdf.html
 http://www.madehow.com/Volume-1/Paint.html#ixzz69ZKfW4Mr
 [Halling, J., “Introduction: Recent Development in Surface Coating and Modification Processes”,
MEP, London, 1985].
 surfaceshttps://www.aexcelcorp.com/resources/guides/industrial-coatings-guide
 https://blog.misumiusa.com/surface-treatment-processes-and-coating-techniques
 [Stokes, J., “Theory and Application of the High Velocity Oxy-Fuel (HVOF) Thermal Spray
Process”, Dublin City University, 2008].