Periodic Reporting for period 4 - KEMISTATIC (New ElectroSTATIC Spraying Process of Two-Component, Solvent-Free, Fast-Curing, Liquid Resins) Reporting period: 2021-04-01 to 2021-12-31 Summary of the context and overall objectives of the project Water-based coatings lead the coating demand worldwide. However, they present some drawbacks (poor durability and resistance to corrosion). Powder coatings have better durability and performance, but still present important disadvantages: They contain hazardous compounds (Bisphenol A) and require a curing step in oven (200ºC) that makes them energetically costly and not suitable for substrates like wood and EPS or big objects/infrastructures, like bridges or wind turbines. In addition, they have poor aesthetic value.We have developed KEMISTATIC, a disruptive, environmentally friendly and patented coating technology, which aims to replace the conventional powder coating and liquid paint coating systems. It is based on the electrostatic application of a polyurethane resins specially developed for that application. They are free of solvent, Bisphenol and VOCs (volatile organic compounds). KEMISTATIC provides enhanced protection (corrosion, wear resistance, electrical insulation) and aesthetic potential, at a lower production cost (up to 5 times) and sales price (up to 3 times), and not requiring a curing step in oven. Thus, KEMISTATIC overcomes the substrate limitation and is suitable for a wide range of materials and in toolshop, while requiring a low initial investment (€150,000).KEMISTATIC can be used in many industries (Automotive, Architectural, Furniture, etc.), and save up to €180,000/ year/job coater and 150m3/hour of gas emissions. We aim to reach worldwide markets, starting in Europe, then North Africa and Asia and finally US and the rest of the World. Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far From a proof of concept, we have first developed a prototype version before building two serial representative machines : one dedicated to the electrostatic coating and the second one dedicated to the internal pipeline coating. A specific spraying head has been built, made of an injector, a rotating bowl and a drive specifically developed for that application. The resin, injected into the rotating bowl, is sprayed thanks to the centrifugal force generated. For the electrostatic spraying machine, a high voltage is applied to charge the resin and to create the necessary electric field to push the resin towards the target. A specific 2K PU resin has been developed for the application. Critical parameters have been measured and adjusted in function of the temperature such as the viscosity and the electrical conductivity. The sprayed coating quality has been validated by measuring mechanical properties such as the hardness and the mechanical tensile strength.In addition, we have tested and validated a technical solution to apply electrostatically powders or fibers on top of the coating in order to create new aesthetic finishes. We can apply mineral or metallic powders as well as fibers on top of a surface, in order to change the color and/or the texture of the surface.We have defined and implemented a communication and dissemination plan in order to promote our solutions : posts publication on a weekly basis on the main social medias, creation of a bi-monthly newsletter, update and referencing of our website, participation to trade fairs and to congresses, …First in-house workshops with customers have been set-up to prepare the sales activity. Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far) KEMICA COATINGS has created an innovative electrostatic spraying equipment to incorporate the new KEMISTATIC two-component, solvent-free, liquid resins. For the spraying method, we have developed a technology able to spray electrostatically a two-component, solvent free, fast curing resin to spray very fine particles. For this purpose, we have incorporated a low-pressure pumping unit (20 bars). When the resin is sprayed, the two components are mixed in a rotating bowl at a very high speed (20,000rpm). The result is the creation of a ‘’cloud’’ like smoke, which is electrically charged with a high voltage power generator, to be deposited on a grounded substrate to coat.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, water heaters, 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. KEMISTATIC has also a big potential market in protecting ventilation ducts internally and externally, especially in plants requiring decontaminatable coatings like nuclear plants, pharmaceutical plants where coating preventing development of bacteria contamination , and also Legionelas are looked for.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 which 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 which identified the ‘’green’’ aspect of KEMISTATIC, has already confirmed their support into helping potential customers (through subsidies) to invest in our technology. Finally, our solution has an A+ environmental qualification by CSTB. kemica coatng logo
