56 One of the biggest issues with phenolic urethanes are the volatile organic compounds (VOCs) that are used. These are the solvents that are added in the second phase of producing a Part-1 resin to reduce the viscosity which allows foundries to pump the product. The use of methyl esters in phenolic urethanes is not a new idea. This practice has been around since the mid-90s. However, during that period, the methyl esters used were derived from vegetable oils or rapeseed, leading to significant safety issues. The processing of these methyl esters resulted in the production of drying oils that oxidize, posing a potential risk for bag house and ductwork fires This new resin system (Emerald EQC) uses a non-drying methyl ester which has the same benefits as petroleum solvents without compromising safety. A significant benefit of incorporating a non-drying methyl ester solvent package into the resin is the dramatic decrease in VOCs. VOCs reductions range from 30-60% when compared with petroleum solvents. The Ohio Cast Metals Association (OCMA) protocol for VOC Testing for Foundry Binder Systems was used to determine the VOC emissions of this new resin system. An important secondary benefit is that these esters are non-hazardous and therefore are not regulated by the Department of Transportation (DOT). This provides more less expensive transportation options, which translates into increased savings for foundries. OCMA RESULTS Results for PUCB System – Emerald EQC In accordance with the Ohio Cast Metals Association (OCMA) protocol for VOC Testing for Foundry Binder Systems, the VOC Emission Factors were determined for Emerald EQC Part-1 and Part- 2 Phenolic Urethane Cold Box (PUCB) system. General Procedure A KitchenAid mixing bowl, blade, and 3,000 grams of a round grain silica sand: 48-54 AFS/GFN, were heated to 150° C for 4 hours. Upon cooling, this material was weighed, then the resin system was added and reweighed. The sand and resin mix were mixed in the KitchenAid mixer for two minutes, reweighed, and set in a fume hood. The entire bowl mix was reweighed over a period of 24 hours. The measured weight loss is calculated as the VOC emitted from this mix. VOC Emission Factor Calculation: VOC EF (Grams of VOC) (454 g of sand) (2,000 lb of sand) (1 lb of VOC) = lb of VOC (,3000 g of sand) (1 lb of sand (1 ton of sand) (454 g of VOC) ton of sand Grams of VOC = determined by the weight loss that occurs during the procedure sitting period. Procedure binder level is 1.0%, Part-1: Part-2 ratio is 55:45. Room Temperature: 77F Relative Humidity: 45% RICK YRIGOYEN National Sales Manager United Erie ARTICLE TAKEAWAYS: • Non-drying methyl ester solvents decrease VOCs • Non-hazardous esters mean less expensive transportation options NEW GENERATION OF PHENOLIC URETHANE RESIN SYSTEMS REDUCES VOCs
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