Green Chemistry and Design Demonstration Project

Intent: Demonstrate the extent to which state grant support can stimulate green chemistry and design projects in the private sector.

This web page will serve as a clearinghouse for updates on the implementation of ongoing projects and for other information supporting or generated by the demonstration projects.

Ongoing projects

Cortec Corporation

 MPCA Contact: This e-mail address is being protected from spambots. You need JavaScript enabled to view it.   (for referrals to company contacts)

Project Summary

The MPCA developed an agreement on a demonstration project with Cortec Corporation (White Bear Township, Minn.). The objective of this project is to develop a commercially viable, water-borne, corrosion-resistant metal primer, with a Volatile Organic Compound (VOC) level of less than 25 grams/liter. If successful, this will provide performance (and renewable content) similar to a traditional Alkyd coating, with the convenience and environmental benefits of a latex paint.

Metrics

1. Reduction in VOC content achieved with the new product formulation
2. Reduction in pounds of chemicals used and/or released at baseline and a projection of what will be used/released  and a percentage reduction for all metrics categories (use, waste, energy) after the project is implemented
3. Life-cycle production/distribution inputs and management methods to demonstrate how new technology will be an overall improvement

Budget

Grant amount $17,811 + Matching funds/In-kind $9,000 = Total project budget $26,811

Basic Workplan

• Task 1: Develop and test primer formulations
• Task 2: Adjust formulations per results of Task 1
• Task 3: Test 1-3 test formulations in pilot quantities
• Task 4: Prepare and submit interim reports (9/15/11 and 11/30/11) and final report (06/01/12)

Progress Report

Test panels were produced from 13 different formulations. To date, the company is making good progress towards their target of 500 hours in the salt spray chamber but reaching 500 hours in the humidity chamber is proving to be more of a challenge. The specific test formulations are confidential information. The current best formulation has a VOC content of approximately 50 g/l (somewhat above the target of 25 g/l).

The current focus is finding a more optimal combination of extender pigments and anti-corrosive pigments, to improve the salt spray and especially the humidity chamber performance. They still have several more raw materials to evaluate. Cortec may reassess the scope/direction for this project if the resin technology being tested proves to be incapable of reaching the performance targets Cortec has set.

Salo Manufacturing

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Project Summary

The objective of the project was for Salo Manufacturing (Menahga, Minn.) to determine whether the company could economically manufacture bathtub and shower units with low styrene soy-based or non-styrene resins and gel coats, and at the same time maintain the structural and cosmetic characteristics of the units manufactured with their previous raw materials. They determined occupational exposure to styrene during production experimentation.

Metrics

Replace acetone with Acrastrip

1. Replaced 8,000 pounds of acetone with Acrastrip
2.  Will replace 14,000 pounds/year of acetone with Acrastrip
3. Avoided 600 pounds of acetone-related hazardous waste
4. Will avoid 900 pounds/year of acetone-related hazardous waste
5. Will avoid 3570 pounds/year VOC emissions
6. Will save $400 to $600 annually in hazardous waste fees

Switch to foam slab material component

1. Will avoid 470 pounds/year of polyurethane waste
2. Will avoid 5.8 grams/year of isocyanate emissions

Switch to VOC-free release agents

1. Will avoid 100 pounds/year VOCs

Budget

Grant amount $16,080.00 + Matching funds/In-kind $8,340.16 = Total project budget $24,420.16

Basic Workplan

• Task 1: Research Alternative Raw Material
• Task 2: Compatibility Determination
• Task 3: Production Experimenting
• Task 4: Structural/Cosmetic Evaluations
• Task 5: Final Report and Determination

Progress Report

Work on this demonstration began on May 18, 2011, and is now complete. MnTAP intern Paul Henriksen, a U of MN junior majoring in chemical engineering, assisted in this project. 

Resin trials
The company researched several different potential raw materials, including some resins, gel coats, and mold releases to determine what was available on the market, as well as if/how each material would work in the manufacturing process.  Research showed that a low or styrene-free gel coat was not available.

Alternative resins were selected and brought in for analysis.  Sample panels were made as well as full production units.  Sample units were submitted to the National Association of Home Builders (NAHB) Research Center for structural evaluations.  The units did not pass inspection, as they exceeded the allowed level of deflection. 

The best alternative resin Salo tried was the styrene-free resin, which was also the most expensive.  If Salo switched to this resin immediately, they would realize about a $200 annual savings in emission fees, but would see an increase of over $500,000 in annual resin costs.
 
Salo would consider switching to this styrene-free resin in the future if styrene becomes a listed known carcinogen. If this switch is made, this resin could potentially be formulated differently or used with a different catalyst to assist the finished product in having less deflection.

Workplace monitoring
Two samples were taken from the laminate booth while spraying the current resin during normal production.  The lab results from these tests show the readings to be 12ppm and 16ppm.  A sample was taken in the laminate booth while spraying the styrene-free resin, the result being 7ppm.  The floor of their production facility was full of curing parts made with the current resin; this most likely caused the reading to contain some amount of styrene. Further monitoring work would help clarify such situations.

Foam bases
Salo intends to pursue the use of environmentally friendly foam pads to use as support for the bottom side of their handicap accessible barrier-free showers.  If Salo can make this work, it would save the installer time, material, and labor by not having to set each shower in a bedding compound because the unit would have a prefilled floor and could simply be set in place. 

Conversion to water-based mold cleaner, mold sealer, and mold release
Preliminary findings show that a water-based mold cleaner, mold sealer, and mold release will perform similarly to Salo’s current system.  Conversion will probably take over a year, because Salo has so many molds.  Although the product cost is a little higher, the water-based product should last longer, as it will not evaporate as quickly as the current product. Salo estimates that the longer life of the product will even out with the higher cost.

Elimination of Acetone
Salo is partially through complete conversion from acetone to an environmentally-friendly acetone replacement product, Polychem Acrastrip.  Before the use of Acrastrip at their facility, Salo consumed approximately 14,000 pounds of acetone on an annual basis.  At their current status, they have reduced this amount to about 6,000 pounds annually by replacing the other 8,000 pounds with Acrastip.  The conversion accomplished to date will save them about 1.5 barrels, or 600 pounds, of hazardous waste each year, which equals approximately $400-$600 annually in hazardous waste disposal fees. 

Reports
Interim reports and final report were submitted by company.

Ecolab

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Project Summary

Through the MPCA Green Chemistry Demonstration Grant, Ecolab (Eagan, Minn.) will  pursue new designs for several of their key hard surface cleaning products for optimum efficacy and enhanced human health and environmental safety.  Thinking of each product’s cleaning chemistry and its packaging as a system, Ecolab will use life cycle approaches to understand and improve life-cycle impacts of each cleaning system.  The project scope is the core set of Ecolab products used in general hard surface cleaning; glass cleaner, all purpose cleaner, and neutral, alkaline, and acid bathroom cleaners, affecting multiple Ecolab market segments including hospitality, building service contractors, long term care, and government/education.

Metrics

If Ecolab is successful, the ideal final systems will show positives in these metrics:

1. % of the chemistry and packaging based on renewable raw materials;
2. Analysis of chemical raw material choices to include considerations of the renewable source;
3. Bio-based % of the chemistry;
4. Acute Human Oral Toxicity and Aquatic Toxicity;
5. % Volatile Organic Compounds;
6. Biodegradation of the chemistry;
7. Sustainability profile of the packaging, based on packaging source reduction and % recycled content or post consumer resin used in the manufacture of the package;
8. Side by side analysis of the proposed GHS Material Safety Data Sheet (MSDS) for existing best-in-class Ecolab products vs. the products designed within this project.

Budget

Grant amount $52,000.00 + Matching funds/In-kind $26,950.00 = Total project budget $78,950.00

Basic Workplan

• Task 1.  Develop and Optimize Glass Cleaner – May 2011 to December 2011
• Task 2.  Develop and Optimize All Purpose Cleaner - May 2011 to July 2012
• Task 3.  Develop and Optimize Neutral Bathroom Cleaner - May 2011 to April 2012
• Task 4.  Develop and Optimize Alkaline Bathroom Cleaner - June 2011 to September 2012
• Task 5.  Develop and Optimize Acid Bathroom Cleaner - May 2011 to September 2012
• Task 6.  Sustainable Packaging - May 2011 to September 2012
• Task 7.  Preparation of Project Reports – Semi-annual reports (09/30/11 and 03/31/12); Final report (09/30/12)

Market launch of these products is at Ecolab’s discretion depending on market needs.  Certain tasks may extend beyond the timeframe of the project if Ecolab should decide to pursue 3rd party certifications or EPA Registration.

Reporting

Ecolab submitted their first semi-annual September 29, 2011, on-schedule.  Following are edited excerpts.

Status versus Work Plan
Objective 1: Glass Cleaner — Per the tasks outlined in the Work Plan, the glass cleaner project is currently in local field tests (task 1F). Feedback is positive regarding the performance of the formula. Next steps include final calculations of all metrics as listed in the metrics tables (tasks 1G & 1H).

Objective 2: All Purpose Cleaner — Per the tasks outlined in the Work Plan, the all purpose cleaner project is currently in development in the lab (task 2C). Next steps include regulatory consultation and submission to field test (tasks 2D & 2E).

Objective 3: Neutral Bath Cleaner — Per the tasks outlined in the Work Plan, the neutral bath cleaner is currently in development in the lab (task 3C). Submission for regulatory consultation began in September (task 3D). Next steps include packaging compatibility and field test (tasks 3E & 3F).

Objective 4: Alkaline Bath Cleaner — Per the tasks outlined in the Work Plan, the alkaline bath cleaner is currently in lab development (task 4C). Next step includes regulatory consultation (task 4D).

Objective 5: Acid Bathroom Cleaner — Per the tasks outlined in the Work Plan, the acid bathroom cleaner is currently in local field tests (task 5F). Next steps include additional optimization of the formula (task 5G).

Objective 6: Sustainable Packaging — Per the tasks outlined in the Work Plan, the sustainable packaging project is currently in testing of alternative packaging materials (task 6B). Next step includes proposal of new designs (task 6C).

Objective 7: Reporting – First Interim Report submitted September 29.  Two invoices submitted through September 29.  Ecolab and MPCA staff met at Ecolab on August 31 for a project briefing and tour.

Project-Wide Discussion by Metric

Section 1: Percentage of chemistry and packaging based on renewable raw materials

1.0 The Ecolab team is working with multiple raw materials across their hard surface product line which allows them to remove petroleum based raw materials and move towards renewable raw materials. Examples of renewable raw materials being used or considered are listed in section 2.0. The formulations are striving to move away from both petroleum based materials and harsh materials which cause eye/skin irritation. The challenge exists that some renewable materials (non-petroleum based) are actually harsher to the eye/skin/airway than the petro-based materials. Ecolab will continue to strive to balance this impact. Since all formulas are still in the prototype phase, calculations to show projected reduction in petroleum-based chemistry are not complete.

1.1 The team researched options for renewable packaging sources. The prime focus was on plant based resins (corn, sugar cane, cellulose). Plant based resins have very limited availability. In fact, large corporations have already locked down the current supply of sugar cane based resin from Brazil. The current cost of plant based resin is approximately twice that of similar petroleum based sources. With this in mind, Ecolab continues to work with their suppliers to find other economical sources of plant based resin. Ecolab has conducted chemical compatibility testing on biodegradable corn-based polylactic acid plastic material with some success. However, the packaging was sensitive to heat which is challenging in many Ecolab accounts and warehouses.

Section 2: Analysis of Chemical Raw Material Choices

2.0 Considering the raw materials listed in section 1.0, the team outlined the sourcing options of these raw materials. In table 2.0 below, each raw material in consideration is outlined. Research is ongoing to determine exactly how chemicals used or considered by Ecolab are extracted from corn, coconut, palm kernel, orange peel, soy or animal sources.  Many of these renewable raw materials can compete with human food sources. However, chemical suppliers and universities are researching raw material feedstocks based on non-food agricultural by-products. For example, lactic acid could be based on corn pulver. Ecolab continues to research opportunities to bring these types of raw materials from non-food sources into their formulation portfolio.

Section 3: Bio-Based Percentage of chemistry

3.0 Preliminary bio-based percentage calculations are complete for the glass cleaner, neutral bath cleaner and acid bath cleaner. The initial calculations are completed based on the estimated carbon containing fraction of the raw material. However, final analysis will require a submission to the USDA bio-preferred program for testing and verification.

Section 4: Acute Human Oral Toxicity and Aquatic Toxicity

4.0 & 4.1 Preliminary acute human oral and aquatic toxicity calculations are complete for the glass cleaner and acid bath cleaner. The calculation method is per the Green Seal 37 standard. In general, the renewable materials exhibit acute oral toxicity and aquatic toxicity that are well within the standard. However, certain mineral components used to neutralize the formulas (such as potassium or sodium hydroxide) contribute negatively to overall acute human oral toxicity and aquatic toxicity. Further investigation is underway to determine the toxicity of the neutralized materials, rather than the individual toxicities of separate acids and bases.

Section 5: Volatile Organic Compounds

5.0 Preliminary VOC calculations are complete for the glass cleaner. The glass cleaner has been modified significantly to minimize the percent of VOC well below the California Air Resources Board standards. Since all formulas are still in the prototype phase, calculations to show projected reduction in volatile organic compounds are not complete.

Section 6: Biodegradation of the Chemistry

6.0 Preliminary biodegradation review is complete for the glass cleaner. The formula meets the Green Seal 37 standards for biodegradation.

Section 7: Sustainability Profile of the Package

7.0 Source Reduction: Ecolab’s flexible pouch packaging options require less material to produce, and also better utilize space in the case and pallet. Flexible packaging options continue to play a major role in Ecolab’s sustainable packaging.

7.1 Recycled Content: Ecolab already features packaging containing mixtures of post consumer resin and virgin resin. Testing is underway with spray bottles featuring 100% post consumer resin (from milk bottles).

Section 8: Globally Harmonized System MSDS

8.0 Preliminary GHS MSDSs are complete for the glass cleaner, neutral bath cleaner and acid bath cleaner. Ideal language for all use solutions will be:

• WHMIS classification: Not hazardous by WHMIS criteria.
• Potential acute health effects: No known significant effects or critical hazards.
• Personal protection: No protective equipment is needed under normal use conditions.

At this time, the glass cleaner and neutral bath cleaner have preliminary use solution MSDSs that follow the ideal language listed above. However, the acid bath cleaner requires further modification to meet this target.

It is very likely that the concentrate MSDSs will contain cautionary language. However, the advantage of shipping concentrates (reduction of energy, reduced storage space) far outweighs the disadvantage of additional cautionary language. Ecolab provides closed-loop dispensing systems to minimize the exposure to the concentrated products

Background

Demonstration projects test whether grants of around $50,000 can provide threshold funding to businesses to undertake green chemistry and design changes to their products, or to the components of products they deliver to customers or supply chains.

Grants can co-fund basic chemistry research, move research or development already in progress closer to completion, or adapt off-the-shelf green chemistry technology. Actual implementation of product changes through retooled production would be ideal, but product design or redesign and testing with a commitment to carry the new design through to production could suffice. Such commitment could be demonstrated by business and capital planning and long-term metrics. 

Funds are awarded in the form of a grant to a company that controls the design of a product or component and commits to a green chemistry and design improvement of such a product or component. Internal teams and external partnerships are vital, possibly including the company designing the product or component, their customer(s), their production supply chain, and either internal or third-party (external) technical resource providers such as consultants, graduate research students, labs or testing facilities, mentoring companies, or others.

Demonstration projects are designed to support the research and development side of the product design process. Grant funds cannot be used for purchasing the equipment necessary to produce the newly designed or redesigned product. Equipment purchases may be a better fit with state low-interest loan programs, either MPCA environmental loans or those available through other state agencies.