MW Milling
LLC
San Diego, California
&
TM
Metal Flake Technologies LLC
Nashville, Tennessee
Hiding in Plain Sight
Might We Already
Have A Sensible
Antifouling
Alternative…..
and Not Even Realize It ??
What Are We Fighting?
A Flurry Of Activity
• The “Gold Standard”
Tri-Butyl Tin
*Banned By International Maritime Organization
*Banned Individually By Most Maritime Countries
• The “Replacement”
Copper
*Banned or Max Leaching Rates Imposed in Many Countries
*IMO Concern and Dialogue Growing
*California Imposed Outright Ban in Impaired or Sensitive Areas
*History and Political Inertia Indicate Severe Restrictions In Near Future
• “Copper-Free”
Foul Release, Algaecidal
*Durability Concerns Remain
*Launchable Time, Special Application Equipment???
My Cleaning Frequency Go Up?
Did You Say That Was????????
• “Exotics”
*Does
*How Much
Metallizing, Ceramic, Slip Liner
*Industry Needs Retraining and Education About The Process
*Very High Implementation Costs
High Tech and Ultra Engineered
Coatings
• Self-polishing copolymer, an elegant formulation that
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controls biocide delivery and extends coating
effective lifespan.
Ablative formulations either hard or soft constantly
slough off to expose active biocide.
Low surface energy formulations take advantage of
slickness to deter fouling growth without the use of
biocides.
Chemical biocides as primary agent or in combination
with another agent.
Hybrid systems use combinations of all of the above.
Thermal Spray coatings.
Who Am I?
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I have been in the paint industry for 100 years.
Billions of dollars are saved every year because of me.
Everybody knows how to use me.
I am cheaper than many of my peers.
I am not currently banned or restricted. *
I am already used throughout the marine industry.
I provide fantastic cathodic protection.
Data has shown me to be a good anti-fouling
substance if used correctly.
* California has established some localized TMDL’s.
Zinc
but in the form of a flake
CA Regional Water Quality Control Board
Chollas Creek
CMC (Criteria Maximum Concentration)
Copper
Zinc
13 ug/l
120 ug/l
CCC (Criteria Continuous Concentration)
Copper
Zinc
9 ug/l
120 ug/l
So Who Says Zinc Works?
• US Army Corps of Engineers……
ZMR-2-15 Nov.
1994
• Marine Environmental Research…
Two Surprises
From Inorganic Zinc-rich Silicate Coating, C. William Anderson, EPA Publishing
• United States Patent 4835050
US Army Corps of Engineers
Zebra Mussel Research Program
Black Rock Lock November 1994
T. Race and Dr. A. Miller
Goal: Evaluate the efficacy of antifouling
coatings as a function of metal leaching rate.
Test Structure: Determinations of in situ test
panel performance and in vitro panel leach rate.
Duration: 15 months
Conclusion about zinc:
“zinc coatings would offer a significant
advantage in terms of cost and simplicity over
other antifoulants.”
Marine Environmental Research
Two Surprises From Inorganic Zinc-rich Silicate
Coating
Dr. C. William Anderson
Publisher: U.S. EPA Office of Research and
Development
Research Summary: The interface between any
surface and an ionic solution (seawater) has an
inherently electrochemical character. This study
examined an antifouling approach that exploited
this electrochemistry.
Results: While the initial suspicion was that the
charge applied to the coating was the principal
antifouling factor,…..it became clear that the zinc
had profound effects on the larval metabolism
(especially on the charged polymer glue) in
barnacles. Dr Dan Rittschof….Duke Univ.
United States Patent 4835050
• 1986 Patent claiming: “A non-toxic composition of matter capable of providing long-
lasting suppression of the growth of fouling organisms in an aquatic environment…. such that
said composition is capable of generating a voltaic current.”
• Concept: This invention relates to paints which store a voltage in a composition consisting
of a large multiplicity of very small (zinc) particles capable of producing an emf and thus a
potential difference. The mechanical mixture of metal powders when incorporated in a
suitable vehicle makes a good antifouling paint. When it is applied to a Zinc coated steel
surface or a wood surface it will, when immersed in an electrolyte such as sea water, provide
millions of small individual batteries that act to prevent the attachment of marine animals
such as Barnacles, Tunicates, Oysters, Clams and other organisms and also will serve to
retard vegetation growth on the panels exposed at antifouling stations for months or years at a
time. Most of the miniscule antifouling batteries were included in a non-leachable vehicle
suitably diluted with solvent.
• Results: All of the samples gave most encouraging results, but in this test two were
outstanding: the 50--50 Zinc Tin and the 90% Zinc and 10% Graphite. Both samples
were completely free of all growth, both animal and vegetative and there was no
slime giving them a rating of 10. Most of the other samples were almost free of
barnacles, and if there were barnacles they were very tiny especially in comparison
with barnacles growing on the wooden frames which were on average about 20
times as large. The combination of zinc with a non-metal was striking and further
validates the voltaic cell principle.
The Corrosion
Advantage
Two Birds With One Stone?
NewCo Paint
ZFLAKE
Top and Bottom
Anti-Corrosion/Anti-fouling
Marine Coating
Move Over Dust…
Zinc Flake Does The Job Better
and At Less Cost
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Corrosion Control At 40% Lower Loading Rates
Less Weight In Dry Film
Improved Pot Life
Improved Application Characteristics
Proven Salt Spray Performance
No Change In Binder Chemistries
Environmental Impacts Already Known
Why Will My Loading Rates Drop?
Does Particle Shape Mean Something?
• A sphere has the smallest surface area of
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any shape that encloses a given volume.
A sphere encloses the largest volume of
any shape with a given surface area.
A flake has 3 times the surface area of an
equivalent volume of a sphere.
Graphic courtesy of ZRC Worldwide
Physical Comparison of Dust vs. Flake
Dust Particle – 8 um sphere
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Area = 201 sq um (r = 4 um)
Tap Density = 7 gm/cm3
Typical Loading Rate = 75-90%
11-17 lbs into a paint vehicle
Weight of 75 um dry film solvent
based coating = 185g/m2
Salt Spray = 2000+ hours
@ 15um DFT
8um sphere made into flake
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Area = 684 sq um (125 x 45 x1)
Tap Density = 2 gm/cm3
Typical Loading Rate = 35-50%
6-10 lbs into a paint vehicle
Weight of 75 um dry film
solvent based coating = 53g/m2
Salt Spray = 2000+ hours
@ 15um DFT
Sphere
Scanning electron micrograph of zinc dust
to
flake
Scanning electron micrograph of zinc
flake made from dust on left
Zinc Dust Coating After 900 Hrs Salt Spray
Zinc Flake Coating After 900 Hrs Salt Spray
Zinc Flake
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Anti-Fouling Capability Established
Industry Already Educated In It’s Use
Lower Cost Than Other Active Ingredients
Corrosion Control At 40% Lower Loading Rates
Less Weight In Dry Film
Improved Pot Life
Improved Application Characteristics
Proven Salt Spray Performance
No Change In Binder Chemistries
Environmental Impacts Already Known
What Needs To Be Done?
Implement longer term evaluation to establish service
life expectation
Field test a vessel with trial coating to prove durability
and identify hull cleaning schedule
Contact Metal Flake Technologies!
Thanks!