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1、CaseStudyCookCompositesandPolymersCo.Coatingdefinedbyprotectiveisoneofthemostwidelymethodsforavoidingcorrosion.ItsprotectivepropertiesencompassPhysicalBarrierfunction-toseparatethemetalfromcomingintocontactwithacorrosiveenvironment,andchemicalbarrierfunction-tocontrol
2、themicroenvironmentatthemetal/coatinginterface.Inall,therearethreetypesofprotectivecoatingsasshowninTable1.Table1:TypesofProtectiveCoatingsTypeofExamplesCoatingsMetallicHot-dipgalvanizing,electroplating,electrolessplating,Coatingsanodizing,thermalsprayingormetallizing
3、,cladding,diffusioncoatingInorganicPorcelaincoating,glass-liningCoatingsOrganicPaints,vanishes,lacquersandnumerousotherpolymericCoatingsmaterialsthatreadilyformdurabledryfilmsGelcoatsusedtoprovidecolor,durability,andstrengthtofinishedproductsprotectandincreaseproducts
4、’lifespanscreateahugefortuneinrecentyears.By2007,thevalueofcoatingindustryhadbeen$85billion.Coatingindustryisapartialmonopolyindustry.ToptenincludingCookCompositesandPolymersCo.(CCP)controlled50%ofthemarket.Gelcoatwasproducedinabatchprocesswithinamixingvessel.Material
5、s(resin,thixotropic,monomers,promoters/orinhibitors,fillers,pigments)arestoredinbagsandpailsintherawmaterialswarehousejustneartheproductionarea.Theproductiveprogressincludespreparation,mixingandtesting,fillingandrinsing.Andthelastonestepiscrucialbecauseevensmallamount
6、sofgelcoatfromapreviousbatchthatremainedinthevesseloronthemixingequipmentcoulddestroythenextbatch.Afterreaction,thedisposalof“rinsestyrene”maycausehazardouseffecttoenvironmentalsystemsandthepriceofstyreneisveryexpensive,about$0.7perpound.Atitscurrentusagerate,atotalco
7、stofa10-drumbatchofgelcoatcanbe$4620.Unluckily,lessstyrenemeansmoreriskofproductqualitythatCCPwouldneverliketotakebecausethecompanyisfamousforitshigh-endproducts.Infact,CCPtechnicalstaffhadalreadyreducedtheuseofrinsestyrenetotheultimateforacceptablequality.Besides,asC
8、romacki,vicepresidentofengineering,said“Thetraditionalwasteminimizationapproachthroughsourcereductionwouldcausecontamination
