Reference Document on Best Available Techniques on Surface

5,24
MB Treatment using Organic Solvents

722
stron

6071
ID JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2007
rok

EXECUTIVE SUMMARYI

PREFACEXI

SCOPE XXXIX

1 GENERAL INFORMATION ON SURFACE TREATMENT USING ORGANIC SOLVENTS 1

1.1 Organic solvents and treating surfaces. 1

1.2 Key environmental issues. 2

1.2.1 Overall . 2

1.2.2 Solvents. 3

1.2.3 Metals 4

1.2.4 Other pollutants 4

1.2.5 Energy. 5

1.2.6 Raw material usage 5

1.2.7 Water usage 5

1.2.8 Solid and liquid wastes 5

1.2.9 Airborne particles. 5

1.2.10 Noise . 5

2 PRINTING 7

2.1 General information on printing. 7

2.1.1 Printing industry in the European Community. 7

2.1.2 The products. 11

2.1.2.1 Newspapers 11

2.1.2.2 Magazines and catalogues 11

2.1.2.3 Books . 12

2.1.2.4 General printing . 12

2.1.2.5 Security printing. 12

2.1.2.6 Labels . 12

2.1.2.7 Business forms . 12

2.1.2.8 Paper and cardboard packaging 13

2.1.2.9 Flexible packaging . 13

2.1.2.10 Products requiring thick ink films 13

2.1.2.11 Wallpaper, decorative paper and paper-based foils for the furniture and lamination

industry. 13

2.1.2.12 Envelopes . 14

2.2 Applied processes and techniques in printing 14

2.2.1 Pre-press and proofing systems 14

2.2.2 Creating the image carrier: printing plate, cylinder, stencil making and computer-toplate (CTP).

15

2.2.3 Printing 16

2.2.3.1 Letterpress and letterset 16

2.2.3.2 Flexography . 16

2.2.3.3 Offset: general 18

2.2.3.4 Sheetfed offset 20

2.2.3.5 Web presses (heatset and coldset offset) 21

2.2.3.6 Gravure. 22

2.2.3.7 Screen printing . 23

2.2.3.8 Digital printing. 25

2.2.3.9 Laminating and varnishing in flexible packaging 25

2.2.4 Finishing 26

2.2.5 Associated activities. 26

2.3 Current consumption and emission levels in printing 28

2.3.1 The printing industry as a whole 28

2.3.2 Heatset web offset 28

2.3.2.1 Mass balances – heatset 28

2.3.2.2 Consumptions – heatset 35

2.3.2.2.1 Constituents and additives 35

2.3.2.2.2 Printing inks . 35

2.3.2.2.3 Dampening solutions 35

2.3.2.2.4 Varnishes 36

2.3.2.2.5 Cleaning agents 36

2.3.2.2.6 Energy and resources 38

2.3.2.2.7 Printing substrates and other consumptions . 39

2.3.2.3 Emissions – heatset 39

2.3.2.3.1 Emissions to air – sources and fugitive emissions . 39

2.3.2.3.2 Waste 41

2.3.2.3.3 Waste water 42

2.3.3 Flexible package printing – flexography and gravure 43

2.3.3.1 Mass balances – flexible packaging . 43

2.3.3.2 Consumptions – flexible packaging . 47

2.3.3.2.1 Organic solvents. 47

2.3.3.2.2 Printing inks and varnishes. 48

2.3.3.2.3 Cleaning agents 52

2.3.3.2.4 Adhesives in lamination . 53

2.3.3.2.5 Energy and resources 53

2.3.3.3 Emissions – flexible packaging 54

2.3.3.3.1 Emissions to air 54

2.3.3.3.2 Waste 58

2.3.3.3.3 Waste water 59

2.3.4 Publication gravure 59

2.3.4.1 Mass balances – publication gravure 59

2.3.4.2 Consumptions – publication gravure 63

2.3.4.2.1 Printing inks . 63

2.3.4.2.2 Cleaning agents 63

2.3.4.2.3 Energy and resources 64

2.3.4.2.4 Printing substrates and others. 64

2.3.4.3 Emissions – publication gravure 64

2.3.4.3.1 Emissions to air 64

2.3.4.3.2 Waste 65

2.3.4.3.3 Waste water 66

2.4 Techniques to consider in the determination of BAT for printing . 66

2.4.1 Heatset offset printing 67

2.4.1.1 Conventional heatset inks. 67

2.4.1.2 Replacement of conventional heatset inks (substitution) . 68

2.4.1.2.1 Inks based on vegetable oils. 68

2.4.1.3 Reducing emissions from the dampening solution. 69

2.4.1.3.1 Replacement of IPA in the dampening solution (substitution). 69

2.4.1.3.2 Optimising the concentration of IPA in the dampening solution . 70

2.4.1.3.3 Ceramic, metal and hydrophilic distributing and plate rollers 71

2.4.1.3.4 Exact adjustment of the inking rollers 72

2.4.1.3.5 Apply a spray system in the dampening unit 72

2.4.1.3.6 Cooling the dampening solution. 73

2.4.1.3.7 Cooling the dampening rollers and plate cylinders 73

2.4.1.3.8 Removal of IPA solutions from the dampening unit 74

2.4.1.4 Filtering the dampening solution 74

2.4.1.5 Controlling the hardness of the water for the dampening solution. 75

2.4.1.6 Waterless offset 75

2.4.1.7 Waste gas collection and treatment 76

2.4.1.7.1 Encapsulation of presses or extraction and treatment of air from the press room. 76

2.4.1.7.2 Extraction and treatment of air from the driers 77

2.4.1.8 Cleaning . 78

2.4.1.8.1 Replacement (substitution) and control of VOCs used in cleaning 78

2.4.1.8.2 Automatic high pressure cleaners for dampening rollers . 79

2.4.1.8.3 Automatic cleaning systems for printing and blanket cylinders. 79

2.4.2 Flexography and packaging gravure 80

2.4.2.1 Conventional solvent-based inks 81

2.4.2.2 Replacement of conventional solvent-based inks (substitution) 81

2.4.2.2.1 UV curing alternatives 81

2.4.2.2.2 Electron beam (EB) curable alternatives 83

2.4.2.2.3 Water-based inks 83

2.4.2.3 Conventional solvent-based varnishes and adhesives 85

2.4.2.4 Substitutes for conventional varnishes and adhesives 85

2.4.2.4.1 Water-based varnishes and adhesives. 85

2.4.2.4.2 High solid alternatives 86

2.4.2.4.3 UV curing alternatives 87

2.4.2.4.4 Solvent-free alternatives. 87

2.4.2.4.5 Co-extrusion. 88

2.4.2.5 Waste gas treatment . 88

2.4.2.5.1 Encapsulation/enclosure. 88

2.4.2.5.2 Extraction and treatment of air from the presses and other production areas. 89

2.4.2.5.3 Peak volume bypass and peak/trough smoothing: extraction and treatment of air from the

presses and production areas 90

2.4.2.5.4 Maintenance of waste gas treatment equipment, bypasses, collection systems, etc. 90

2.4.2.5.5 Automatic and timely closure of a bypass system 91

2.4.2.6 Cleaning . 91

2.4.2.6.1 Replacement of VOCs with less volatile solvents for cleaning floors (substitution). 91

2.4.2.6.2 Cleaning machine parts and equipment in automatic cleaning/washing machines. 92

2.4.2.6.3 Cleaning of machine parts with high pressure water spray 92

2.4.3 Publication gravure printing. 92

2.4.3.1 Conventional solvent-based inks 93

2.4.3.2 Substitutes for conventional solvent-based inks. 93

2.4.3.2.1 Water-based alternatives 93

2.4.3.2.2 Using retention inks . 94

2.4.3.3 Waste gas treatment . 95

2.4.3.3.1 Increased temperature in the press room 95

2.4.3.3.2 Increasing drying time 95

2.4.3.3.3 Discontinuous air extraction from the driers 96

2.4.3.3.4 Continuous air extraction from the driers. 96