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Summary

Electron Beam Curing

Curing: Electron Beam vs. Autoclave

Use of an electron beam to cure inks, laquer, paint, adhesives, resins, composites, and for crosslinking of polymers.

Synopsis:

Electron beam (E-beam)  curing uses high energy electrons in controlled doses to polymerize and cross-link polymer materials.  Curing of composites can take place at ambient temperature.  E-beam curing is a well-established technology -- first applied to processing wire insulation in the 1950's -- that is now being applied to an ever wider range of products.  The technology is environmentally friendly as it reduces the use of solvents, offers energy savings benefits, and eliminates cooling station requirements. Curing time and plant sizes are reduced. Paints, epoxy-based resins, powder coatings, and composites with reactive accelerators are being developed that are suitable for electron beam curing.  Some products claim excellent mechanical properties, better scratch resistance, low void content, color stability, and higher gloss.  Curing can take place in reduced oxygen environments

Traditional thermal curing often requires a dryer or autoclave,  requiring long cure times, high energy consumption, and often producing toxic by-products.  Residual stresses are created in the materials, sometimes requiring finishing or tooling.  E-beam processing has expanded to include curing of laminates, composites, leather finishes, heat-shrinkable plastics, fiber-reinforced resin coatings, thermosetting composites, vulcanized pressure-sensitive adhesives, cross-linking of binding agents for magnetic materials, semiconductor enhancement, and flexible packaging often used in food processing. 

Use of electron beam curing methods to cure specially formulated inks can reduce energy consumption by over 50% when compared to conventional convection ovens and significantly reduce emissions and explosion concerns.  The U.S. EPA cites energy savings of 75% to 90%.  Eight independent studies have shown savings of 25% to 65% to curing costs of manufacturing. Solvent emissions are also greatly reduced.  Savings are especially good for complex shaped components often used in engines and military vehicles, and aerospace applications. Because the process occurs at ambient temperatures, molding materials can be made of low cost materials such as wood or foams. 

Energy Savings: 88%
Energy Savings Rating: Extensive Assessment  What's this?
LevelStatusDescription
1Concept not validatedClaims of energy savings may not be credible due to lack of documentation or validation by unbiased experts.
2Concept validated:An unbiased expert has validated efficiency concepts through technical review and calculations based on engineering principles.
3Limited assessmentAn unbiased expert has measured technology characteristics and factors of energy use through one or more tests in typical applications with a clear baseline.
4Extensive assessmentAdditional testing in relevant applications and environments has increased knowledge of performance across a broad range of products, applications, and system conditions.
5Comprehensive analysisResults of lab and field tests have been used to develop methods for reliable prediction of performance across the range of intended applications.
6Approved measureProtocols for technology application are established and approved.

Status:

Details

Electron Beam Curing

Curing: Electron Beam vs. Autoclave

Use of an electron beam to cure inks, laquer, paint, adhesives, resins, composites, and for crosslinking of polymers.
Item ID: 466
Sector: Industrial
Energy System: Process Loads & Appliances--Industrial Processes

Synopsis:

Electron beam (E-beam)  curing uses high energy electrons in controlled doses to polymerize and cross-link polymer materials.  Curing of composites can take place at ambient temperature.  E-beam curing is a well-established technology -- first applied to processing wire insulation in the 1950's -- that is now being applied to an ever wider range of products.  The technology is environmentally friendly as it reduces the use of solvents, offers energy savings benefits, and eliminates cooling station requirements. Curing time and plant sizes are reduced. Paints, epoxy-based resins, powder coatings, and composites with reactive accelerators are being developed that are suitable for electron beam curing.  Some products claim excellent mechanical properties, better scratch resistance, low void content, color stability, and higher gloss.  Curing can take place in reduced oxygen environments

Traditional thermal curing often requires a dryer or autoclave,  requiring long cure times, high energy consumption, and often producing toxic by-products.  Residual stresses are created in the materials, sometimes requiring finishing or tooling.  E-beam processing has expanded to include curing of laminates, composites, leather finishes, heat-shrinkable plastics, fiber-reinforced resin coatings, thermosetting composites, vulcanized pressure-sensitive adhesives, cross-linking of binding agents for magnetic materials, semiconductor enhancement, and flexible packaging often used in food processing. 

Use of electron beam curing methods to cure specially formulated inks can reduce energy consumption by over 50% when compared to conventional convection ovens and significantly reduce emissions and explosion concerns.  The U.S. EPA cites energy savings of 75% to 90%.  Eight independent studies have shown savings of 25% to 65% to curing costs of manufacturing. Solvent emissions are also greatly reduced.  Savings are especially good for complex shaped components often used in engines and military vehicles, and aerospace applications. Because the process occurs at ambient temperatures, molding materials can be made of low cost materials such as wood or foams. 

Baseline Example:

Baseline Description: Autoclave Curing of Polymer Matrix
Baseline Energy Use: 616000 kWh per year per unit

Comments:

Use of a 10 MeV electron beam instead of an autoclave with a four-hour cure cycle for polymer matrix composite (PMC) materials reduced curing energy use from 1.76 kWh/kg to only 0.22 kWh/kg (Source: E-Beam Services, "Electron-Beam Curing of Polymeric Composites As An Enabling Technology for Advanced Manufacturing". The U.S. EPA cites energy savings of 75% to 90% ("Ultraviolet and Electron Beam (UV/EB) Cured Coatings, Inks, and Adhesives). The baseline annual energy use is estimated by assuming that 5 cure cycles per day are run, with 350 days/year of operation, and that each cycle involves 200 kg of polymer matrix composite material material.

Manufacturer's Energy Savings Claims: Currently no data available.
Best Estimate of Energy Savings:

"Typical" Savings: 88%
Energy Savings Reliability: 4 - Extensive Assessment

Comments:

Energy Use of Emerging Technology:
73,920 kWh per unit per year What's this?

Energy Use of an Emerging Technology is based upon the following algorithm.

Baseline Energy Use - (Baseline Energy Use * Best Estimate of Energy Savings (either Typical savings OR the high range of savings.))

Technical Potential:
Units: unit
Currently no data available.
First Cost: Currently no data available.

Cost Effectiveness:

Simple payback, new construction (years): N/A

Simple payback, retrofit (years): N/A

What's this?

Cost Effectiveness is calculated using baseline energy use, best estimate of typical energy savings, and first cost. It does not account for factors such as impacts on O&M costs (which could be significant if product life is greatly extended) or savings of non-electric fuels such as natural gas. Actual overall cost effectiveness could be significantly different based on these other factors.

Reference and Citations:

B Laurell, 09/22/2003. Industrial Application of Electron Beam Curing in the Field of Coatings
Electron Crosslinking AB

Robert Norris, 01/14/2000. Electron Beam Curing of Composites Overview
SAE Technical Paper

T. Lund, 08/17/2009. New Developments of Electron Beam Accelerators
RadTech Europe 2009

Sayaka Uchida, 03/12/2008. Utility and Advantages of Electron Beam Curing in Flexible Packaging
San Jose State University

E-Beam Services, 05/10/1999. Electron-Beam Curing of Polymeric Composites as an Enabling Technology for Advanced Manufacturing
International Composites Expo '99

ECW, 01/01/2000. Ultraviolet and Electron Beam Curing
Energy Center of Wisconsin

Clean Energy Technology Center, 07/01/2001. Ultraviolet and Electron Beam (UV/EB) Cured Coatings, Inks and Adhesives
U.S. EPA , Technical Bulletin

Rank & Scores

Electron Beam Curing

There is no TAG available for this technology.
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