Methylene Chloride Ban: What to Expect and Alternatives

The Environmental Protection Agency (EPA) has banned most uses of methylene chloride. Also known as dichloromethane (DCM), methylene chloride is used in various industrial applications, including paint stripping and degreasing, and as a solvent in chemical processes. However, due to significant health risks associated with its use, the EPA has implemented stringent regulations to curtail its use.

The ban reflects a broader shift toward safer chemical management, prioritizing human health and environmental sustainability. Organizations must transition to alternative solvents and implement rigorous safety protocols to ensure compliance with evolving regulations. Learn more about the methylene chloride EPA ban and what you can use as an alternative below.

Understanding the Methylene Chloride Ban

Methylene chloride is a volatile organic compound (VOC) historically used in paint stripping, degreasing, pharmaceuticals, and chemical processing. In recent years, mounting evidence of its severe health and environmental hazards has led to increasing global regulatory restrictions.

Key Dates in the Compliance Timeline

In response to various health risks, the EPA proposed an overall ban on methylene chloride in April 2023 under the Toxic Substances Control Act (TSCA), prohibiting most uses of methylene chloride. The rule outlines specific compliance dates for various stakeholders:

• February 3, 2025: All persons are prohibited from distributing in commerce.
• May 5, 2025: All retailers are prohibited from distributing in commerce.
• May 5, 2025: The manufacturing and importing of methylene chloride is prohibited except for specific conditions of use that will continue under the Workplace Chemical Protection Program (WCPP). This also includes a ban on imports.
• August 1, 2025: Processing methylene chloride, including any products containing it, is prohibited except for specified conditions under the WCPP.
• January 28, 2026: All non-retailer distributors are prohibited from distributing methylene chloride except for specified conditions under the WCPP.
• April 28, 2026: Industrial and commercial users of methylene chloride are prohibited except for specified conditions under the WCPP.
• May 8, 2029: This is the extended compliance date. On this date, all persons are prohibited from manufacturing, processing, importing, or using methylene chloride, even if in the special use cases that were included in the WCPP, such as paint and coating removal for refinishing wooden furniture and certain applications in aircraft and turbine manufacturing.

Impact on Operations

Organizations involved in the manufacture, distribution, or use of methylene chloride must conduct comprehensive operational reviews to ensure compliance with the new regulations by May 2025.

This evaluation includes an inventory assessment and identification of products and processes involving methylene chloride. Modifying these processes by exploring alternative methods or substances to replace methylene chloride in industrial applications is also imperative.

Why Is Methylene Chloride Banned?

Exposure to methylene chloride poses severe health hazards. Acute exposure can result in symptoms like dizziness, fatigue, headaches, and respiratory irritation. More severe consequences include suffocation, loss of consciousness, and even death. Chronic exposure has been linked to liver toxicity and various cancers, including liver and lung cancer.

Notably, fatalities have occurred among workers in projects like bathtub refinishing, where methylene chloride-based products were used in confined spaces without adequate ventilation or protective equipment. Once inhaled, methylene chloride is metabolized in the liver, producing carbon monoxide (CO). This can result in CO poisoning, which is particularly dangerous for individuals with preexisting cardiovascular conditions.

Environmental Impact

Methylene chlorides are classified as hazardous under the Clean Air Act due to their role in environmental degradation. Its environmental impact extends to:

• Atmospheric impact: Although this substrate has a relatively short atmospheric life span, it contributes to ozone depletion and smog formation.
• Soil contamination: Improper disposal leads to groundwater and soil contamination, posing risks to drinking water suppliers and aquatic ecosystems.
• Bioaccumulation risks: While not highly persistent, methylene chloride degrades into more toxic compounds, increasing long-term environmental risks.

Regulatory Evolution and Restrictions

In the United States, the case against methylene chloride started in 2017 when the EPA proposed banning DCM in consumer paint removers under the TSCA. In 2019, the agency finalized the rule, and in 2024, the Biden administration expanded the ban and established more strict workplace safety measures for exempted uses.

The regulatory landscape will continue to develop, necessitating proactive industry adaptation to minimize health risks and environmental harm.

Alternatives to Methylene Chloride Chemical Strippers

Chemical strippers containing DCM have long been a cornerstone of industrial coating removal, particularly in the aerospace, automotive, and heavy manufacturing sectors. These products rely on methylene chloride as the active ingredient to break down paint, varnish, and other coatings through chemical dissolution.

Banning this base ingredient compromises the effectiveness of traditional paint strippers. Without DCM, alternative formulations struggle to deliver the same speed and efficacy, often requiring additional dwell time, increased mechanical agitation, or harsher chemicals that pose their own safety concerns.

Abrasive blasting, the mechanical removal process that uses high-velocity particles to strip surface contaminants, is adaptable and delivers consistent performance. Materials like glass beads, garnet media, copper slag, nickel slag, and coal slag are common abrasives used as methylene chloride alternatives. However, many of these abrasive blasting materials can cause diseases like silicosis from respirable crystalline silica dust exposure.

Superoxalloy as a Methylene Chloride Replacement

Superoxalloy is a next-generation material engineered for high-performance surface preparation. This product is engineering-focused and delivers unrivaled value to any operations. As a DCM-free solution, this abrasive blasting media exceeds the effectiveness of traditional strippers while adhering to modern safety and environmental standards:

• Faster coating removal: Superoxalloy abrasive resists breakage at nozzle pressures exceeding 120 psi, leading to a quick surface preparation process.
• Surface preservation: It minimizes substrate damage, which is crucial for aerospace and precision engineering applications. This product also significantly delays the onset of rust bloom formation.
• Healthy operation: Superoxalloy is made from mineral wool by-products, which are noncarcinogenic, and is the only biosoluble abrasive available.
• Cost-effective: The particles are manufactured for durability and impact strength, which results in a highly efficient abrasive blasting material. The decrease in abrasive material required to complete a job and the enhanced productivity make 10X supeoxalloy abrasives a highly cost-effective choice.

Transition to Superoxalloy Today

The methylene chloride EPA ban marks a pivotal shift in industrial chemical regulations, prioritizing worker safety and environmental responsibility. Organizations must now adapt to a new regulatory landscape where traditional DCM-based chemical strippers are no longer viable, necessitating the adoption of alternative coating removal methods. By embracing innovation, industries can mitigate disruptions, enhance operational safety, and contribute to long-term environmental sustainability.

Superoxalloy abrasives are formulated to be biosoluble in human lungs, which makes the body able to clear inhaled abrasive dust with no long term harm. Blasting with superoxalloy abrasives is a much safer process than using the products that are being targeted by the methylene chloride EPA ban. Superoxalloy represents the next evolution in industrial stripping technology. It provides a sustainable alternative to banned DCM-based products while aligning with industry-wide efforts to enhance worker safety and environmental responsibility. EpiX, DynamiX, and KinetiX superalloy abrasives also help reduce surface preparation costs per square foot. 

Browse 10X Engineered Materials’ range of superoxalloy abrasives, or contact us today for more information on how these materials can transform your projects.