With the entry of fast acting paint booth chemicals (coagulants/flocculants), the entire method of paint sludge removal has changed world-over. This has led to the elimination of large sized, open sludge pits/tanks and a drastic reduction in the water requirement of paint booths.
In the conventional design, the chemical action time (hold time) for over-sprayed paint is substantial. This leads to voluminous sludge pit or booth tank water volumes. This also leads to heavy sludge blockade inside the paint booths. The whole focus has now changed to minimize the water quantity and to improve the water quality required for the paint booth system.
In the new technology, the over-sprayed paint is mixed thoroughly with water & coagulant in the paint booths. This mixing converts it into a non-sticky homogenous slurry (without sludge flocculation). Special paint mixers can also be used for efficient mixing and flow of the slurry. The slurry is then passed through the Sludge Removal System, with in-line dosing of the Polyelectrolyte chemical. A special pipe mixer is used for thorough mixing of the polyelectrolyte. The paint sludge separates instantly and this floating sludge is removed continuously by the sludge removal system.
Proper collection and mixing of the over-sprayed paint with the water & chemicals is the key to the success of this technology. The efficiency is enhanced with suitable paint booth design. Moreover, for down draft paint booths with civil tanks, the large sized sludge pits can be easily avoided.
The new technology can also be applied to exisiting paint booths as well as large sludge pits. Proper use of special mixing systems and proper system engineering makes this possible.
Floatation type (Hydrofloty) as well as Centrifugal Sludge Removal Separators are available, with Semi-Automatic and Automatic options.
These systems are available for single as well as multiple paint booth installations;Side Draft as well as Down Draft Paint Booths.
Conventional Phosphate Sludge & Degrease Sludge removal systems are very cumbersome and require high level of maintenance and they occupy a lot of space. Moreover, the SS equipment comprising of clarifiers, filter presses, pipelines, tanks, pumps, etc requires inordinate time for cleaning and has high running costs.
Dewatering Systems like Centrifuges and Special Presses are compact and have low running costs compared to conventional systems. Additionally, the sludge separation efficiency is very high for particles up to 5 microns & below.Centrifuge Separators, which dewater the sludge by centrifugal force, do not have any filtration media, thus avoiding choking problem.
Iron and Zinc Phosphate have comparatively lower bath temperatures as compared to that of Manganese Phosphate. Special systems are available that can handle bath temperatures up to 100 deg C.
The initial washing of components in the Degrease Tank produces dirt, fines, etc inside the tank. Degrease Sludge Systems are used to clean this dirt on-line. Centrifuge Separators are preferred, as they require no consumable media and do not face the problem of choking.