METHOD FOR OPERATING A TREATMENT PLANT AND TREATMENT PLANT

Description

[0001] The invention relates to a method for operating a treatment plant and to a treatment plant. State of the art

[0002] In the past, bactericidal chemicals and operating materials were used in treatment systems used by surface technology companies, such as pretreatment systems and cathodic dip painting (CDP) systems, where metallic and non-metallic materials are given a surface coating, as well as in various air supply systems, such as spray booths. Due to the tightening of environmental legislation, these germicidal substances (e.g., lead, chromium, etc.) were gradually replaced with more environmentally friendly substances. However, under the operating conditions of the air supply, pretreatment, and CDP systems, this led to greatly increased germ and fungal growth due to the aqueous media present in the systems, temperatures between approximately 20°C and 55°C, sufficient nutrient input from the workpieces being treated, etc.

[0003] In order to ensure the safe operation of process tanks and rinsing tanks, as well as the associated storage tanks, supply air systems, etc., samples are taken daily from the corresponding baths and tanks and examined for their bacteriological contamination.

[0004] Depending on the level of bacterial contamination detected, the contaminated areas are treated at regular or irregular intervals with biocides, such as hydrogen peroxide, usually in the form of a shock dose.

[0005] Sampling involves a relatively long waiting time, which can lead to critical situations, for example in the case of high bacterial load in the system, because biocide treatments can only be initiated with a corresponding delay.

[0006] It is also known that the continuous dosing of germicidal substances can keep germ loads at an acceptable level. One well-known example is the "Clorious" process, in which highly oxidative chlorine dioxide is produced and injected into contaminated areas. However, depending on the process, continuous dosing carries the risk of undesirable resistance development.

[0007] US 20020148738 A1 discloses a method for determining the presence of biological contaminants in a coating or cleaning bath by measuring the carbon dioxide content of the atmosphere above the coating bath and comparing the measured carbon dioxide content with a baseline carbon dioxide content. When the measured carbon dioxide content reaches a certain level, a biocide can be added to the bath in question to control the level of biological contaminants. Disclosure of the invention

[0008] The object of the invention is to create a method for operating a treatment plant with which the risk of resistance formation can be reduced.

[0009] A further task is to create a treatment facility that reduces the risk of resistance developing.

[0010] The objects are achieved by the features of the independent claims. Advantageous embodiments and advantages of the invention emerge from the further claims, the description, and the drawings.

[0011] The features listed individually in the patent claims can be combined with one another in a technologically meaningful manner and can be supplemented by explanatory facts from the description and by details from the figures, whereby further embodiments of the invention are shown, as long as the resulting combinations and the further embodiments fall within the scope of protection of the claims.

[0012] A method is proposed for operating a treatment plant having at least one sub-area in which fluid for treating components is stored and / or a treatment of components, in particular with the fluid, is carried out and / or a fluid and / or a component is transported, wherein at least one of the sub-areas is monitored by at least one measuring sensor which has at least one biological component for detecting at least one biological contamination layer in the form of a biofilm as a preliminary stage of contamination in the at least one sub-area. The biological contamination layer is detected and monitored from the start of the growth of the biological contamination layer on the measuring sensor.

[0013] Advantageously, sampling from the treatment plant and thus an undesirable delay can be eliminated. Furthermore, the detection of a biofilm allows for early detection of impending contamination in the treatment plant, allowing corrective action to be taken before layered biological contaminants can be detected in aqueous media or humid areas of the treatment plant.

[0014] Biofilms are commonly referred to as layers of microorganisms and their metabolic products, so-called extracellular polymeric substances, that grow on moist surfaces. Microorganisms such as bacteria, algae, fungi, and protozoa typically occur in non-sterile environments.

[0015] This solves another problem of the state of the art: the conventional sampling from process tanks, rinsing tanks, and storage tanks only detects the microbial load present in the medium. Biofilm detection allows early detection of contamination risks, as biofilms are found on tank walls and pipes, and only after a certain amount of growth do biofilms release the microbes into the medium, which are then measured in the samples taken. These biofilms and their development cannot be detected in any way by the sampling practices used to date.

[0016] Sub-areas of the treatment plant operated with the process can, for example, include humidifiers of supply and recirculation air systems of, for example, spray booths, hall ventilation, etc., fresh water systems; demineralized water systems with fully salted water, here in particular one or more ion exchangers and buffer tanks, one or more membrane systems for fresh water treatment and / or waste water treatment, one or more pre-treatment systems in surface technology (e.g. automotive painting), one or more cathodic and / or anodic dip painting systems; one or more spray booths with wet separation of the overspray.

[0017] Instead of regular sampling, one or more measuring sensors in the form of biosensors can be installed in the containers or pipes of the aforementioned process tanks, rinsing tanks, and / or storage tanks, as required. These biosensors detect and monitor the growth of biofilms from the very beginning. Depending on the requirements of the respective sub-areas of the treatment plant, individual, system-specific limit values ​​can be set. These, depending on the biofilm thickness, lead to alarm notifications, biocide dosages, or changes, for example, to the dosage amount in the case of continuous biocide dosing.

[0018] The sensor can advantageously react selectively to biofilms and not only to a simple layer of dirt or inorganic deposits, so-called scaling layers, which form when solubility products precipitate in the medium as salts or the like.

[0019] Sensors for biofilm detection are well known. Optical measurement methods whose signals are modulated by biofilms are suitable. Physical and chemical parameters can be detected, and data relevant to the biofilm can be extracted from them, particularly using computer-aided methods. This can advantageously be done in real time.

[0020] According to a favorable embodiment, monitoring of the at least one partial area can be carried out continuously by the at least one measuring sensor.

[0021] This allows for early detection of potential future biological layer-like contamination. Information from a database or similar can be used to estimate or predict when biocide treatment might be required. This allows for proactive planning of any interruption in the treatment plant's operation.

[0022] Continuous online measurement in real time eliminates the previously necessary downtime between sampling and the availability of the analysis results. Critical situations caused by contamination-related tipping, for example, in treatment baths, with their high cost consequences, can be avoided.

[0023] The biofilm is detected as soon as it begins to grow on the sensor and not only when germs are released into the process medium and / or rinsing medium and / or medium in the storage tank.

[0024] Early intervention to reduce the bacterial load is possible, thereby reducing the amount of biocides required to keep the systems stable.

[0025] Advantageously, biocide dosage can be controlled based on the sensor's measured values ​​in the event of an overdose or a drop below specified limits. Likewise, the effectiveness of a biocide treatment can be directly recorded by removing / removing the biofilm grown on the sensor. This can advantageously increase the process stability of the treatment plant. Lower consumption can reduce biocide costs; likewise, environmental pollution can be reduced due to lower biocide consumption. Advantageously, improved employee protection is possible due to reduced microbial contamination in the treatment plant and reduced handling of biocides.

[0026] According to a favorable embodiment, a limit value of a biological contamination layer for detection by the at least one sensor in at least one sub-area can be set depending on respective process requirements in the at least one sub-area.

[0027] This allows specific conditions of a particular process to be taken into account.

[0028] According to a favorable embodiment, when a measured value of a biological contamination layer is detected by the at least one sensor in at least one partial area, a cleaning sequence can be carried out in the at least one partial area depending on a predetermined limit value. Advantageously, biocide treatment can be limited to necessary applications.

[0029] According to a favorable embodiment, upon detection of a measured value of a biological contamination layer by the at least one sensor in at least one partial area, an alarm can be triggered depending on a predetermined limit value and / or a biocide dosage can be applied to the at least one partial area and / or, in the case of continuous biocide dosing, a biocide dosage can be adjusted. This allows specific conditions of a particular process to be taken into account. Likewise, the consumption of the biocide can be targeted and, if necessary, limited.

[0030] According to a favorable embodiment, a position of the at least one measuring sensor in the at least one partial area can be selected according to a probability of an expected early and / or increased occurrence of biological layer-like contamination.

[0031] According to a favorable embodiment, a cleaning sequence in a treatment plant with several sub-areas can be carried out individually for each of the sub-areas.

[0032] According to a further aspect of the invention, a treatment system is proposed with at least one sub-area for carrying out the method according to one of the preceding claims, wherein at least one sub-area is provided in which fluid for treating components is stored, and / or a treatment of components, in particular with the fluid, is carried out, and / or a fluid and / or a component is transported, wherein at least one of the sub-areas has at least one measuring sensor which has at least one biological component for detecting at least one biological contamination layer in the form of a biofilm as a preliminary stage of contamination in the at least one sub-area. The biological contamination layer can be detected and monitored from the start of growth of the biological contamination layer on the measuring sensor.

[0033] Sub-areas of the treatment plant can, for example, include humidifiers for supply and recirculation air systems of, for example, spray booths, hall ventilation, etc., fresh water systems; demineralized water systems with fully salted water, here in particular one or more ion exchangers and buffer tanks, one or more membrane systems for fresh water treatment and / or waste water treatment, one or more pre-treatment systems in surface technology (e.g. automotive painting), one or more cathodic and / or anodic dip painting systems; one or more spray booths with wet separation of the overspray.

[0034] Instead of regular sampling, one or more biosensors can be installed in the containers or pipes of the aforementioned process tanks, rinsing tanks, and / or storage tanks, as required. These biosensors can detect and monitor biofilm growth from the very beginning.

[0035] Depending on the requirements of the respective sub-areas of the treatment plant, individual limit values ​​can be set that are tailored to the respective system. Depending on the biofilm thickness, these limit values ​​lead to alarm messages, biocide dosages or changes, for example in the dosage amount in the case of continuous biocide dosages.

[0036] According to a favorable embodiment, at least one of the subregions can be designed as a water treatment device and / or water tank and / or pretreatment basin and / or immersion bath and / or spray tunnel and / or pipeline for guiding the fluid and / or a transport path of the at least one component.

[0037] Biofilm formation is to be expected, particularly in wet or humid areas of the treatment plant, which ultimately leads to the spread of germs into the process media.

[0038] According to a favorable embodiment, the at least one sensor can be arranged in a section of the at least one partial area where there is a higher than average probability of an early and / or increased occurrence of biological contamination layers. This enables early detection and early intervention in the form of biocide treatment. Thanks to early detection, biocide treatment in the treatment plant can be well coordinated with the processes taking place therein and the capacity utilization of the treatment plant.

[0039] According to a favorable embodiment, the at least one sensor can be connected to a control and / or regulation unit, which, based on a measured value indicating a biological contamination layer, can issue an alarm message in at least one partial area based on a predetermined limit value and / or can administer a biocide dosage into the at least one partial area and / or, in the case of continuous biocide dosing, adjust a biocide dosage. A biocide-saving and time-efficient cleaning process can be achieved.

[0040] According to a favorable embodiment, the at least one sensor can be arranged in a wall region of the at least one partial region that is not in direct contact with the fluid. A biofilm can grow relatively undisturbed and be detected early.

[0041] The sensor is ideally subject to the same microbiological conditions as the sub-area.

[0042] It is also possible to directly measure the effectiveness of a biocide treatment by removing or reducing the size of the biofilm grown on the sensor. For this purpose, the sensor can be advantageously embedded in the wall of the sub-area.

[0043] According to a favorable embodiment, the at least one sensor can have a selective sensitivity for the biological contamination layer, in particular for biofilms. Inaccurate measurements can be reduced. drawing

[0044] Further advantages will become apparent from the following description of the drawings. The drawings illustrate exemplary embodiments of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will expediently consider the features individually and combine them into further meaningful combinations, as long as the resulting combinations fall within the scope of the claims.

[0045] Examples include: Fig. 1 shows an embodiment of the invention, with a treatment plant; Fig. 2 shows a flow diagram of a method according to an embodiment of the invention. Embodiments of the invention

[0046] The figures show only examples and are not to be understood as limiting.

[0047] Before describing the invention in detail, it should be noted that it is not limited to the specific components of the device and the specific method steps, as these components and methods may vary. The terms used herein are intended only to describe particular embodiments and are not intended to be limiting. Furthermore, when the singular or indefinite articles are used in the description or claims, this also refers to the plural of these elements, unless the overall context clearly indicates otherwise.

[0048] The directional terminology used below, including terms such as "left," "right," "top," "bottom," "before," "behind," "after," and the like, is intended solely to enhance understanding of the figures and is in no way intended to limit the scope of the invention. The components and elements depicted, as well as their design and use, may vary according to the considerations of a person skilled in the art and may be adapted to specific applications.

[0049] Figure 1 schematically illustrates an embodiment of a treatment plant 100 with sub-areas 102, 104, 106, 108, 110, 112 for carrying out the method according to the invention.

[0050] Sub-areas 102, 104, 106, 108, 110, 112 of the treatment plant 100 operated with the method can, for example, comprise humidifiers of supply and recirculation air systems of, for example, spray booths, hall ventilation, etc., fresh water systems; demineralized water systems with fully salted water, here in particular one or more ion exchangers and buffer tanks, one or more membrane systems for fresh water treatment and / or waste water treatment, one or more pretreatment systems in surface technology (for example, automotive painting), one or more cathodic and / or anodic dip painting systems; one or more spray booths with wet separation of the overspray.

[0051] In the illustrated embodiment, the sub-areas 102, 104, 106, 108, 110, 112 are, for example, a water treatment facility 102, a water tank 104, a pretreatment basin 106, an immersion bath 108, and a spray tunnel 110. Pipelines 112, drawn as examples, for conveying the fluid, as well as transport lines for transporting components between the sub-areas are also included. For example, vehicle bodies can be painted in the treatment system 100.

[0052] By way of example, in each of the sub-areas 102, 104, 106, 108, 110, 112, a measuring sensor 300 is mounted, which has at least one biological component for detecting at least one biological contamination layer in the at least one sub-area 102, 104, 106, 108, 110, 112.

[0053] Advantageously, the sensors 300 are arranged in a section of the sub-areas 102, 104, 106, 108, 110, 112 in which there is a higher than average probability of an early and / or increased occurrence of biological contamination layers.

[0054] The measuring sensors 300 are connected to a control and / or regulation unit 200, which, based on measured values ​​of a biological contamination layer in the form of a biofilm by the measuring sensors 300 in the sub-areas 102, 104, 106, 108, 110, 112, issues an alarm message depending on a respectively predetermined limit value and / or carries out a biocide dosage in the respective sub-areas 102, 104, 106, 108, 110, 112 and / or carries out an adjustment of a biocide dosage in the case of continuous biocide dosage.

[0055] Advantageously, the control and / or regulation unit 200 is connected to a computer which executes a computer program product for carrying out the method according to the invention for operating a treatment plant 100, comprising at least one computer-readable storage medium with program code instructions stored thereon, wherein the program code instructions executable by a data processing system cause a limit value of a biological contamination layer for detection by the at least one sensor 300 in at least one sub-area 102, 104, 106, 108, 110, 112 to be set depending on respective process requirements in the at least one sub-area 102, 104, 106, 108, 110, 112; that a check is carried out continuously or at predetermined time intervals to determine whether a measured value of the at least one measuring sensor 300 in at least one sub-area 102, 104, 106, 108, 110, 112 violates the predetermined limit value; that if the limit value for the corresponding sub-area 102, 104, 106, 108, 110, 112 is violated, an action is triggered, in particular that an alarm message is issued and / or a treatment of the corresponding sub-area 102, 104, 106, 108, 110, 112 with a biocide, or, in the case of continuous dosing of a biocide in one or more of the sub-areas 102, 104, 106, 108, 110, 112, the biocide dosage is adjusted; that after completion of the action, the continuous monitoring of at least one sub-area 102, 104, 106, 108, 110, 112 is continued; that, if the limit value is not violated, the continuous monitoring of at least one sub-area 102, 104, 106, 108, 110, 112 is continued.

[0056] Advantageously, the measuring sensors 300 are each arranged in a wall region of the sub-regions 102, 104, 106, 108, 110, 112 that is not in direct contact with the fluid. The measuring sensors 300 are subject to the same microbiological conditions as the sub-regions 102, 104, 106, 108, 110, 112.

[0057] In Figure 2a flow diagram is shown which describes the method for operating a treatment plant 100 with at least one sub-area 102, 104, 106, 108, 110, 112 in which fluid for treating components is stored, and / or a treatment of components, in particular with the fluid, is carried out, and / or a fluid and / or a component is transported, wherein at least one of the sub-areas 102, 104, 106, 108, 110, 112 is monitored by at least one sensor 300 which has at least one biological component for detecting at least one biological contamination layer, in particular a biofilm, in the at least one sub-area 102, 104, 106, 108, 110, 112.

[0058] In step S100, the at least one partial area 102, 104, 106, 108, 110, 112 is continuously monitored by the at least one sensor 300.

[0059] In this case, a limit value of a biological contamination layer for detection by the at least one sensor 300 in at least one partial area 102, 104, 106, 108, 110, 112 is set depending on respective process requirements in the at least one partial area 102, 104, 106, 108, 110, 112.

[0060] In step S102, a check is performed continuously or at predetermined time intervals to determine whether a measured value from the at least one sensor 300 in at least one sub-area 102, 104, 106, 108, 110, 112 violates the predetermined limit value. Depending on the situation, a limit value may be violated if it is reached, undershot, or exceeded. This can be selected depending on the sub-area 102, 104, 106, 108, 110, 112, the treatment method used, and the like.

[0061] If the limit value is violated ("y" in the flowchart), an alarm message is issued in step S104 for the corresponding sub-area 102, 104, 106, 108, 110, 112. Alternatively or additionally, the corresponding sub-area 102, 104, 106, 108, 110, 112 is treated with a biocide, or, if a biocide is continuously added to one or more of the sub-areas 102, 104, 106, 108, 110, 112, the biocide dosage is adjusted.

[0062] After completion of step S104, the continuous monitoring of the at least one subarea 102, 104, 106, 108, 110, 112 is continued in step S100.

[0063] If the limit value is not violated ("n" in the flow chart), the continuous monitoring of the at least one sub-area 102, 104, 106, 108, 110, 112 is continued in step S100.

Claims

1. Method for operating a treatment installation (100) having at least one subregion (102, 104, 106, 108, 110, 112) in which fluid for treating components is stored and / or treatment of components, in particular with the fluid, is carried out and / or a fluid and / or a component is transported, wherein at least one of the subregions (102, 104, 106, 108, 110, 112) is monitored by at least one sensor (300) which has at least one biological component for detecting at least one biological contamination layer in the form of a biofilm as an initial stage of contamination in the at least one subregion (102, 104, 106, 108, 110, 112), wherein sensing and monitoring of the biological contamination layer is carried out from the beginning of growth of the biological contamination layer on the sensor (300).

2. Method according to Claim 1, wherein monitoring of the at least one subregion (102, 104, 106, 108, 110, 112) is continuously carried out by the at least one sensor (300).

3. Method according to Claim 1 or 2, wherein a limit value of a biological contamination layer for detection by the at least one sensor (300) in the at least one subregion (102, 104, 106, 108, 110, 112) is set depending on respective process requirements in the at least one subregion (102, 104, 106, 108, 110, 112).

4. Method according to any of the preceding claims, wherein, when a measurement value of a biological contamination layer is sensed by the at least one sensor (300) in the at least one subregion (102, 104, 106, 108, 110, 112), a cleaning sequence is carried out in the at least one subregion (102, 104, 106, 108, 110, 112), depending on a specified limit value.

5. Method according to any of the preceding claims, wherein, when a measurement value of a biological contamination layer is sensed by the at least one sensor (300) in the at least one subregion (102, 104, 106, 108, 110, 112), an alarm message is issued and / or biocide is metered into the at least one subregion (102, 104, 106, 108, 110, 112) and / or biocide metering is adjusted in the event of continuous metering of biocide into the subregion (102, 104, 106, 108, 110, 112), depending on a specified limit value.

6. Method according to any of the preceding claims, wherein a position of the at least one sensor (300) in the at least one subregion (102, 104, 106, 108, 110, 112) is selected according to a probability of early and / or increased occurrence of biological contamination layers.

7. Method according to any of the preceding claims, wherein a cleaning sequence in a treatment installation (100) having several subregions (102, 104, 106) is carried out individually for each of the subregions (102, 104, 106, 108, 110, 112).

8. Treatment installation (100) having at least one subregion (102, 104, 106, 108, 110, 112) for carrying out the method according to any of the preceding claims, wherein at least one subregion (102, 104, 106, 108, 110, 112) is provided, in which fluid for treating components is stored and / or treatment of components, in particular with the fluid, is carried out and / or a fluid and / or a component is transported, wherein at least one of the subregions (102, 104, 106, 108, 110, 112) has at least one sensor (300) which has at least one biological component for detecting at least one biological contamination layer in the form of a biofilm as an initial stage of contamination in the at least one subregion (102, 104, 106, 108, 110, 112), wherein the biological contamination layer can be sensed and monitored from the beginning of growth of the biological contamination layer on the sensor (300).

9. Treatment installation according to Claim 8, wherein at least one of the subregions (102, 104, 106, 108, 110, 112) is in the form of a water treatment device (102) and / or water tank (104) and / or pretreatment basin (106) and / or immersion bath (108) and / or spray tunnel (110) and / or pipeline (112) for guiding the fluid.

10. Treatment installation according to Claim 8 or 9, wherein the at least one sensor (300) is arranged in a portion of the at least one subregion (102, 104, 106, 108, 110, 112) in which there is a higher than average probability of early and / or increased occurrence of biological contamination layers.

11. Treatment installation according to any of Claims 8 to 10, wherein the at least one sensor (300) is connected to an open-loop and / or closed-loop control unit (200), which emits an alarm message and / or meters biocide into the at least one subregion (102, 104, 106, 108, 110, 112) and / or adjusts biocide metering in the event of continuous metering of biocide based on a measurement value of a biological contamination layer by the at least one sensor (300) in at least one subregion (102, 104, 106, 108, 110, 112), depending on a specified limit value.

12. Treatment installation according to any of Claims 8 to 11, wherein the at least one sensor (300) is arranged in a wall region of the at least one subregion (102, 104, 106, 108, 110, 112) which is not in direct contact with the fluid.

13. Treatment installation according to any of Claims 8 to 12, wherein the at least one sensor (300) has selective sensitivity for the biological contamination layer, in particular for biofilms.