Aqueous Separation Liquid for Paint Overspray Removal
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Solution Overview
Problem
Current paint overspray removal processes in paint spray booths are energy-intensive and costly, with high investment costs due to the large amounts of water required for wet-wash systems, and existing solutions do not efficiently recycle carrier streams, leading to high energy consumption and contamination issues in automated high-capacity lines.
Innovation Solution
An aqueous separation liquid comprising at least 49.95% water, non-ionic surfactants, and organic water-soluble film-supporting components, such as polyols, is used to form a continuous film on contact surfaces within the paint spray booth, effectively capturing paint overspray from a gas stream, which is then recycled and purified, reducing the need for large amounts of carrier liquid and minimizing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large amounts of water are used for wet-wash systems to remove paint overspray, then paint removal effectiveness is improved, but energy consumption and investment costs increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the carrier liquid by formulating an aqueous separation liquid with specific compositional ratios (49.95-95 wt% water, 0.01-5 wt% non-ionic surfactant, 0.01-5 wt% film-supporting component). This optimized composition enables effective paint overspray removal while reducing the total volume of carrier liquid needed, thereby lowering energy consumption for pumping and circulation.
Solution Approach 2:
The patent creates a composite aqueous separation liquid combining water with non-ionic surfactants and film-supporting components (polyols). This composite formulation provides both the effectiveness needed for paint removal and the efficiency to reduce carrier liquid volume, resolving the contradiction between removal effectiveness and energy consumption.
2Reliability
If large amounts of water are used for wet-wash systems to remove paint overspray, then paint removal effectiveness is improved, but investment costs increase
Solution Approach 1:
The patent optimizes the compositional parameters of the carrier liquid to achieve effective paint overspray removal with reduced water volume. This parameter optimization simplifies the system requirements, reducing investment costs for pumps, tanks, and associated equipment while maintaining paint removal effectiveness.
Solution Approach 2:
The patent employs a cost-effective aqueous separation liquid formulation that can be easily produced and disposed of or recycled, replacing expensive and complex traditional wet-wash systems. The simplified chemistry reduces capital investment while maintaining operational effectiveness.
3Reliability
If traditional carrier streams are used without recycling, then paint overspray removal is achieved, but carrier stream contamination and energy consumption increase
Solution Approach 1:
The patent implements a feedback mechanism through the separation and recycling of the aqueous carrier liquid. The liquid is separated from paint overspray, purified, and recycled back to the spray booth, creating a closed-loop system that prevents carrier stream contamination and reduces energy consumption compared to continuous fresh liquid consumption.
Solution Approach 2:
The patent recovers and reuses the aqueous separation liquid after it has performed its function of capturing paint overspray. By separating the liquid from contaminants and recycling it, the system prevents substance loss and reduces the need for continuous fresh carrier liquid, thereby reducing energy consumption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a high recycling ratio of carrier streams, significantly reducing energy consumption and maintaining process stability, while effectively removing paint overspray with low amounts of carrier liquid, suitable for high-capacity coating lines like those in the automotive industry.
Implementation Method 1
contacting paint overspray with the gas stream flowing through the paint booth thereby forming a paint loaded gas stream containing paint particles or droplets dispersed therein, directing the paint loaded gas stream to said surface, in order to bring the gas stream in contact with the flowing substantially continuous film of the aqueous separation liquid, thereby transferring paint particles or droplets from the gas stream into the separation liquid
Implementation Method 2
An aqueous separation liquid for collecting paint overspray from a gas stream comprising: a) at least 49.95 wt-% water, based on the total weight of the aqueous separation liquid; b) at least one non-ionic surfactant
Implementation Method 3
5 to 50 wt.-% based on the total weight of the aqueous separation liquid of an organic water-soluble film-supporting component selected from monomeric polyols having at least three hydroxyl groups in the molecule and polymeric polyols selected from poly(ethylene glycols, polyester polyols, acrylic polyols and polyurethane polyols)
Data Source
AI summary
The present invention relates to a specific aqueous separation liquid and to a process for removing paint overspray from a paint spray booth comprising: i) directing a gas stream through a paint spray booth; ii) contacting paint overspray with the gas stream flowing through the paint booth thereby forming a paint loaded gas stream containing paint particles or droplets dispersed therein, iii) forming a flowing substantially continuous liquid film of the aqueous separation liquid on a surface positioned within the flow path of the gas stream; iv) directing the paint loaded gas stream to said surface, in order to bring the gas stream in contact with the flowing substantially continuous film of the aqueous separation liquid, thereby transferring paint particles or droplets from the gas stream into the separation liquid to form a first paint loaded separation liquid; and v) removing the first paint loaded separation liquid and the gas stream having a reduced paint load.