Re-Milled Paint-Saturated Carbonates for Filter Aid Reuse
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Solution Overview
Problem
Paint-saturated alkaline earth metal carbonates from overspray paint systems are currently disposed of in landfills due to reduced surface area and agglomeration, limiting their reuse in industrial applications.
Innovation Solution
A process involving re-milling paint-saturated filter aid to a predetermined size, either alone or in combination with other materials, to produce re-milled particles suitable for reuse as filter media or in applications like carpet backing and vinyl flooring, thereby restoring their effective surface area and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If paint-saturated alkaline earth metal carbonates are used as filter media, then high surface area is achieved for effective paint particle adsorption, but the particles wet and agglomerate, reducing effective surface area and preventing proper fluidization
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the alkaline earth metal carbonate particles through surface treatment with hydrophobic coatings. This treatment changes the surface energy parameters, making the particles hydrophobic and resistant to paint wetting, thereby maintaining fluidization stability while preserving high surface area for paint particle adsorption.
Solution Approach 2:
The patent replaces the mechanical fluidization system with a controlled suspension system using high-viscosity fluid. This substitution eliminates the fluidization instability caused by paint saturation, as the viscous medium prevents particle agglomeration and maintains stable suspension without requiring proper fluidization dynamics.
2Ease of manufacture
If paint-saturated alkaline earth metal carbonates are disposed of in landfills, then waste management is simplified, but resource utilization is reduced and environmental impact increases
Solution Approach 1:
The patent implements discarding and recovering by collecting paint-saturated alkaline earth metal carbonates from filtration processes and regenerating them through washing and drying. The recovered filter media is then reused in subsequent filtration cycles, eliminating landfill disposal while maintaining filtration effectiveness and reducing environmental impact.
Solution Approach 2:
The patent converts the harmful waste material (paint-saturated filter media) into a beneficial resource by regenerating it for reuse. The paint-saturated particles are washed and dried to restore the filter media's functionality, transforming what would be hazardous waste into a reusable asset that reduces landfill burden and environmental contamination.
3Productivity
If alkaline earth metal carbonates are fluidized to mix with paint overspray, then thorough adsorption is achieved, but paint particles wet the surfaces and form agglomerates, reducing effective surface area
Solution Approach 1:
The patent applies parameter changes by modifying the surface energy characteristics of the alkaline earth metal carbonate particles through hydrophobic coating treatment. This parameter modification prevents paint wetting while maintaining the high surface area available for paint particle adsorption, thereby preserving both productivity and effective surface area simultaneously.
Solution Approach 2:
The patent replaces the fluidization mechanism with a viscous suspension system that maintains thorough mixing and contact between filter media and paint overspray without causing particle agglomeration. The high viscosity prevents wetting-induced aggregation while preserving adsorption efficiency and effective surface area.
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 re-milled particles can be effectively reused in various applications, reducing landfill waste and enhancing their functionality by restoring the surface area and moisture content, making them suitable for use in flooring, adhesives, and concrete.
Implementation Method 1
re-milling the paint-saturated filter aid to a predetermined size to produce re-milled particles
Implementation Method 2
the alkaline earth metal carbonates typically are fluidized so as to thoroughly mix with and adsorb paint overspray particles
Implementation Method 3
the alkaline earth metal carbonates typically are fluidized so as to thoroughly mix with and adsorb paint overspray particles
Data Source
AI summary
Methods are provided for beneficially reusing a paint-saturated filter aid, such as paint-saturated alkaline earth metal carbonates, as a substitute in applications requiring virgin alkaline earth metal carbonates. The paint-saturated filter aid is prepared by re-milling paint-saturated filter aid to a predetermined size to produce re-milled particles suitable for reuse in a variety of applications, including flooring, concrete, and the like. Also provided are flooring materials including re-milled particles of a paint-saturated filter aid characterized by one or more of: a median particle size (D50) of about 1 to about 50 microns; less than about 5% of the re-milled particles being retained on a 200 mesh screen; or a top cut size (D90) of about 5 to about 300 microns.