Discussion on energy saving and emission reduction in electrostatic powder coating production

Electrostatic coating equipment technology is a high solid content and low VOL environment, excellent surface quality and high rust resistance, has been widely used in building materials, household appliances, communication cabinets, automobile manufacturing, high-speed rail cars and all kinds of electrical control box and furniture, traffic signs and so on. With the emergence of new materials, new processes will be further widely used, but electrostatic powder spraying is a high energy consumption process after all, cleaning phosphating needs energy, dehydration, curing needs heat. How to reduce energy consumption, how to reduce pollution, how to reduce costs, and to produce high quality and low consumption products is the subject of research and development of process engineers. In response to the national low carbon environmental protection requirements, at the same time in order to improve product quality, reduce production costs, improve product market competitiveness, should actively promote the introduction of new materials, new technology and new process, from the perspective of energy saving and reducing the. After years of on-site exploration and practice, the electrostatic coating equipment will significantly reduce energy consumption, productivity increased significantly, the cost dropped significantly, specific measures to share with peers.

I. apply high speed curing powder

In 2009, my company was faced with spraying line production capacity is not enough, energy consumption, high spraying costs. When we use the powder curing temperature is 200 DEG C for 10 minutes, while the low temperature powder market has developed 180 DEG C for 15 minutes. With this powder, energy consumption decreased by 10%, but the production rate decreased by 50%, the cost increased, The loss outweighs the gain. Together with the powder supplier, we have developed a high-speed curing powder, which can increase the production capacity by 200 degrees per 5 minutes, and the unit energy consumption has decreased by 100%

Two. High temperature passivation treatment of stainless steel

Electrostatic powder spraying spraying stainless steel is a difficult thing, electrostatic powder spraying coating is stainless steel than difficult, before treatment is not good, not good adhesion will happen by accident, and the processing cost is high, the traditional process is as follows:

Discussion on energy saving and emission reduction in electrostatic powder coating production

Usually spraying process does not have pickling process, because the use of strong acid, corrosion of equipment, pollution of the environment, usually outside the professional factory processing, the cost of large, long cycle. After many experiments, we made a purification process for stainless steel (304201) by using high temperature purification process instead of the original pickling process. The stainless steel (304201) high temperature purification process was as follows:

Discussion on energy saving and emission reduction in electrostatic powder coating production

Three. Before spraying, the place should be vitrified instead of phosphating

Main features of pottery treatment:

1., without surface conditioning, it can be done at normal temperature, low concentration and short time

2. tank liquid maintenance is convenient, phosphating treatment needs to be heated 35-40 degrees, vitrified treatment, without heating. Phosphating produces slag, and a little bit of slag. Phosphating needs to control the total acidity, free acid, accelerant, ceramic, only need to control pH value.

3., conversion agent consumption less, phosphating film thickness 2um, ceramic film thickness 200 nanometer, is phosphating 10%.

4., the use of ceramic process can be used before the original coating phosphating production line, without the need to replace the new equipment.

5. 、 suitable for various metal (steel, zinc, aluminum, magnesium alloy) coating pretreatment.

6., environmental protection, no phosphorus in wastewater.

7., reduce the operation cost of pretreatment, and the cost of ceramic treatment is phosphating treatment 69%.

Discussion on energy saving and emission reduction in electrostatic powder coating production

Less than 1 phosphating process, less a heating process.

The original phosphating heating 30 hours per hour, work 16 hours a day, work 480 hours a month, 14400 hours per month electricity. The use of Tao process does not need electric heating can save 14400 yuan per month, and adjustment costs can also be, the monthly 60000 square meters per square meter, 0.24 yuan, pre operating costs is 59% phosphating solution.

The traditional pretreatment phosphating process, heating, to watch, to test the total acidity, free acid production in the accelerator debugging operation is more complicated, and often produce phosphate slag blocked nozzle, sewage treatment is relatively complex. Now we use ceramic processing instead of phosphating, without heating, no need to watch and control is relatively simple, only need to test the pH value, not a lot of residue, less amount of nozzle is not blocked, the cost is one of the 10 points of phosphatizing wastewater treatment is simple, it can deal with the aluminum plate, galvanized plate, the production cost is greatly reduced.

In the practice of ceramic film is the film book is 10%, so the high carbon content of the material conditions, parts of the surface will have black, in the slow speed chain situation will rust phenomenon, we add Tao liquid countermeasure is small after degreasing second water washing, Tao after the last road to purification of purified liquid acid played a very good effect, to avoid the carbon black and rust reappears the.