Ecopaint Booth - Efficient and Sustainable Painting

Ecopaint Booth
Efficient and sustainable painting
www.durr.com
Focus on efficiency
and sustainability
– this is the concept which rules all
Dürr products and innovations. To live up to it, we
developed the
, a paint shop
optimized for highest efficiency, which now is
the benchmark in automotive paint finishing.
The
is efficient in every aspect: optimized
processes, fewer emissions, reduced energy consumption,
less material used, and a flexible system with a space-­
saving layout – these criteria are of top priority for Dürr.
The paint booth is at the heart of the paint shop. Here, the painted
surfaces get their finish – and it is the quality of the finish that
forms the impression of the quality of the product as a whole.
Classical spray booth
for optimum application
The spray booth as heart of the paint shop has a modular structure and
easy to clean components and can be flexibly adapted to all r­ equirements.
The customer specifies process parameters such as structural constraints, space requirements, capacities, and cycle times. Based on this
information, Dürr implements the spray booth with integrated application technology and conveyor system. With our in-depth knowledge
of the processes involved based on decades of experience, we ensure
optimum co-action of all components via standardized interfaces. This
allows for fast assembly and smooth start of production and results in
high first-run rates with optimized unit costs – not least due to earlystage testing of processes in realistic simulations of the painting processes. We guarantee this security for new installations as well as for
retrofits or extensions of your existing lines.
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EcoReBooth – the ideal
paint booth concept
With EcoReBooth, Dürr has completely transformed the
paint booth. We integrate the ducts, the air conditioning
and the air recirculation system in the booth crosssection below the spray booth. This is where the reliable
EcoDryScrubber modules are located as well. In this way,
all of the relevant components are arranged on one level.
The building-independent concept is highly modular. The
integrated process air system serving each booth unit
separately allows for individual conditioning of each
painting zone. These benefits are complemented by a
small footprint and an excellent energy efficiency.
Paint booth
Police filter
EcoDryScrubber
Fan and
air conditioning
» All relevant components are arranged on one level.
Because of the compact layout, a modular arrangement
of the paint booth in a line without interfering contours is
possible. In ideal cases, an entire building level (the penthouse) can be completely omitted thanks to the integrated
process air technology. This makes the EcoReBooth perfect
for retrofitting or refurbishment of existing painting f­ acilities
where limited space is available. The modular concept
further­more makes the conversion of existing facilities
much easier.
This newly designed paint booth has already been proven
and tested in practical use: The EcoReBooth is operating
successfully on the shop floor of a reputable German OEM.
» EcoReBooth – compact and modular.
3
Paint separation –
one step ahead
In wet paint application, the efficiency depends on the degree of automation.
But even with the most favorable scenario of automated exterior painting, up
to 15 % of the paint does not end up on the car body. Dürr offers a number of
innovative systems for resource-efficient separation of this paint overspray.
EcoDry X
EcoDry B
EcoDryScrubber
EcoEnvirojet
One goal –
four routes
Separation system
Dry separation
Characteristics
Paint absorption
capacity
Simple, stable process
Wet separation
Highest degree
of separation
Standard
+
+
++
++
0,5 – 3,0 mg / Nm³
0,5 – 3,0 mg / Nm³
< 0,1 mg / Nm³
< 3,0 mg / Nm³
Pressure drop
Increasing
Increasing
Constant
Constant
Operation and
maintenance
Instructed personnel
Instructed personnel
Qualified personnel
Qualified personnel
Emissions
Suitable for
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Greenfield and Brownfield solutions
EcoDryScrubber – Efficiency
by dry separation
With this technology, Dürr revolutionized paint overspray separation. This
­s ystem, used successfully all over the world, relies on dry separation with
limestone powder as binding agent for the overspray. This system works
without water and coagulation agents.
Furthermore, the EcoDryScrubber convinces with the following benefits:
»» Up to 60 % less energy consumption in the spray booth
»» Up to 95 % recirculated air
»» Stable processes practically unaffected by climatic changes
»» Constantly high painting quality
»» Limestone material as binding agent, readily available worldwide
»» Fully automated feed of limestone material
»» Re-use of the paint-saturated limestone powder
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EcoDry X – the intentionally
simple and robust
paint overspray separation
For facilities with small to medium overspray volumes, EcoDry X is the first
choice. It is a multi-stage filter system with disposable paper filters that are
extremely easy to replace. Filter replacement trolleys ensure fast filter change,
if necessary also during ongoing production. When the filters are saturated,
the replacement trolley is undocked manually and replaced by another trolley
prepared with new filters. The saturated paper filters are then comfortably
­disposed of in containers at a well-ventilated preparation station.
»» Successfully used for years in industrial series painting
»» Separation filters adapted specifically for automotive series painting
»» Low-cost, easy to operate technology
»» Suitable for greenfield and brownfield solutions
»» Quality of the filtered air equivalent to wet separation level
»» In many countries, the saturated paper filters may be disposed
of as industrial waste
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EcoDry B – the exclusive
paint overspray separation
without additives
EcoDry B is a dry separation system for any volumes of overspray. The overspray is caught by rotating brushes. Once it has dried, it is removed from the
brushes by means of scrapers. What is more, EcoDry B works without any water, chemicals, or additives. Accordingly, this system can likewise be operated
primarily with recirculated air, which reduces energy consumption and stabilizes the painting process.
»» Quality of the filtered air equivalent to wet separation level
»» For many years, the process has been used very successfully
in industrial series painting
»» Based on our many years of experience in paint separation,
the design of this system has been improved for automotive painting
»» Automated drying, cleaning, and pre-coating of the brushes
»» Disposal of almost pure paint
»» Extremely easy to operate technology for greenfield and brownfield solutions
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EcoEnvirojet – Wet separation
with minimum design height
Our constantly improved wet washing process is an excellent alternative to
dry separation. Our EcoEnvirojet 3 system allows for high-end paint overspray
separation with low noise level thanks to intelligent sound reflection. This
technology convinces with its small paint build-up attributable to its superior
flow properties.
»» Extremely flat improved version EcoEnvirojet 3S
»» Perfect for applications with severe structural constraints
due to low overall height
»» Ideal for retrofit of existing lines
»» Good accessibility for cleaning and maintenance purposes
»» Time-proven individual components, combined in an intelligent
overall system
The decision for the type of separation actually employed depends on various
factors, such as the conditions on site, the degree of sustainability sought,
or the scheduled line capacity.
8
Limestone powder recycling
for the EcoDryScrubber
With a fluidized-bed process customized to the EcoDryScrubber, Dürr now
makes recycling of the limestone possible – directly at the customerʼs site.
In this oven, the saturated limestone is separated from the overspray in the
paint shop ready for re-use. This on-site treatment can be repeated several
times.
It is based on a simple principle: The process air extracted from the ambient
environment by a fan is heated and used for direct heating of the oven.
A temperature control ensures that only the paint is burned, leaving the
pure limestone powder. The re-use of the limestone significantly reduces
the supply and disposal logistics on site.
The fluidized-bed oven can easily be integrated in an existing dry separation
system. Only the support concept is changed, the EcoDryScrubber itself is not
affected. The oven can be started up fully independent of the operation of the
system.
The speedy paint station
Our new
conveyor system
increases the capacity while improving
the quality of the paint application. The
system has been specifically designed
for the stop-and-go operation in the
paint booth. It uses the time-proven
skid technology. The carrying and
guiding functions are implemented
by non-driven roller beds. The drive
is provided by linear units arranged
centrally.
The reduction of nonproductive
times increases the capacity. With
, Dürr manages to reduce
the transfer time by 50 % from 16 to
8 seconds without interruption of the
positive locking. The high positioning
accuracy during application achieved
in this way ensures superior quality.
These benefits are further enhanced by
the speedy color change in 8 seconds with
AB technology.
A speedy paint station: the result of a combination of various innovative Dürr technologies.
A minor but attractive aspect is the reduced
cleaning effort on the smaller footprint.
Ecopaint Airhandling –
Dürrʼs performance is measured by the quality of the paint application and
the perfection of the painted car body. One of the decisive factors for this perfection is the optimum conditioning of the booth air. To this end, Dürr offers
its customers innovative solutions for complete routing of the air flow around
the booth.
Complete routing of air flow with Dürr products
Supply and circulation air control
For inlet and circulation air treatment, Dürr offers a new premium product:
EcoSmart AC – the next generation of temperature and humidity control.
Heat recovery
» EcoAir Supply
Hot air saves energy
Despite the increasing use of circulation air units in spray booths, made particularly economical by our dry separation technologies, there is still a residual
content of fresh outside air which needs to be put into the proper state for the
process conditions.
EcoHeat Recovery – the Dürr heat recovery technology – uses the thermal energy from the exhaust air to heat up the incoming outside air, thus reducing the
10
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te d
u
EcoSmart AC is not only designed for integration in new equipment
but also for comfortable expanding of existing facilities, irrespective
of whether these have been manufactured by Dürr or another supplier.
rc
The system is very easy to configure: An intelligent process
­management allows for flexible adaptation of the system behavior to the customerʼs preferences. This makes it possible to
save time and money when configuring the conditioning process,
and to minimize operating costs.
Re c i
» EcoSmart AC
ir
a
y
Su
pp
l
This new product for an optimum regulation of the supply and
circulation of air systems creates the prerequisites for stable and
energy-efficient operation of your facility. The setpoint value is
adjusted fully automatically to the external conditions ten times
per second, and the different variables are optimally coordinated.
In this process, energy potentials which cancel each other are
determined by software beforehand, and the individual setpoint
values are output in an energetically optimized manner.
a
good atmosphere for top quality
energy consumption of the spray booth. Whether regenerative thermal wheels,
recuperative plate heat exchangers, or a circulation system – we are offering
the system solution which best matches the overall situation.
The environment breathes a sigh of relief
Exhaust air purification plants
The painting process leaves traces in the air which – if untreated – may harm
the environment. To protect the environment, the process air must be cleaned
before it is discharged to atmosphere.
Exh
a
ir
ta
us
r
Ecopure RTO
The Ecopure RTO is primarily i­ntended for
exhaust air volume flows with p
­ ollutant
concentrations of up to approx. 10 g / mN3.
Autothermic operation of the equipment
is already possible starting from a
pollutant concentration of approx.
1.5 g / mN3. In this case, it is possible
to do totally without addi­tional fuel.
Regenerative thermal oxidation is
indicated if heating of the process
exhaust air during cleaning is not
desired or required. For the disposal
of combustible, organic pollutants,
oxidation is the most efficient method
of exhaust air purification.
air
» Ecopure RTO
ra
ti o
n
Process air
conditioning for
the
Ecopaint Booth
Ecopure KPR – VOC concentrator
For high volume flows and low pollutant concentrations, Ecopure KPR
units are particularly efficient. Exhaust air
with a low content of pollutants is concentrated
by means of adsorption via continuously rotating
rotor systems, which makes the purification of this air
more economical. The KPR is characterized by its intelligent modular design and optimum accessibility. Manufactured
in-house by Dürr, the Ecopure KPR units offer excellent quality and high flexibility.
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nt
C
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on
The above-listed products for the process air circuit are examples for Dürrʼs
extensive expertise in respect of the regulation and purification of process air.
Based on our many years of experience, we have the matching solution for every
customer requirement.
» Ecopure KPR-Rotor
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Dürr – Leading in Production Efficiency
Four divisions, one goal: maximum production efficiency for our customers
»» Paint and Assembly Systems: Paint shops and final assembly plants for the automotive industry and aerospace construction
»» Application Technology: Robot and application technology for applying paint, adhesives and sealants
»» Measuring and Process Systems: Balancing technology, cleaning and surface processing technology as well as testing,
filling and assembly products
Subject to change. The information in this brochure contains only general descriptions or performance characteristics which may vary in actual cases.
The requested performance parameters shall be binding only if they are explicitly agreed within the sales contract. © Dürr Systems GmbH 2014
»» Clean Technology Systems: Exhaust air purification systems, energy efficiency technologies
www.durr-paint.com