Building aluminum profile powder coating energy-saving solution - low temperature fast curing powder coating

A foreword
1, China's aluminum profile production reached more than 15 million tons, ranking first in the world, Guangdong Province, the existing aluminum profile processing enterprises more than 200, aluminum profile production accounted for more than 50% of the country, powder spray aluminum profiles accounted for more than 50% of the share, the national powder spray aluminum profile powder amounted to 300,000 tons.
2, traditional powder coatings, curing temperature 190 to 210 degrees C, curing time 10 to 15 minutes, natural gas energy consumption 20 to 45m3/T (different equipment and processes, different components, continuous production conditions, etc. lead to large differences), sustained high temperature on the equipment loss, high maintenance costs.
3, low temperature rapid curing powder coating system Defuson ® 09, curing temperature 160 to 180 degrees C, curing time of 6-10 minutes, natural gas energy consumption 14 to 25m3/T
China
. Coating impact resistance, adhesion, boiling water performance, salt spray performance, wet heat performance and weather resistance meet the technical requirements of GB5237.4-2017, Qualicoat class I, class II, AAMA2603, AAMA2604.
4, low temperature rapid curing powder coating system Defuson® 09 coating, the requirements of the equipment and the existing powder coating consistent, no need for new inputs and modifications to existing spraying equipment, only according to the actual conditions of the existing spray line, appropriate adjustment of the process Parameters, including lowering the temperature and curing time of the curing furnace, or adjusting the chain speed appropriately, can effectively improve production efficiency, increase production by more than 30%, reduce the discharge of organic volatiles after powder curing and the generation of ash accumulation, and effectively improve the production environment.
2 Technical requirements and implementation conditions
1, new low temperature rapid curing powder coating system Defuson ® 09, using a new low temperature curing resin Ualac® Easycaretm series of resins, with this resin made of powder coating to reduce the curing temperature by 30 To 40 degrees C, curing time between 6-10 minutes, significantly speed up the spray line chain speed, still has good leveling and related surface properties, such as no powder clothing, no pinholes, its leveling and weather resistance can be fully comparable with the traditional curing conditions of the powder coating.
1) After mass production, data analysis, curing graph see Figure I
2) Building spray aluminum profile weather resistance is the most critical requirements for powder coating, the powder coating system xenon lamp artificial acceleration aging curve see Figure 2, Florida standard white formula natural exposure to Figure III.
III Florida Natural Exposure (Standard White Formula)
The new value of aluminum profile powder coating in construction is reflected in increased productivity, natural gas energy savings, and reduced organic emissions. Theoretically, based on the ratio of energy savings such as thermal energy, the maintenance power can be calculated to obtain the data to maintain the power reduction, as shown in Figure 3, P1/P2 is approximately equal to 130% of the maintenance temperature, which means that the work part temperature is reduced from 200 degrees C to 160 degrees C, and the maintenance power is reduced by 25-30%. Considering the thermal energy dissipation and energy efficiency, the higher the temperature, the greater the thermal energy dissipation, the lower the thermal wind efficiency, the longer the time, reduce the temperature, thermal dissipation of energy geometric level decreased, and Q dispersion occupies the largest thermal energy dissipation, energy savings of more than 35%.
2, inspection report 1
inspection report 2
3, production line practical report
Guangdong Wynn Aluminum Co., Ltd. is China's extruded aluminum alloy building profiles and industrial aluminum profiles in one of the integrated aluminum processing enterprises. The company has 24 extrusion production lines, oxidizing electrophoresis line 3, spray line 3, fluorocarbon line production line 1, wood line production line 3, insulation bridge production line 2 and deep processing line 1, products up to more than 200 series, more than 10,000 kinds of specifications, the company set up the Guangdong Provincial Engineering and Technology Research and Development Center and Guangdong Provincial Enterprise Technology Center, with the ability to develop new technologies and new products. Guangdong Defusheng New Materials Technology Co. , Ltd. is engaged in the development, production, sales and service of thermostasteric powder coatings joint-stock enterprises, products are widely used in building materials, general industry, home appliances, automotive, information industry and other industrial fields, is a larger domestic scale, research and development capabilities of strong powder coatings company. Wynn Aluminum and Defusheng Powder Coatings Company have good product and technical cooperation, over the years, jointly developed a number of new technologies and new products to the market.
4, after 30 days of mass production, the test confirmed that the system powder coating can achieve a predetermined effect. Because the experiment is not continuous and stable production, high and low temperature switching did not achieve the most ideal energy-saving effect, but also can further certify the full continuous production of energy-saving and efficiency.
1) Test 1: Spray Defuson (9) RAL9016 powder coating furnace temperature setting: curing temperature of 160 degrees C, curing time of 10 minutes, chain speed: 2.5 to 1 3 m/min, the production of YLJ25001, YLJ25002, YLJ25004, YLJ196001 and other building powder aluminum profiles a total of 150 tons. The powder consumption is 6000 kg (40 kg/tonne) and the natural gas consumption is 15.3m3/tonne. Traditional powder spraying naturally consumes 22m3/tonne, saving 30.5% of energy compared to conventional production processes.
2) Test 2: Spray Defuson (9) RAL9016 powder coating furnace temperature setting: curing temperature of 170 degrees C, curing time of 8 minutes, chain speed: 2.5 to 3 m/min Production of YLJ19002, YLJ19003, YLJ19004, YLJ19005, YLJ19007 and other building powder aluminum profiles a total of 110 tons. It consumes 4500 kg (41 kg/tonne) of powder and 16 m3/tonne of natural gas. Traditional powder spraying naturally consumes 22m3/tonne, saving 27.3% of energy compared to conventional production processes.
3) Test 3: Spray Defuson (9) RAL9016 powder coating furnace temperature setting: curing temperature of 180 degrees C, curing time of 6 minutes, chain speed: 2.5 to 3 m/min Production of YLJ19002, YLJ19004, YLJ19005, YLJ19006, YLJ19007 and other building powder aluminum profiles a total of 160 tons. It consumes 6200 kg (38.7 kg/tonne) of powder and 16.5 m3/tonne of natural gas. Traditional powder coating naturally consumes 22m3/tonne, saving 25% of energy compared to conventional production processes.
3 Conclusions
1, Low temperature rapid curing powder coating system Defuson ® 09, sprayed building aluminum profile product quality is stable, coating impact resistance, adhesion, boiling water performance, salt spray performance, wet heat performance and weather resistance can meet GB5237.4-2017, Qualicoat Class I, Class II, AAMA2603, AAMA2604 technical requirements.
2, low temperature rapid curing powder coating system Defuson ® 09, curing temperature 160 to 180 degrees C, curing time of 6 to 10 minutes, natural gas energy consumption of 15 to 18m3/T, can save more than 25%-30% of natural gas energy, achieve energy saving effect, reduce carbon emissions. According to different equipment and substrates, such as continuous and stable low-temperature curing production, can bring greater energy-saving effect
3, improve equipment uivity and production efficiency of more than 30%, each ton of aluminum profile production to reduce production costs of about 100 yuan / ton. To the enterprise annual production of powder spray aluminum profile 20,000 tons calculated, each year for enterprises to reduce production costs of about 2 million yuan. (Production line depreciation, working hours, efficiency and different)
4, low temperature rapid curing powder coating system Defuson ® 09, can effectively improve production efficiency, product quality and stability, help the production floor safety management. The promotion of this series of products, the market prospect is considerable, will produce obvious economic and environmental benefits, help in the coating industry chain to reduce the total carbon emissions.
reference:
DSM on low temperature curing powder coating resin material.Zhu Yaohui 1, Zeng Xiangrong 2, Wu Qingsong 3, Liu Kefei 3, Zhao Yong 3, Xiong Qiquan 4, Wu Jun 4, Liu Fan 4
1, Fujian Yanfa Aluminum Co., Ltd.
2, DSM (China) Co., Ltd.
3, Guangdong Defusheng New Materials Technology Co., Ltd.
4, Guangdong Yonglijian Aluminum Co., Ltd.