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Abstract: With the rapid development of my country's industrialization, my country is also facing serious environmental pollution problems, and the country has successively promulgated a series of laws and regulations.
In response to the large-volume exhaust gas generated during the automobile painting process, source control and treatment of emission reduction are required.
In recent years, OEMs have actively responded to environmental protection policies and carried out upgrading and transformation of coating water-based paint processes.
The article adopted a solvent-based coating production line in accordance with The three water-based paint process plans of B1B2, 3C2B, and 3C1B were compared and analyzed, and the effects of the implementation of the transformation were selected, and the ideas for the upgrading and transformation of the water-based paint process were explained.
Keywords: water-based topcoat; coating process; upgrading and transformation 1 background and current situation my country's automobile coating production line built before 2012, the paint materials mainly use traditional solvent-based topcoats, which are far behind in terms of environmental protection, safety, quality, etc.
In the current mainstream water-based paint process, exhaust emissions can no longer meet the "Volatile Organic Compounds Emission Control Standard" (DB61/T1061-2019).
At the same time, the equipment has long-term high-load operation, serious aging, high failure rate, and equipment operation and maintenance costs year by year.
The rise will affect the production cycle and the appearance quality of the high-end cab.
2 Necessity of transformation In terms of environmental protection, laws and regulations require the implementation of raw material substitution projects, process technology transformation projects, recycling and comprehensive treatment projects, and all enterprises are required to ensure stable and up-to-standard emissions in accordance with standard requirements.
In terms of quality, the solvent-based production line usually adopts natural wind, and the performance and quality of the paint film are restricted.
By adding constant temperature and humidity transformation to the spray booth, the process control ability is improved.
In terms of safety, the original sprinkler fire-fighting system is mainly carbon dioxide fire extinguishing, which has insufficient design and risks, and requires an open-type high-pressure water mist upgrade.
Through the upgrading and transformation of the coating water-based paint process, the production line has been improved in terms of environmental protection, safety and quality to comply with national laws and regulations and improve the market competitiveness of the company's products.
3 Water-based paint process transformation plan The paint line can be divided into traditional solvent-based paint line and water-based paint line according to the paint materials.
In recent years, the national environmental protection policy has become more and more stringent.
Laws and regulations require the implementation of raw material substitution projects, process technology transformation projects, recycling and Comprehensive treatment project, and the "Twelfth Five-Year Plan for Air Pollution in Key Areas" (Huanfa [2012] No.
130) approved by the State Council on September 27, 2012, proposes VOC pollution control as a construction project for the paint and coating industry As an important part of the environmental impact assessment, strict pollution control measures are adopted: new motor vehicle manufacturing coating projects, and low-VOC content coatings such as water-based coatings account for no less than 80% of the total coating usage.
The traditional solvent-based paint line emission standards can no longer meet the environmental protection standards, and the whole area of the spray paint must be used for the rotary adsorption concentration + RTO exhaust gas treatment process to achieve exhaust gas emission standards.
Due to the large total exhaust air volume, the equipment investment cost is high and the area is occupied.
Large area, high operation and maintenance cost.
The use of water solvents instead of organic solvents in the water-based paint process for intermediate coating, silver base, and color paints is the most effective measure to reduce VOCs emissions from the source.
After the water-based paint process is applied, the waste gas treatment volume is reduced.
The water-based paint process has been widely used at home and abroad.
.
In order to ensure that the exhaust gas emissions from painting meet the environmental protection standards for a long time, this scheme adopts the water-based paint process scheme.
The current water-based paint processes mainly include: B1B2 water-based process, 3C2B water-based process, and 3C1B water-based process.
The three transformation schemes are as follows: 3.
1 Scheme 1: Line A B1B2 water-based topcoat line, Line B water-based solid-color topcoat line B1B2 water-based topcoat process requires pre-drying of the color paint, and the current length of the original topcoat A line is insufficient , The spray booth must be extended by about 15.
5m on the original foundation (considering the relocation of the central control room), the line body shall be extended by about 6.
6m.
The construction of line A and B mainly includes: cleaning room, painting room (including air seal), leveling room (adding air curtain), hot flashing (including air seal and cooling), air conditioning, offline polishing room, robot, transportation and adjustment Paint, transportation, electric control, etc.
The A line process layout includes: cleaning, air sealing, BC1 external spray, air sealing, BC2 internal spray, BC2 external spray, paint touch-up, air sealing, hot flashing, air sealing, cooling, air sealing, varnish inner spray, varnish External spraying, paint touch-up, leveling, compared with the original hot flashing process (including air seal, cooling); B line is a water-based solid color paint spraying line, the B line process layout remains unchanged, and at the same time according to the requirements of water-based paint characteristics Public and fire fighting system.
3.
2 Scheme 2: 3C2B water-based topcoat line 3C2B water-based topcoat process requires that the topcoat must be sprayed and dried before the topcoat is sprayed, that is, the cab can enter the topcoat and spray the water-based paint on the A line before the topcoat is sprayed.
Paint, varnish.
A and B line bodies mainly include: cleaning room, painting room (including air seal), leveling room (adding air curtain), hot flashing (including air seal and cooling), air conditioning, robots, paint transfer, transportation, Electric control, etc.
, while restoring the supporting public and fire-fighting systems.
3.
3 Scheme 3: A line 3C1B water-based topcoat line, B line water-based solid-color topcoat line topcoat A line uses 3C1B water-based topcoat technology, B line water-based solid-color topcoat line.
The paint spraying room of line A of the finish paint must be extended by about 30m (the central control room and toilet must be relocated), and the line body shall be extended by about 18.
5m.
The line body mainly includes: cleaning room, painting room (including air seal), leveling room (adding air curtain), hot flashing (including air seal and cooling), air conditioning, offline polishing room, robot, paint transfer, Conveying, electric control, etc.
, and supporting public and fire-fighting systems according to the characteristics of water-based paint.
The process layout includes: cleaning, air sealing, intermediate coating, air sealing, hot flashing, air sealing, silver bottom spraying, silver bottom spraying, paint touch-up, gas sealing, hot flashing, gas sealing, cooling, gas sealing , Varnish inner spray, varnish outer spray, paint touch-up, leveling, adding intermediate coating spraying, intermediate coating hot flashing (including air sealing, cooling), silver bottom hot flashing (including air sealing, cooling) processes compared to the original.
4 Scheme comparison 4.
1 Water-based paint process scheme Table 1 Water-based paint process scheme comparison 4.
2 Water-based paint modification content (Table 2) Table 2 Water-based paint modification content comparison 4.
3 Water-based paint paint cost Table 3 Paint cost comparison of three water-based paint processes Note: Bike cost Need to consider the proportion of metallic paint and solid color paint; the statistics in the table are only the cost of topcoat paint; the cost of paint is subject to the manufacturer's quotation, and this table does not reflect the paint price.
4.
4 Comparison of the budget cost of water-based paint.
The content and cost of the water-based paint process upgrade and transformation mainly involve the cleaning room, spray room, leveling room, hot flashing, air conditioning, offline polishing room, robots, paint delivery and mixing, transportation, electronic control, and exhaust gas treatment.
, Public facilities, fire protection system, safety, environmental protection, occupational hazards "three assessments", peripheral engineering, workshop public facilities, unpredictable expenses and demolition, civil works, floor, high-pressure water guns, refined exhaust air, drying furnace restoration, Cleaning, etc.
, the investment budget for option one is RMB y million, option two is RMB 0.
87 million, and option three is RMB 102 million.
4.
5 Water-based paint cost comparison (Table 4) Table 4 Three types of water-based paint process costs and existing process comparison 5 Scheme selection Because scheme one and scheme three water-based paint process involves process layout changes, the new >
6 Conclusion Through the upgrading and transformation of the 3C2B water-based paint process, the current coating line is leading the industry in terms of environmental protection, safety, and paint film quality.
The DOI value, gloss and color difference of the cab paint film have been significantly improved, and the VOCs exhaust gas content is far Lower than the environmental protection standard, the rate of refurbishment of the cab is at the lowest level in history, and the process goals, safety goals, environmental goals, intelligent goals, and quality goals set by the water-based paint upgrade and transformation have been achieved.
It can be seen that the water-based paint process plans have their own advantages and disadvantages.
For different water-based paint processes, companies need to analyze and demonstrate the production status, product quality, transformation cycle, input cost, operating cost and other aspects when upgrading the water-based paint process.
Only by choosing the water-based paint process plan that suits the company can the goal of upgrading and transformation be achieved.
In response to the large-volume exhaust gas generated during the automobile painting process, source control and treatment of emission reduction are required.
In recent years, OEMs have actively responded to environmental protection policies and carried out upgrading and transformation of coating water-based paint processes.
The article adopted a solvent-based coating production line in accordance with The three water-based paint process plans of B1B2, 3C2B, and 3C1B were compared and analyzed, and the effects of the implementation of the transformation were selected, and the ideas for the upgrading and transformation of the water-based paint process were explained.
Keywords: water-based topcoat; coating process; upgrading and transformation 1 background and current situation my country's automobile coating production line built before 2012, the paint materials mainly use traditional solvent-based topcoats, which are far behind in terms of environmental protection, safety, quality, etc.
In the current mainstream water-based paint process, exhaust emissions can no longer meet the "Volatile Organic Compounds Emission Control Standard" (DB61/T1061-2019).
At the same time, the equipment has long-term high-load operation, serious aging, high failure rate, and equipment operation and maintenance costs year by year.
The rise will affect the production cycle and the appearance quality of the high-end cab.
2 Necessity of transformation In terms of environmental protection, laws and regulations require the implementation of raw material substitution projects, process technology transformation projects, recycling and comprehensive treatment projects, and all enterprises are required to ensure stable and up-to-standard emissions in accordance with standard requirements.
In terms of quality, the solvent-based production line usually adopts natural wind, and the performance and quality of the paint film are restricted.
By adding constant temperature and humidity transformation to the spray booth, the process control ability is improved.
In terms of safety, the original sprinkler fire-fighting system is mainly carbon dioxide fire extinguishing, which has insufficient design and risks, and requires an open-type high-pressure water mist upgrade.
Through the upgrading and transformation of the coating water-based paint process, the production line has been improved in terms of environmental protection, safety and quality to comply with national laws and regulations and improve the market competitiveness of the company's products.
3 Water-based paint process transformation plan The paint line can be divided into traditional solvent-based paint line and water-based paint line according to the paint materials.
In recent years, the national environmental protection policy has become more and more stringent.
Laws and regulations require the implementation of raw material substitution projects, process technology transformation projects, recycling and Comprehensive treatment project, and the "Twelfth Five-Year Plan for Air Pollution in Key Areas" (Huanfa [2012] No.
130) approved by the State Council on September 27, 2012, proposes VOC pollution control as a construction project for the paint and coating industry As an important part of the environmental impact assessment, strict pollution control measures are adopted: new motor vehicle manufacturing coating projects, and low-VOC content coatings such as water-based coatings account for no less than 80% of the total coating usage.
The traditional solvent-based paint line emission standards can no longer meet the environmental protection standards, and the whole area of the spray paint must be used for the rotary adsorption concentration + RTO exhaust gas treatment process to achieve exhaust gas emission standards.
Due to the large total exhaust air volume, the equipment investment cost is high and the area is occupied.
Large area, high operation and maintenance cost.
The use of water solvents instead of organic solvents in the water-based paint process for intermediate coating, silver base, and color paints is the most effective measure to reduce VOCs emissions from the source.
After the water-based paint process is applied, the waste gas treatment volume is reduced.
The water-based paint process has been widely used at home and abroad.
.
In order to ensure that the exhaust gas emissions from painting meet the environmental protection standards for a long time, this scheme adopts the water-based paint process scheme.
The current water-based paint processes mainly include: B1B2 water-based process, 3C2B water-based process, and 3C1B water-based process.
The three transformation schemes are as follows: 3.
1 Scheme 1: Line A B1B2 water-based topcoat line, Line B water-based solid-color topcoat line B1B2 water-based topcoat process requires pre-drying of the color paint, and the current length of the original topcoat A line is insufficient , The spray booth must be extended by about 15.
5m on the original foundation (considering the relocation of the central control room), the line body shall be extended by about 6.
6m.
The construction of line A and B mainly includes: cleaning room, painting room (including air seal), leveling room (adding air curtain), hot flashing (including air seal and cooling), air conditioning, offline polishing room, robot, transportation and adjustment Paint, transportation, electric control, etc.
The A line process layout includes: cleaning, air sealing, BC1 external spray, air sealing, BC2 internal spray, BC2 external spray, paint touch-up, air sealing, hot flashing, air sealing, cooling, air sealing, varnish inner spray, varnish External spraying, paint touch-up, leveling, compared with the original hot flashing process (including air seal, cooling); B line is a water-based solid color paint spraying line, the B line process layout remains unchanged, and at the same time according to the requirements of water-based paint characteristics Public and fire fighting system.
3.
2 Scheme 2: 3C2B water-based topcoat line 3C2B water-based topcoat process requires that the topcoat must be sprayed and dried before the topcoat is sprayed, that is, the cab can enter the topcoat and spray the water-based paint on the A line before the topcoat is sprayed.
Paint, varnish.
A and B line bodies mainly include: cleaning room, painting room (including air seal), leveling room (adding air curtain), hot flashing (including air seal and cooling), air conditioning, robots, paint transfer, transportation, Electric control, etc.
, while restoring the supporting public and fire-fighting systems.
3.
3 Scheme 3: A line 3C1B water-based topcoat line, B line water-based solid-color topcoat line topcoat A line uses 3C1B water-based topcoat technology, B line water-based solid-color topcoat line.
The paint spraying room of line A of the finish paint must be extended by about 30m (the central control room and toilet must be relocated), and the line body shall be extended by about 18.
5m.
The line body mainly includes: cleaning room, painting room (including air seal), leveling room (adding air curtain), hot flashing (including air seal and cooling), air conditioning, offline polishing room, robot, paint transfer, Conveying, electric control, etc.
, and supporting public and fire-fighting systems according to the characteristics of water-based paint.
The process layout includes: cleaning, air sealing, intermediate coating, air sealing, hot flashing, air sealing, silver bottom spraying, silver bottom spraying, paint touch-up, gas sealing, hot flashing, gas sealing, cooling, gas sealing , Varnish inner spray, varnish outer spray, paint touch-up, leveling, adding intermediate coating spraying, intermediate coating hot flashing (including air sealing, cooling), silver bottom hot flashing (including air sealing, cooling) processes compared to the original.
4 Scheme comparison 4.
1 Water-based paint process scheme Table 1 Water-based paint process scheme comparison 4.
2 Water-based paint modification content (Table 2) Table 2 Water-based paint modification content comparison 4.
3 Water-based paint paint cost Table 3 Paint cost comparison of three water-based paint processes Note: Bike cost Need to consider the proportion of metallic paint and solid color paint; the statistics in the table are only the cost of topcoat paint; the cost of paint is subject to the manufacturer's quotation, and this table does not reflect the paint price.
4.
4 Comparison of the budget cost of water-based paint.
The content and cost of the water-based paint process upgrade and transformation mainly involve the cleaning room, spray room, leveling room, hot flashing, air conditioning, offline polishing room, robots, paint delivery and mixing, transportation, electronic control, and exhaust gas treatment.
, Public facilities, fire protection system, safety, environmental protection, occupational hazards "three assessments", peripheral engineering, workshop public facilities, unpredictable expenses and demolition, civil works, floor, high-pressure water guns, refined exhaust air, drying furnace restoration, Cleaning, etc.
, the investment budget for option one is RMB y million, option two is RMB 0.
87 million, and option three is RMB 102 million.
4.
5 Water-based paint cost comparison (Table 4) Table 4 Three types of water-based paint process costs and existing process comparison 5 Scheme selection Because scheme one and scheme three water-based paint process involves process layout changes, the new >
6 Conclusion Through the upgrading and transformation of the 3C2B water-based paint process, the current coating line is leading the industry in terms of environmental protection, safety, and paint film quality.
The DOI value, gloss and color difference of the cab paint film have been significantly improved, and the VOCs exhaust gas content is far Lower than the environmental protection standard, the rate of refurbishment of the cab is at the lowest level in history, and the process goals, safety goals, environmental goals, intelligent goals, and quality goals set by the water-based paint upgrade and transformation have been achieved.
It can be seen that the water-based paint process plans have their own advantages and disadvantages.
For different water-based paint processes, companies need to analyze and demonstrate the production status, product quality, transformation cycle, input cost, operating cost and other aspects when upgrading the water-based paint process.
Only by choosing the water-based paint process plan that suits the company can the goal of upgrading and transformation be achieved.
