Eco DryScrubber

Dryseparationatitsbest

2

A step closer to a green painting process

Overspray separation is now dry and

environmentally friendly

Lessenergyandresourcerequirementswithreduced

CO2emissions–thatiswhatDürr’sEcoDryScrubber

stands for. This innovative overspray separation technology

providessubstantialenergysavingsintheareathatisthe

mostenergyintenseprocessinautomotiveproduction.

Energyconsumptioninafullpaintshopcanbereduced

upto30%whileinthesprayboothalone,consumption

canbereducedupto60 %.EcoDryScrubber achieves this

throughdryremovalofoverspraypaintparticlesduring

the paint application process in connection with the re-

circulationofsprayboothprocessair.

A single standard around the globe

Re-circulationofsprayboothprocessairisthekeytoa

globallystableprocess,resultinginconstantapplication

quality.WhetherrunningtheplantinIndia–in35°C

andextremelyhighhumidity;orinRussia–inminus

20°Canddryair,temperatureandhumidityinthepaint

applicationprocessareacanbeheldconstantwithout

effort.Thesmallamountofconditionedfreshairmakes

theprocesspracticallyclimateindependent.

EcoDryScrubber saves resources, stabilizes the

painting process and at the same time lowers

investment and costs per unit.

EcoDryScrubber in the Bietigheim test center

The new EcoDryScrubber filters wet overspray with the

help of a dry filter – no water or detackifier chemicals are

required.

3

+ =Advantages – =Disadvantages

= Not required = Not relevant

Wet overspray separation versus dry overspray separation

Whencomparingthecurrentindustrystandardwet

overspray separation to the new dry overspray separation

processthefollowingkeydifferencesstandout.

The arguments listed above are part of the

reason why an independent third party institute

has confirmed that, across all key environmental

parameters, dry separation is the superior method

for overspray separation.

Wet Separation Dry Separation

Direct re-circulation of process air without additional

air conditioning +Demand for air supply houses to meet industrial

hygiene requirements – +

Reduction of particle emissions (3 mg/Nm3) – +

Further treatment of waste paint material +

Heat recovery system –Process water and water treatment equipment for

overspray separation –

Corrosion of ducts due to carryover of water –Contamination of ducts due to carryover of paint

and water –

Sludge disposal –Bacterial growth in treatment tanks and ducts

Need for additional chemicals (bacteria, odor, foams) –

Coagulation process controlled by chemicals –

Mass share

Paint solids : water / paint solids : precoat material

1 : 1 up to 1 : 2

paint solids : water

1 : 4

paint solids : precoat

Theinnovation–Dryseparation!

4

EcoDryScrubberEcoDryScrubber

EcoDryScrubber stands for attractive operating costs,

environmentallyfriendlyprocessesandautomated

painting technologies.

Comparedtothestandardwetseparationprocess,the

EcoDryScrubber does not require process water,

detackifierchemicalsorthedisposalofpaintsludge.

Combinedwiththesignificantsavingsachievedbythe

re-circulation of process air, the overall dry separation

processprovidesannualenergysavingsof16mill.kWh.

foraproductionvolumeof160.000units.Thisinturn

resultsinareductionof5.200tonsofCO2emissions.

Savings of up to:

• 80%onheatingenergy,

• 50%onelectricityand

• 80%onwaterforairconditioning

arerealizedbyusingtheDürrdryseparationprocess

comparedtoastandardwetseparationprocess

(with heat recovery unit).

Additional savings

Thenewsprayboothconcept,withfullyautomated

robots,canbebuiltwithoutfloorgratesandcombines

smallerboothdimensionswithareducedairvolume

flow.TheseelementsaloneresultinaCPUsaving

of2€.

Building

PT / EC

Oven

58 %

Layout comparison: Standard wet separation (right)

and new EcoDryScrubber layout (left)

8 %

11%

23 % Booth /Work decks

Standard:Wet separation

Air conditioning (fresh/exhaustair)

Higher energyrequirements

New:Dry separation

Significant reduction of air conditioning (only5-20%freshair

supply)

Higher energy cost savings

Energy requirements in the paint shop

Dry separation process

Environmental conservation and CPU savings

5

+ /-

7.20

+ /--

Achieved cost reductions in Euro per automobile

in a standard installation with heat recovery

6.00

0.60

0

0.60

7.20

Wet separation process

Customer benefits and savings in detail

Lower energy costs

• Directre-circulationofprocessairwithoutthe

needforadditionalfiltrationorconditioning

• Reductionofairsupplyhousingduetoreduced

airtreatment

• Noheatrecoverynecessary

• Smallersprayboothdimensionsandreduced

airvolumeflow

>>Reductionof60%ofenergycosts

Lower material costs

• Nowaterrequiredforoversprayseparation

• Nousageofdetackifiersolventsorother

coagulationchemistry

• Nodisposalofsludge

>>80%reducedwaterforairconditioning

Lower maintenance costs

• Simple,fullyautomatedsystem

• Nosprayboothgratetoclean

• Longfilterreplacementcycle(lifetimeproven

beyond3years)

>>Reductionofupto5%inrunningcosts

Lower investment costs

• Standardizedmodules

• Smallerfootprint,reducedcrosssection

• Reducedairsupplyhousingcomponents

• Smallerairductsandairsupplysystems

• Galvanizedsteelducts–noneedforstainlesssteel

>>Upto35%reductionincrosssection

Process advantages

• Carefree,reliableandhygienicairre-circulation

system

• Lowboothclimateimpactfromoutsideairconditions

(freshairresupplyofonly5-20%)

• FiltrationqualityHEPA12(nearly100%)

• Well-balancedboothconditions(constantpressure)

guaranteedbytheautomatedfilterregeneration

• Avoidanceofpaintparticleemissionscausedby

paintagglomerations

• MultipleuseandrecyclingofEcoDryLime precoatmaterial

The Dürr EcoDryScrubber provides significant

CPU savings, reduces operating costs and is

environmentally friendly.

Depending on location and complexity of the installation, up to

14 Euro per automobile can be saved with EcoDryScrubber.

Energy costs

Building costs

Labor costs

Material costs

Total CPU savings

Environmentalefficiency

6

Key elements and processes

The EcoDryScrubber concept consists of the following

components:

• Direct re-circulation of process air

EcoDryScrubber functions with a direct air circulation

systemwhichonlyneeds5to20% fresh air supply,

leadingtosignificantenergysavings.Viathespray

boothairflow,wetoversprayparticlesaccumulatein

themodularfiltermodulesstickingtoeachindividual

filterelement.Theoversprayseparationprocess

takesplaceonthesurfaceofthefiltermembrane.

Theairisthenfedbackintothecirculationprocess.

• Dry separation of wet overspray

AtthebeginningofafiltrationcyclefreshEcoDryLime

precoatmaterialisintroducedintothehopper.Air

nozzlesmovethedrymaterialintotheairallowingitto

jointheairflowcomingfromthecabin.EcoDryLime

passesthroughthefiltermodulesincircularchannels

andensurescirculationacrossallfilterelements.

Precoatparticlesintheairsticktothefiltersurfaceand

moduleasaclosed,thinprotectionlayer.Thisprevents

directcontactofthestickywetoversprayparticles

withthefiltersurfaceandinsidethefiltermodule.

• RegenerativefilterelementsEcoDryTac

Theprocess-optimized,automaticallyregenerated

filter,coveredbyamembranelayer,providesparticle

filtrationofbelow0.1mg/m3.Thiscloseto100%

filtrationprocesspermitsdirectre-circulationwithout

therequirementofadditionalfilterlevels.Thisfiltration

processtakesplaceonthesurfaceofthefilter

element,allowingdirectre-circulationoftheclean

air in the circulation process, as no precoat or paint

particlesgetthroughthefiltermembrane.

• Fully automated cleaning process

Duringpaintapplication,separationofthepaint

particlestakesplaceontheEcoDryTacfiltervia

theaircirculation.Thepaintparticlesaccumulateof

theprecoatmaterialandbuild-upafiltercake.This

resultsinanincreaseinairresistanceoverthefilter.

Onceamaximumdecreaseindifferentialpressure

occurs,automaticcleaningofthefiltercakeis

triggered.Ajetofcompressedairfromthecleangas

sideofthefilterelementispulsedforapproximately

0.25secondswhichcausesthefiltercaketobe

releasedfromthefilter.Cleaningofthefiltermodule

istimelyoffsetandtakesplaceapproximatelyevery

25minutes.Themixtureofprecoatandpaintmaterial

fallstothebottomofthehopperandstaysthere

untilacertainsaturationpointisreached.Once

thissaturationpointhasbeenreachedtheused

precoatmaterialisremovedandreplacedbynew

material.Cleaningdoesnotaffectboothbalance.

EcoDryScrubber – an environmentally friendly

process, which saves energy.

Filter element with compressed air back-flushing device

7

Global supply and recycling of precoat material

Dürroffersa‘worryfree’packagefortheentirematerial

cycle–fromsupplyrightthroughtorecyclingofthe

precoatmaterial.

The EcoDryLime precoatmaterialusedisanaturallime-

stonematerial.Dürrhasoutlineddetailedspecifications

for EcoDryLimewhichistailoredtoautomatedproduction

systems.Togetherwithaglobalpartner,astate-of-the-art

qualitytrackingsystemhasbeenset-uptoensureoptimal

processesandmaximumsavings.

The EcoDryLimecanbedeliveredinlargebagsorsilos,

dependingonyourneeds.Thecostsforthismaterialare

alreadyestablishedwithaglobalsupplier,tomaintain

savingsforyourbenefit.Thisensuresthatthereisalways

asupplyavailable,nomatterwhereintheworldyour

facility is located.

Recycling of used material

Thestandardprocessofremovingpaintsludgefromwet

separationisuptofourtimesmoreexpensivethanthe

removalofusedprecoatmaterialfromdryseparation.

Thiswastematerialcanbereusedinotherproduction

processes,suchasthecementindustryorfluegas

desulfurization,withoutrequiringfurthertreatment.This

isbeneficialtoyourbalancesheetandtotheenviron-

ment.

Dry agglomeration of overspray and EcoDryLime

The future separation process

Your benefits

The new EcoDryScrubber provides highest levels of energy

savings, cost effectiveness and resource conservation.

• Dryfiltrationofwetoverspraywithautomatically

regenerated Eco DryTacfilters

• Upto60%energycostsavings

• ReuseandrecyclingofEco DryLime precoatmaterial

• Morethan90%reductioninparticulateemissions

• Compactlayoutandupto35%reducedcrosssection

www.durr.com

Eco DryScrubber

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©D

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2009