CHEMICAL AND MECHANICAL ALTERNATIVES FOR HANDLING HIGH SOLIDS PAINT SLUDGES

J.E. Kruzynski BetzDearborn possible to simply change booth water pH as was often the case with the lower-solids lacquer paints. Specialized chemical treatment programs have been developed to control the many problems associated with the new compliance coatings. A wide variety of products are now available including clay-, polymer-, and surfactant-based that effectively detackify and condition the paint sludge for further handling and disposal. Several chemical and mechanical treatment strategies that are being used for effective high solids paint sludge handling in automotive plants are described in this paper. Both chemical and mechanical (equipment) approaches are typically required to successfully prepare high solids paint sludges for transport and ultimate disposal.

ABSTRACT
The use of high solids enamels, base/clear coat and other compliance coatings has now become the norm in the automotive and other industries. Along with this change, however, have come major concerns over how to treat, handle and dispose of the paint sludge generated in the spray booth operation. These concerns stem from pressures caused by increasing environmental regulations and disposal costs. Several alternatives to paint sludge handling will be presented. These will include chemical and mechanical ways to detackify, transport and dewater paint sludge based on actual experiences within the automotive industry. A variety of sludge dewatering equipment options will be presented.

STAGES IN THE SLUDGE HANDLING PROCESS

A paint spray booth is an enclosed system that is designed to confine the painting operation. This assures a quality finish, provides an illuminated, safe working environment, and allows paint overspray to be removed from the air before its discharge to the environment. Most automotive paint spray booths are recirculating water systems. The function of the water is to scrub the overspray from the air, trap it, and transport it to a holding tank where the sludge (paint solids) is separated from the water. These systems are normally treated with a variety of chemicals to detackify and condition the paint sludge. Proper selection and application of chemicals requires a thorough understanding of the type and quantity of overspray, as well as system design the equipment available to transport the sludge from the spray booth to the pit area, and the mechanics of how the sludge is dewatered. For example, a basecoat/clearcoat system may require the detackified paint sludge to float before being skimmed and pumped to a filter operation for dewatering. In this case, a clay-based detackifier and cationic polymer(s) program would most likely produce the well-killed, floating, pumpable sludge required. Other programs, such as polymer-based detackifiers, may not be acceptable because they may not produce a pumpable sludge, even though other system requirements may be met. Paint overspray/sludge treatment typically includes the folIowing stages: detackification solids separation 1

INTRODUCTION
Finishing operations in the automotive industry have dramatically changed since the EPA imposed more stringent VOC standards in the late 1970s. Changes include the installation of various process equipment (e.g., carbon adsorption units or incinerators), the increased use of state-of-the-art spray application technology (electrostatics, robotics and bells), and the conversion from low to higher solids and other compliance coating formulations. While these changes helped plants comply with the new regulations and improved the appearance and durability of many paint finishes, other difficulties surfaced with the introduction of the new paints and application technologies. When the overspray from the new paints entered the scrubbing water systems beneath the spray booth work areas, it soon became obvious that yesterday's standard treatment practices were no longer adequate. The consequences of these high solids enamels and base coat/clear coat paint sludges in the spray booth system were excessive maintenance to remove the uncured paint from grates, walls and paint lines; increased potential for excessive stack emissions; greater potential of foaming in the scrubbing water systems; increased paint sludge volumes; and higher disposal costs. The need for improved paint detackifier technology became evident with the change to higher solids, compliance coatings. No longer was it

 sludge thickening sludge dewatering transport and disposal Some of these stages, for example sludge thickening, may not occur as a separate step in the process but may be accomplished with the dewatering stage. Other stages, such as proper detackification, are essential for subsequent stages to occur.

Transport and Disposal

The transport and disposal stage provides the means of removing sludge from the plan site and safely storing or destroying it. The most common methods are trucking and landfilling, but other methods of disposal (e.g., incineration, use as boiler fuel, etc.) are being pursued as environmental regulatory restrictions on disposal increase.

Detackification
The objective of the detackification stage is to kill the paint overspray, reduce its tacky nature, and transform it into a manageable form that matches system design and is easily processed. To be successful, this stage requires proper chemical treatment and good paint/air/water contact - that is, maximum scrubbing efficiencies.

THE SYSTEM GOAL - MAXIMIZING SOLIDS REMOVAL

The overall objective is to remove as many solids from the system as are entering. The process of monitoring and controlling "solids in" versus "solids out" is referred to as mass balancing and is depicted in Figure 1. "Solids in" includes paint plus detackifier solids (from both clay and polymer treatments). "Solids out" consists of the paint sludge removed from the pit and/or leaving the plant from the doctrine process. It also includes particulate stack emissions and deposits in supply header, back motion, booth pan, and exhaust plenum areas that are costly to remove. The desired result is to remove as many "solids out" as possible through the plant's dewatering process, or at least move the sludge to an area in the system where it can be easily removed during a shutdown. An automotive assembly plant can generate up to 20 yd3 of sludge per day from the spray booth operation. Quantities and characteristics of sludge generation from a plant producing 50 units per hour are shown in Figures 2 and 3. With a nonhazardous clas-

Solids Separation
The solids separation stage involves the removal of paint solids from the bulk recirculating water by either floating or sinking. This occurs most successfully in low turbulence areas and is often a necessary step to minimize foaming in the system and maximize scrubbing efficiency. Separation can be assisted by the use of chemicals. Generally, the application of cationic polymers is the treatment of choice for controlIing the degree and duration of flotation and/or sinking. Many systems require the paint sludge to remain in a dispensed state in the bulk water until the solids separation area is reached.

Sludge Thickening and Dewatering

The purpose of the sludge thickening and dewatering stages is to decrease the moisture (water) content of the sIudge to a minimum value. The desired effect is to reduce the total sludge volume and minimize sIudge hauling and disposal costs. Government regulations, such as the EPA paint filter test, must be met before sludges are acceptable for landfilling. Many types of thickening/dewatering processes can be optimized by using chemical additives, such as anionic, cationic, and/or nonionic polymers. Sludges conditioned with polymers have a rigid structure with a porosity that enhances free-water drainage for maximum dewatering efficiency. In one example, a recirculating water with 0.1 to 0.2% total suspended solids (i.e., 1000 to 2000 ppm TSS) increased to 2% solids in the solids separation stage as a result of treatment with cationic polymers. This was followed by thickening (where solids were increased to 18%) and dewatering (solids increased to 32%) stages prior to transport and disposal. 2 Solids In (100%) Solids Out (100%)

Solids In (100%)

Solids Loss* (15%)

Solids Out (85%)

Solids In (100%)

Solids Loss* (65%)

Solids Out (35%)

Figure 1: Mass balancing. *Solids losses can result from particulate stack emissions, ambient losses, and deposits in fan/stack areas, water supply headers, pumps, scrubbing sections, and sump.

SYSTEM PARAMETERS

production: 50 units/hr; 12 hr/day paint: 55% average solids basecoat/clearcoat; 9.2 lb/gal density; 0.8 gal/unit overspray detackifier program: liquid containing 20% solids, fed at 20%, based on overspray
SOLIDS GENERATION EQUATIONS

EQ. 1:

lb/day overspray paint solids

lb/day detackifier solids

lb/day total solids generated

EQ. 2:

lb/day X Factor* % solids in dewatered cake

yd3/day = to disposal

* Factor to convert dry (wet) solids from pounds to cubic yards is 4.14 X 10-4 (5.52 X 10-4) Assumes a 12.0 lb/gal dry (9.0 lb/gal wet) sludge density.

Example:

EQ. 1: [50 X 12 X 0.8 X 9.2 X 0.55] + [50 X 12 X 0.8 X 9.2 X 0.20 X 0.20]
= 2600 lb/day total solids generated

EQ. 2:

2600 X (4.14 X 10-4) 1.00

1.1 yd3/day dry solids

Figure 2: Spray booth solids generation calculations.

sification and no pretreatment (fixation) at the disposal site, transportation and landfill disposal costs for the sludge in this example averaged $12.25/yd3. Costs for disposal as a hazardous waste were estimated at $145.00/yd3 for this sludge because of increases in distance to and disposal in a certified hazardous waste landfill. With the quantity of sludge being generated and the disposal costs increasing, proper sludge handling and dewatering becomes critical to minimizing plant operating costs.

STRATEGIES FOR SYSTEM OPERATIONS

In the automotive industry, a variety of sludge handling system designs are found. Two common ways for operating spray booth water system and sludge handling operations are shown in Figures 4 and 5.

In the first operating method (Figure 4), paint solids are not removed from the system but are typically
3

allowed to accumulate in the pit to await cleanout. These systems contain up to 1,000,000 gal of recirculating water and are normally cleaned on an annual basis. The total suspended solids (TSS) can continue to increase in the recirculating water unless the system is chemically treated to separate the solids by flotation or settling, and there is a quiescent area in the spray booth sludge system that allows these treated paint solids to separate. Water velocities less than 10 ft/sec appear to be most effective in allowing separation of solids. Having detackified paint solids is the first step in minimizing problems with this type of operation. However, if even completely detackified-paint solids are not separated from the bulk water, the increase in total suspended solids can result in more foaming. This in turn can lead to reduced scrubber efficiency, increased stack carryout, and difficulties in maintaining booth balance. The proper selection of chemical treatment program coupled with sound system design allow efficient operation of these systems between shutdown and cleanout cycles.

16
14.4

14 12 10 yd
3

yd3/day generated at various % solids in dewatered cake*

Spray Booth

8 6
4.8

Makeup Sump Sludge

4
2.9

NC Strainer
1.1

2 0 10 20 30 40 50 60 70 80 90 100 % Solids

Waste Treatment Filter

Sludge

Figure 3: Solids to dispose as a function of dewatered cake percent solids. *For example, 30% solids: 2600 X (5.52 X 10-4)/0.30 = 4.8 yd3/day.

Figure 5: Continuous water recycle with continuous or intermittent (batch) sludge removal and periodic system shutdown for water and sludge removal.

Spray Booth

Sludge

Sump

The second type of operating method (Figure 5) requires the same initial stages as the first type detackification and separation of paint solids from the bulk recirculating water by flotation or sinking. In this case, however, the solids loading is controlled (e.g., at 250 ppm TSS) by removing paint sludge solids from the system on either a continuous or intermittent basis. This can be accomplished by a sidestream flow of 10 gpm up to 100% of the total flow. For example, the entire basin can be used as a flotation cell for solid separation. The removal step can be combined with thickening and dewatering of the paint sludge in preparation for disposal. Removal and dewatering efficiencies of these solids are dependent on the quantity and type of sludge generated, as weII as the type and operational mode of dewatering equipment on site.
Makeup

NC

Waste Treatment

Figure 4: Continuous water recycle with periodic system shutdown for water and sludge removal.

The fate of the waste stream also plays a role in how this sludge is treated. The sidesteam flow of paint sludge can be separated from other plant wastes by equipment at the pit area, such as flatbed vacuum filters. Alternatively, the flow can be sent to the waste treatment plant where the sludge can be mixed with other plant wastes before being dewatered. Both methods are designed to achieve the same result controlling solids by removing them between system drainage and cleanout cycles.

Physical and Mechanical Considerations

Plant personnel charged with paint spray booth operations should evaluate several factors when considering the need for additional dewatering equipment. These factors include: Quantity and characteristics of sludge to be handled Degree of dewatering required Type of on-site equipment Capital and operating budgets Manpower limitations Space requirements Local/State/Federal regulatory requirements Distance to disposal site Waste treatment plant capacities During a pit-cleanout operation, systems are typically drained, and the cleanest water is sent to an on-site or public waste treatment plant for processing, treatment, and discharge. The quantity and consistency of the remaining sludge/water mix, dependent on how effectively the system has been chemically treated, dictates the selection of the best removal method and the amount of dewatering necessary for disposal. Pick and shovel, front end loader, vacuuming, or pumping operations are the most common cleaning methods for spray booth sludge pits. Although higher in percent solids content, unkilled or partially-killed paint sIudge can be difficult to handle. Well-killed, easily-moved sludge that can be handled by vacuuming or pumping also generally lend themselves well to subsequent dewatering by one of the methods to be described. Some of the common physical and mechanical ways to handle paint solids include: Shovel/pitchfork/rake Bottom drag devices/sludge rakes Paddle/blade skimmers Gravity/vacuum flatbed filters Centrifuge separators Belt filter/plate and frame presses Sludge dryers These methods and devices can be used separately or in combination to achieve the required degree of sludge removal, thickening, and dewatering.

The simpler mechanics method, such as skimming or bottom dragging, generally produces sludges containing 2 to 5% solids, which require further thickening and dewatering before disposal. With polymer treatment, mechanical skimmers can achieve thickened sludge containing up to 20% solids. Other methods designed to separate, thicken and dewater - including gravity and vacuum filters, belt filters, plate and frame presses, and centrifuges - can produce sludges with solids content in excess of 50%. Figure 6 illustrates several examples of thickening and dewatering processes. Table I compares the sludge solids content for the various methods with well-killed high solids paint sludges. Operating parameters for several cases are shown in Table II. These examples illustrate that sludges generated from high solids paints can be effectively dewatered by several readily available methods.

SUMMARY
When the automotive industry was making the transition from low to higher solids and other compliance coatings, attention was justifiably focused on fine product finish and the introduction of the new paints and application technologies. Few questions were raised on the effects of these new paint formulations on maintenance, sludge handling, and overall operating costs. With the increased use of these new compliance coatings, many of the "hidden" consequences on spray booth operations surfaced - greater deposition and corrosion in booth internals, more frequent maintenance, increased booth balance and stack emission problems, and more difficult sIudge handling. Solving these problems typically requires the integration of mechanical and chemical approaches following a careful evaluation of system operations and design, as well as a thorough understanding of the chemical treatment and equipment options available. Developing and implementing an operating strategy based on both chemical and mechanical considerations has proven to be the most effective plan for achieving the most efficient, reliable, and cost-effective paint spray booth system operation.
Table 1: Sludge Solids Content For Various Dewatering Methods.

Dewatering Method Gravity filtration Solid bowl centrifuge Belt filter press Filter (plate and frame) Vacuum flatbed filter Continuous operation Batch operation 5

Cake % Solids 10-20 37-42 40-45 42-55 15-30 25-45

Treatment Zone

Influent Clarified Zone Clean Effluent

Figure 6: Examples of equipment used in thickening and dewatering processes. Top: concentrator flotation unit (thickening). Bottom: plate and frame press used for dewatering (left) and resulting sludge cake (right).

Table 2: Operating Parameters for Various Dewatering Methods.

Parameters Paint sludge

Solid Bowl Centrifuge High solids enamel

Belt Filter Press General plant waste containing 25%/vol. high solids basecoat/ clearcoat Clay/polymer Cationic polymer fed at 3 to 6 lb/ton dry solids Belt speed 20 to 30 fpm

Plate and Frame Filter Press General plant waste containing 50%/vol. high solids basecoat/ clearcoat Clay/polymer None

Vacuum Flatbed Filter* High solids enamel

Detackifier program Dewatering program Operating Data

Clay/polymer Anionic polymer fed at 6 to 8 lb/ton dry solids Bowl speed, 5000 rpm; Conveyor speed, 4990 rpm; Centrifugal force, 2139g

Clay/polymer Cationic polymer fed at 3 to 5 lb/ton dry solids Filter area, ~75 ft2 filter media, 0.6 to 0.8 oz/yd3 P, 2 in. Hg; air flow, 4300 cfm, air temp. 120F, batch time, 1 to 2 hr. 8 to 12% 10 gpm/ft2 1 to 3 in. 25 to 45% (15 to 25% for continuous operation) Passed

Number of plates, 69; net filter volume, 100 ft3 max pressure, 100 psig press time, 6 hr; (precoat/body feed of lime, DE, or clay detackifier slurry) 10 to 15% 1 1/2 in. 42 to 55%

Influent slurry solids Influent flow rate Cake thickness Discharged cake solids

8 to 10% 3.5 gpm 37 to 42%

11% 25 1/8 to 3/8 in. 40 to 45%

EPA paint filter test

Passed

Passed

Passed

* Modifications include (1) batch operation and (2) heating ducts in beach area to dry sludge.

BIBLIOGRAPHY
1. Way, Charles T., et al. (task force on sludge dewatering) "Sludge Dewatering". Manual of Practice, no. 20, Water Pollution Control Federation, Washington, D.C. 1983. 2. "BetzDearborn Handbook of Industrial Water Conditioning", 8th edition, BetzDearborn, Trevose, PA 1980. 3. Weber, Walter J. Jr., "Physiochemical Processes for Water Quality Control", Wiley, New York, 1972.

4. Kruzynski, J. E., Wittenbrook, L. S. "Chemical Treatment Considerations for Water Wash Paint Spray Booths", Finishing '85, Society of Manfacturing Engineers, Dearborn, Ml, 1985. 5. Kruzynski, J. E. "Optimizing Spray Booth Operations Requires Customized Maintenance Programs", Metal Finishing, vol. 85 (no. 3), in press (1987).