Eco DryScrubber

Dry separation at its best

A step closer to a green painting process

Overspray separation is now dry and environmentally friendly Less energy and resource requirements with reduced CO2 emissions that is what Drrs EcoDryScrubber stands for. This innovative overspray separation technology provides substantial energy savings in the area that is the most energy intense process in automotive production. Energy consumption in a full paint shop can be reduced up to 30 % while in the spray booth alone, consumption can be reduced up to 60 %. EcoDryScrubber achieves this through dry removal of overspray paint particles during the paint application process in connection with the recirculation of spray booth process air. EcoDryScrubber in the Bietigheim test center A single standard around the globe Re-circulation of spray booth process air is the key to a globally stable process, resulting in constant application quality. Whether running the plant in India in 35C and extremely high humidity; or in Russia in minus 20C and dry air, temperature and humidity in the paint application process area can be held constant without effort. The small amount of conditioned fresh air makes the process practically climate independent. EcoDryScrubber saves resources, stabilizes the painting process and at the same time lowers investment and costs per unit.

The new EcoDryScrubber filters wet overspray with the help of a dry filter no water or detackifier chemicals are required.

Wet overspray separation versus dry overspray separation

When comparing the current industry standard wet overspray separation to the new dry overspray separation process the following key differences standout. Wet 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 Dry Separation

+ + + +
1 : 1 up to 1 :2 paint solids:water 1 :4 paint solids:precoat

+ = Advantages
= Not required

= Disadvantages
= Not relevant 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.

The innovation Dry separation!

Environmental conservation and CPU savings

Building PT / EC 11% 58% Oven 23% Booth / Work decks 8% Combined with the significant savings achieved by the re-circulation of process air, the overall dry separation process provides annual energy savings of 16 mill. kWh. for a production volume of 160.000 units. This in turn results in a reduction of 5.200 tons of CO2 emissions. Savings of up to: 80 % on heating energy, 50 % on electricity and 80 % on water for air conditioning Energy requirements in the paint shop Standard: Wet separation New: Dry separation are realized by using the Drr dry separation process compared to a standard wet separation process (with heat recovery unit). Additional savings Significant reduction of air conditioning (only 5-20% fresh air supply) The new spray booth concept, with fully automated robots, can be built without floor grates and combines smaller booth dimensions with a reduced air volume flow. These elements alone result in a CPU saving of 2 . Higher energy requirements Higher energy cost savings

Air conditioning (fresh / exhaust air)

Eco DryScrubber Eco DryScrubber

EcoDryScrubber stands for attractive operating costs, environmentally friendly processes and automated painting technologies. Compared to the standard wet separation process, the EcoDryScrubber does not require process water, detackifier chemicals or the disposal of paint sludge. Dry separation process Layout comparison: Standard wet separation (right) and new EcoDryScrubber layout (left)

Customer benefits and savings in detail

Lower energy costs Direct re-circulation of process air without the need for additional filtration or conditioning Reduction of air supply housing due to reduced air treatment No heat recovery necessary Smaller spray booth dimensions and reduced air volume flow >> Reduction of 60 % of energy costs Lower material costs No water required for overspray separation No usage of detackifier solvents or other coagulation chemistry No disposal of sludge >> 80 % reduced water for air conditioning Lower maintenance costs Simple, fully automated system No spray booth grate to clean Long filter replacement cycle (lifetime proven beyond 3 years) >> Reduction of up to 5 % in running costs Lower investment costs Standardized modules Smaller footprint, reduced cross section Reduced air supply housing components Smaller air ducts and air supply systems Galvanized steel ducts no need for stainless steel >> Up to 35 % reduction in cross section The Drr EcoDryScrubber provides significant Wet separation process CPU savings, reduces operating costs and is environmentally friendly. Process advantages Carefree, reliable and hygienic air re-circulation system (fresh air resupply of only 5-20 %) Low booth climate impact from outside air conditions Filtration quality HEPA 12 (nearly 100 %) Well-balanced booth conditions (constant pressure) guaranteed by the automated filter regeneration paint agglomerations precoat material Avoidance of paint particle emissions caused by Multiple use and recycling of EcoDryLime Depending on location and complexity of the installation, up to 14 Euro per automobile can be saved with EcoDryScrubber. Building costs Labor costs Material costs Total CPU savings 0.60 Energy costs 6.00 Achieved cost reductions in Euro per automobile in a standard installation with heat recovery

+ /-0
0.60 7.20 7.20

Environmental efficiency

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 system which only needs 5 to 20 % fresh air supply, leading to significant energy savings. Via the spray booth airflow, wet overspray particles accumulate in the modular filter modules sticking to each individual filter element. The overspray separation process takes place on the surface of the filter membrane. The air is then fed back into the circulation process. Dry separation of wet overspray At the beginning of a filtration cycle fresh EcoDryLime precoat material is introduced into the hopper. Air nozzles move the dry material into the air allowing it to join the air flow coming from the cabin. EcoDryLime passes through the filter modules in circular channels and ensures circulation across all filter elements. Precoat particles in the air stick to the filter surface and module as a closed, thin protection layer. This prevents direct contact of the sticky wet overspray particles with the filter surface and inside the filter module. Regenerative filter elements EcoDryTac The process-optimized, automatically regenerated filter, covered by a membrane layer, provides particle % filtration of below 0.1 mg/m3. This close to 100 filtration process permits direct re-circulation without the requirement of additional filter levels. This filtration process takes place on the surface of the filter element, allowing direct re-circulation of the clean air in the circulation process, as no precoat or paint particles get through the filter membrane.

Fully automated cleaning process During paint application, separation of the paint particles takes place on the EcoDryTac filter via the air circulation. The paint particles accumulate of the precoat material and build-up a filter cake. This results in an increase in air resistance over the filter. Once a maximum decrease in differential pressure occurs, automatic cleaning of the filter cake is triggered. A jet of compressed air from the clean gas side of the filter element is pulsed for approximately 0.25 seconds which causes the filter cake to be released from the filter. Cleaning of the filter module is timely offset and takes place approximately every 25 minutes. The mixture of precoat and paint material falls to the bottom of the hopper and stays there until a certain saturation point is reached. Once this saturation point has been reached the used precoat material is removed and replaced by new material. Cleaning does not affect booth balance. EcoDryScrubber an environmentally friendly process, which saves energy.

Filter element with compressed air back-flushing device

Global supply and recycling of precoat material

Drr offers a worry free package for the entire material cycle from supply right through to recycling of the precoat material. The EcoDryLime precoat material used is a natural limestone material. Drr has outlined detailed specifications for EcoDryLime which is tailored to automated production systems. Together with a global partner, a state-of-the-art quality tracking system has been set-up to ensure optimal processes and maximum savings. The EcoDryLime can be delivered in large bags or silos, depending on your needs. The costs for this material are already established with a global supplier, to maintain savings for your benefit. This ensures that there is always a supply available, no matter where in the world your facility is located. Dry agglomeration of overspray and EcoDryLime

Recycling of used material The standard process of removing paint sludge from wet separation is up to four times more expensive than the removal of used precoat material from dry separation. This waste material can be reused in other production processes, such as the cement industry or flue gas desulfurization, without requiring further treatment. This is beneficial to your balance sheet and to the environment.

The future separation process

Your benefits The new EcoDryScrubber provides highest levels of energy savings, cost effectiveness and resource conservation. Dry filtration of wet overspray with automatically regenerated Eco DryTac filters

Up to 60 % energy cost savings Reuse and recycling of Eco DryLime precoat material More than 90 % reduction in particulate emissions Compact layout and up to 35 % reduced cross section

www.durr.com

We reserve the right to make modifications! All outlined values and savings are based on standard layouts and our experience and do not constitute contractual obligations of any kind. Actual values and savings are dependent on project specific layouts, technical specifications and other related determining factors and have to be individually established. Drr 2009

Eco DryScrubber