In the automotive sector, products are generally painted by spraying in water curtain or venturi-type processes, either manually or automatically. In these water curtain or venturi-type processes, the overspray portion of the paint that does not adhere to the product surface must be rapidly removed from the environment.
The HydroFloty system, which HydroTur designed together with its Italian partner Hydroİtalia, aims to decompose and separate the paint mixed with water in these systems. The adhesive properties and characteristics of the paint particles in the system water are lost through coagulant/decomposing agents dosed into the system water.
Subsequently, floating chemicals are added to bring the paint to the surface, and then the decomposed paint is skimmed from the system and removed. This ensures that the total suspended solids (TSS) ratio in the system water is maintained at approximately 2-3%.
The system is generally designed for the treatment of industrial waste from manufacturing. However, not all types of waste can be treated in this system. The definition of wastewater that can be treated is given below:
• Wastewater from spray booths,
• Wastewater from solvent-based paints,
• Wastewater from water-based paints.
Wastewater from processes:
• Screen printing,
• Paint shop,
• Vehicle washing,
• Mechanical workshop,
• Glass grinding,
• Cement process.
Wastewater containing oils:
• Animal oils,
• Vegetable oils,
• Mineral oils.Floty systems must be designed specifically for each process. System equipment and chemicals are selected based on details such as tank size, type and quantity of paint used, overspray ratio, how the painting operation is performed, or the point where water enters the tanks.
Figure 1. Floty system general flow diagram, (Static Mixer (1), Inlet Valve (2), Skimmer (3), Mako Tank (4), Coagulant Tank (5), Flocculant Tank (6), Sludge Pump (7), Filtrate Water Pump (8), Basin (9), Feed Pump (10), Mixer (11))
A – Flotation unit main body
The main component of the flotation system where contaminated water enters and treated water leaves the system.
B – Chemical preparation tank (optional)
The section where the chemical used in the treatment unit is prepared and stored. The prepared chemical is supplied to the static mixer via a dosing pump.
C – Static Mixer
The chemical dosed into the water to be treated is dosed at the static mixer location to provide uniform mixing and increase treatment efficiency.
D – MACO Tank
The tank where sludge skimmed with the help of a skimmer at the end of the sludge flotation process is collected.
E – Electrical Panel
The center where the main electrical and pneumatic connections of the system are located and where all equipment on the system is controlled. If air is required for the conveyor filter, this air is supplied externally and not from the pneumatic panel.
F – Conveyor Filter unit
The equipment where sludge is collected, sent to the maco tank, and the sludge is subjected to a preliminary filtration process. System Operation Technical Data Dimensions and Space Requirements
Pumps with sufficient discharge head should be selected based on the distance and elevation difference between the basin and the Floty. The capacity Q (m³/h, m³/s, l/s, l/h) of a centrifugal pump is the useful volume of liquid sent to the pump discharge in a given time period. The capacity of a centrifugal pump is independent of the density of the pumped liquid.
The viscosity of the pumped liquid affects the capacity of the centrifugal pump. When viscosity increases, capacity decreases; when viscosity decreases, capacity increases. The water taken from the basin and sent to the floty body is taken from the surface to contain more decomposed paint. For this purpose, a specially designed flotation suction head is used.
Advantages Provided by Hydrofloty Systems:
The paint skimming units we have introduced to the market under the Hydrofloty brand offer the following advantages:
• With the reduction in the frequency of paint booth cleaning, the labour hours spent on cleaning decrease and paint booth cleaning costs are reduced.
• Maintenance costs in the paint shop and production losses due to cleaning are reduced.
• With PLC control, there is little need for operator support.
• The amount of paint escaping to the fans decreases, thereby reducing the energy consumption of the fans.
• The quantities of water used and discharged in the paint shop are reduced.
• Paint quality on parts is indirectly improved.
Filiz Giray
Project Engineer – Environmental Engineer
HydroTur Arıtma Sistemleri
