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PAINTS INDUSTRY
Raw Materials & Unit Operations & Equipment &
Manufacturing & Quality Tests
Examiner Committee
Prof. Mostafa Hamdy Azab Assc.Prof. Soad Awad
Professor of chemical enginnering Assc.Professor of organic chemistry
Higher Technological Institute – 10Th of Ramadan City Higher Technological Institute – 10Th of Ramadan City
August 2019
Abstract
i
Acknowledgement
The first one who deserve my thanking is Allah for his reconcile
and attention for me, I can’t achieve thanking for all his great
graces.
I’m entirely grateful to ISIPAC team who give me from there
wide knowledge and their time.
deep gratitude must go to my parents who supported me in my
life and give me the useful advices which make pass through
life tests, also I specially thank my grandfather and my
grandmother for their support.
ii
Dedication
iii
Contents
Abstract………………………………………………………………………….i
Acknowledgement……………………………………………………………...ii
Dedication……………………………………………………………………..iii
Contents………………………………………………………………………..iv
List of Figures………………………………………………………………..viii
List of Tables…………………………………………………………………..ix
List of Abbreviations…………………………………………………………...x
1.3.5: Primers……………..………………………………………2
1.3.6: Varnish……………..………………………………………2
2.1: Introduction…………………………………………………………3
2.2: Resin………………………………………………………………...3
2.2.3: Acrylics…………………………………………………….5
2.2.5: Alkyds……………………………………………………...6
2.3: Solvents……………………………………………………………..7
2.4: Filler……………………………………………………………….10
2.6: Additives…………………………………………………………..11
3.1: Introduction………………………………………………………..12
v
Chapter Four: Paints Products Manufacturing………………………………..18
4.1: Introduction………………………………………………………..18
4.5: Primer……………………………………………………………...21
4.7: Lake………………………………………………………………..21
4.7: varnish……………………………………………………………..23
4.8: Thinners……………………………………………………………24
5.1: Introduction………………………………………………………..25
vi
5.4.7: Adhesion force……………………………………………30
References……………………………………………………………………...33
vii
List of Figures
Chapter Two
Figure (2.1): Classification of solvents according to principle of working……….8
Figure (2.2): classification of solvents according to chemical structure………….9
Chapter Three
Figure (3.1): A mixing unit……………………………………………………..13
Figure (3.2): Representative impellers for fluid mixing in mechanically agitated
vessels…………………………………………………………………………..14
Figure (3.3): Vessel flow patterns………………………………………………15
Figure (3.4): Rotary mill………………………………………………………..16
Figure (3.5): Horizontal ball mill……………………………………………….17
Figure (3.6): Basket-ball mill…………………………………………………...17
Figure (3.7): Screen filter ………………………………………………………18
Chapter Four
Figure (4.1): Paints manufacturing flow sheet………………………………….19
Chapter Five
Figure (5.1): cup used in measuring density……………………………………26
Figure (5.2): Measuring viscosity by using cup 4 device………………………..27
Figure (5.3): Measuring viscosity with visco-meter…………………………….27
Figure (5.4): Measuring fineness with hegman device………………………….28
Figure (5.5): different shapes of pulling tools…………………………………..29
Figure (5.6): Pulled film………………………………………………………...29
Figure (5.7): measuring of hiding power by opacity meter …………………….29
Figure (5.8): Measuring of gloss degree using gloss meter …………………….30
Figure (5.9): Wash-ability testing device……………………………………….31
Figure (5.10): Measuring impact resistance from a hight 60 cm………………...31
viii
List of Tables
Chapter Two
Table (2.1): Alkyds lengths and its properties…………….….………7
Table (2.2): Color and its pigments………………..………...………10
Table (2.3): Paints Additives………………………………………...11
Chapter Four
Table (4.1): epoxy-base components………………………………..19
Table (4.2): epoxy-hardener components……………………………19
Table (4.3): Aluminum paint components…………………..............20
Table (4.4): Aluminum pastel contents……………………………...21
Table (4.5): Primer components…………………………………......21
Table (4.7): Polyurethane-base components………………………...23
Table (4.8): Polyurethane-hardener components……………………23
Table (4.9): Varnish components……...………………………….....23
Table (4.10): Paints and its thinners……………………………..…..24
ix
List of Abbreviations
x
Chapter One
Introduction
1.1: Student mission for training activity
The training mission is linking theory with application which improve
several chemical engineering fields which is paints by knowing its production’s
processes and industrial units, also knowing its several applications which give
some experience for working in this field after graduating.
1.2: Historical background
The surface-coating industry is indeed an ancient one, the origin of paints
dates back to prehistoric times when the inhabitants of the earth recorded some of
their activities in colors on the walls of their caves. These crude paints consisted
probably of colored earths or clays suspended in water. The Egyptians, starting
very early, developed the art of painting and by 1500 B.C. had a wide number and
variety of colors.
Around 1000 D.C. they discovered the forerunner of our present-day varnishes,
using naturally occurring resins or beeswax for their film forming ingredient.
Pliny outlined the manufacture of white lead from lead and vinegar, and it is
probable that this ancient procedure resembles the old Dutch process. It is in more
recent years, however, that the surface-coating industry has made its greatest
strides owing to the results of scientific research and application of modern
engineering, [1].
1.3: Paints products
Paints has a several products, each of it has a purpose for manufacturing it
but the two main purposes are protection and decoration. Protective paints is more
important than decorative paints, In following sections sum of protective paints
are described in some details.
1
1.3.3: TV & Phones Paints
It's thermoplastic acrylic finishing coat with high adhesion and weathering,
water and aliphatic hydrocarbons resistance, which make it suitable for air
spraying for TV and phones.
1.3.5: Primers
It can be manufactured from alkyds, or resins such as epoxy, it used for
covering surface pores, and leveling surface to be painted with other type of paints
such as lake.
1.3.6: Varnish
It’s a color less paint used for protection, and disappearing the primed
surface under it.
2-by spraying, e.g. air-fed spray, airless spray, hot spray, and electrostatic spray;
3-by flow coating, e.g. dipping, curtain coating, roller coating, and reverse roller
coating;
2
Chapter Two
Paints Raw Materials
2.1: Introduction
Once seeing a painted wall or paint package, the first conception is it’s a
colored liquid but this wrong, several ingredients used to manufacture this colored
liquid some of this components are solids such as resin, pigment, additives and
the one liquid component that dissolve all of these mentioned solids is the solvent
that obtain the paint in a liquid state in the following sections each component
will be described in some details.
2.2: Resin
It’s the component that identify the paint, several resins are used in paints
manufacturing, it works as binder for collecting all paint components, the mixture
of solvent and resin usually called “vehicle”. The binder (Resin) classified into
two classifications; the first classification is convertible binders which non fully
polymerized but it partially polymerized and it complete its polymerization during
film formation when painting. An example of convertible binders is polyurethane,
epoxy, and thermosetting acrylics.
3
Equation (2.1), [6]
2.2.3: Acrylics
The term acrylic has come to represent those polymers containing acrylate
and methacrylate esters in their structure along with certain other vinyl
unsaturated compounds. Both thermoplastic and thermosetting systems are
possible, the latter formulated to include monomers possessing additional
functional groups that can further react to give crosslinks following the formation
of the initial polymer structure, [3].
5
2.2.3.2: Acrylics Curing
Curing of acrylic paints or emulsion paints based on physical process which
is water vaporization, no other solvent used so paints that depend on acrylics
considered as environmental paints as it doesn’t pollute environment.
2.2.5: Alkyds
It’s a thermosetting resin produced from reaction of organic alcohol and
organic acid, which both of them are selected carefully to meet the required
specifications, and then can be modified with oils. Also, it can be prepared directly
from reaction of organic acid, organic alcohol, and oil (Tri-glyceride).
6
Table (2.1): Alkyds lengths and its properties, [2]
Alkyd Oil length% Properties
Short 20-25% Non-oxidative, soluble in aromatic hydrocarbon
solvents, it gives a hard film
2.3: Solvents
It’s the second component of vehicle beside resins the first one, it’s function
to give flowability to the paint to make easy applying, and dissolving the resin
and other paint components. The important principle in solvents working is “Like
dissolves like”, solvent selection be according to several factors such as its
suitability to formula of paint, cost, and safety.
The second important factor in solvent working is the evaporation rate, some of
solvents can work as retards to slow the drying rate to give an open time for film
drying, but it required from solvent to have a good evaporation rate for speeding
paint layers applying.
7
Figure (2.1): Classification of solvents according to principle of working
8
Figure (2.2): classification of solvents according to chemical structure
9
2.4: Filler
Fillers is considered as additives but adding it with high quantities in paint
formula, forcing to consider it as a main component of paint formula, it has several
types can perform a co-work as fillers and others such as; retardants for flame like
alumina tri hydrate (ATH). The most common are calcium carbonate, talc, silica,
wollastonite, clay, calcium sulfate, mica, glass structures, and ATH. Fillers serve
a number of purposes such as reducing cost.
2.5: Pigment
Pigments are particulate solids that are dispersed in paints to provide certain
characteristics to them, including color, opacity, durability, mechanical strength,
and corrosion protection for metallic substrates. Pigments classified into organic
pigments; which used in decoration paints, and in-organic pigments; which are
metallic pigments, used in protective paints
Table (2.2): Color and its pigments, [3]
10
2.6: Additives
Although its low percentage in paints composition, it has high effect in
improving properties, through this low percentage paints manufacturer
distinguished, several additives used in paints formula such as thickeners, dryers,
anti-skinning, defoamers, etc.
Table (2.3): Paints Additives
11
Chapter Three
Paints Unit Operations & Equipment
3.1: Introduction
Manufacturing paints depend mainly on three physical processes which are
mixing, milling, and filtration, which will be described in some details, and
according that 3 industrial units used which are mixers, mills, filters, each of them
will discussed in some details.
12
Suspension; the condition where no particle remains on the bottom of the vessel
(or upper surface of the liquid) for longer than 1-2 sec. this position achieved by
existence of anti-settling agents and high rotating speed.
13
3.3.2: Vessel flow pattern
There are four flow patterns for vessels which obtained in figure (3.3), but
according to require to achieve con shape or vortex for solid-liquid mixing, the
first flow pattern will be used.
Figure (3.2): Representative impellers for fluid mixing in mechanically agitated vessels. (a) The
three-bladed Marine Propeller, (b) Chemineer HE-3 hydrofoil, (C) the Rushton turbine, (d) 4-
blade 45° pitched blade, (e) 4-blade flat blade, (F) concave blade, (g) sawtooth, (h) helical
ribbon, (I) Anchor, (j) Ekato intermig, (k) hollow-shaft,(l) paravisc, [9].
14
Figure (3.3): Vessel flow patterns. (a) Axial or radial impellers without baffles produce
vortexes. (b) Off center location reduces the vortex. (c) Axial impeller with baffles. (d) Radial
impeller with baffles, [9].
15
3.5.1: Mill Design
The used mills in paints industry is rotary mills and ball mills, and as
mentioned previously using ball mills is better than rotary mill.
Horizontal ball mill; as obtained in figure (3.5), it consists of cylindrical tube and
inside its horizontal axis and disks fixed on it rotate around its center each impeller
contains holes for moving of paint, this machine can use both of steel or glass or
ceramics balls.
16
Vertical ball mill; it also called with basket mill this type has more efficiency than
the horizontal type, also it only uses ceramic balls which give his its efficiency,
figure (3.6) show the basket-ball mill.
17
Chapter Four
Paints Products Manufacturing
4.1: Introduction
From the ancient time of discovering paints, its making depend on
blending, the first paint not have the required durability, the modern technology
and discovering new resins, make humans be able to manufacture new paints have
high adhesion force, durability, and other specific properties as they need, in this
chapter the stages of manufacturing of paints be discussed, beside manufacturing
of some products.
If the fineness not meet the required specifications, the mixture charged to the
milling unit, after that the other additives and the rest amount of solvent added
and mixed in a procedure called thinning, after this procedure another sample sent
to the laboratory to done some tests such as, viscosity, density, and hiding power.
If test results meet the required specification, the quality lab. Give a permission
to start packaging, and before that the final mixture purified using a bar screen,
after that it packaged manually, semi-automatic, or automatic according
production volume, figure (4.1) show the flow sheet of paints manufacturing.
18
4.3: Epoxy paints
Epoxy systems are considered from the best systems of paints specially and
of coatings generally, most of it using in protection purposes, it has several
systems, but the common system is the 2-component system, an example of 2K
system components is obtained in table (4.1), and the hardener in table (4.2).
Table (4.1): epoxy-base components
This mixture mixed for 30 minutes for dissolving these added powders after
adding BYK 163, which is a dispersion agent. After that a sample sent to quality
control laboratory (QCL) to test its fineness, and with QCL acceptation the
defoamer added, and mixed, after that another sample sent to QCL to test its,
viscosity, density, and hiding power.
20
Table (4.4): Aluminum pastel contents
4.5: Primer
Primer paints used for preparing surface to be painted, as it covers all
surface pores, leveling the surface to painted with a finish painting, its formula
showed in table (4.5), the first procedure is dissolving the hydro carbon resin in
white spirit, and this procedure take usually 2hours, during this mixing we use
another mixing unit for the other procedures.
The long alkyd resin, benton, and methanol added and mixed for 15-20
minutes, after that filler, and the pigment added and mixed for 20-30 minutes. A
sample sent to QCL for testing fineness, and after that dryers, anti-skinning agent,
and dissolved hydrocarbon resin added, and mixed for 10-15 minutes. Another
sample sent to QCL, to get a final report about its meeting to the specific
requirements, after that it milled, filtrated, and packaged.
Table (4.5): Primer components
21
20 minutes to activate benton 34. After that filler and titanium di-oxide added and
mixed for 30 minutes.
A sample sent to QCL to get a report about its fineness, if the fineness
achieved meet the required specifications, dryers, toner, the rest amount of TX,
and anti-skinning agent added and mixed for 10-15 minutes. After that a sample
sent to QCL to get a report about its viscosity, density, and hiding power, also
done some other tests to ensure that it meet the required specification. After that
it filtrated and packaged.
Table (4.6): Semi-gloss lake components
Additives
Zinc strate Solid (Powder) Defoamer
Talk Solid (Powder) Filler
23
4.8: Thinners
It’s a solvents composition, used for thinning paints products, with defined
percentages defined by the manufacturer, methanol is used as a filler, to decrease
cost of thinner, table (4.10) show types of paints and its thinner solvents.
Table (4.10): paints and its thinners
24
Chapter Five
Testing paints
5.1: Introduction
Testing is an important part of the operation of a paint system. Testing is
done to monitor the system and to confirm that the finish meets established quality
standards and the expectations of the customer. The end use of a painted product
should determine what tests are important. The incoming paint material is
sometimes tested to confirm that the color and gloss are correct and the paint is
free of defects. In some cases, the paint supplier will certify that the paint they are
providing meets all required physical properties, [2].
25
Figure (5.1): cup used in measuring density
Vaporization time
it’s a second test also used to be sure that solvent does not mix with other
materials by boiling the solvent and counting the rate that solvent take to vaporize,
and the vaporizing time will be calculated according to the following low;
Flash point
26
5.4.1: Viscosity test
One of tests that applied to paints is viscosity, it can be determined by
measuring the time required for a given quantity of paint to flow through a hole
in the bottom of a metal cup, [2], it also can be measured by a visco-meter to
obtain paint viscosity.
It’s simple method in which a cup with hole has diameter 4mm is used,
which showed in figure (5.2), the sample put into the cup and a stop watch is used
to measure the time that sample take to get out from the cup through the hole.
This method is easy also as it doesn’t take the time that the first one takes,
by using a visco-meter device which give direct value of viscosity dependent on
a spindle rotate in the sample, which showed in figure (5.3).
27
5.4.2: Density test
It’s the second important test after viscosity. It done by using cup has
volume of 100 ml, which shown in figure (5.1), the sample put into this cup
without leaving any spaces in cup, then the density measured by a digital balance.
Wi= 252 gm, Wf= 405 gm, then sample weight = Wf – Wi = 405 – 252= 153gm.
Which mean that this paint can be filled with rate of 1530 gm/liter. So, the
standard value of filling can be calculated from this law;
28
Figure (5.5): different shapes of pulling tools
After pulling the film of paint on paper test an opacity meter, such that
which obtained in figure (5.7), used to obtain the degree of paint hiding
30
5.4.10: Wash-ability test
It’s the resistance of paint film for washing, which done by a device, which
is shown in figure (5.9), that drop water with a regular rate and by using number
of brushes that rub the film and the time counted until film is removed.
(2) paints composed mainly of five components; resin (binder), which collect all
the rest of paint components, it classified to convertible binders such as; epoxy,
and polyurethane. The other classification is non-convertible binders such as;
cellulose, and nitro-cellulose.
(3) The second component is the solvent; which used to dissolve all components
of paint. Other components used such as pigment which give the paint its color,
the filler which perform usually half of formula amount, and finally some
additives such as thickeners, dryers, anti-foaming agents, and other additives
which obtained in table (2.3).
(5) Equipment used in paints manufacturing are mixers, mills, and filters. Mixers
is consisting of impeller, consist of axis and radial or axial disk, and vessel which
must not contain baffles inside it for not reducing vortex, which is important in
solid-liquid mixing. Mills used to damage any coagulated particles, by crashing it
with macro balls manufactured from several materials such as; glass, and
ceramics. Screen filters are used for purification of paint.
32
References
1. [1] R. Norris Shreve, 1956, the chemical process industries, second edition,
McGraw-Hill book company, Tokyo.
2.[2] Rodger Talbert, 2008, Paints Technology Handbook, Taylor & Francis
group, Boca Raton & New York & London.
3.[3] R. LAMBOURNE and T.A. STRIVENS, 1999, Paint and surface Coatings
theory and practice, second edition, Woodhead Publishing Ltd, Cambridge.
4.[4] Charles A. Harper and Edward M. Petrie, 2003, Plastics Materials and
Processes A Concise Encyclopedia, John Wiley & Sons, New Jersey.
5.[5] Robert O. Ebewele, 2000, Polymer Science and Technology, CRC Press,
Florida.
9.[9] James R. Couper, W. Roy Penney, James R. Fair, and Stanley M. Walas,
2012, Chemical Process Equipment Selection and Design, Third edition, Elsevier,
united states of America.
10.[10] Ministry of state for environmental affairs, 2002, Paint Industry- Self-
Monitoring Manual, Egypt.
33