Paint area of Zaporizhy Casting and Mechanical Plant

In 2018, the sales department of our company received a request for a painting and drying chamber and an abrasive blasting chamber from representatives of ZLMZ LLC. In the course of negotiations, lasting a year, we, together with ZLMZ, formed the terms of reference and drew up a detailed plan for the construction of the painting area as a whole. To implement this project, it was necessary, first of all, to carry out work on the design of a new paint area at the enterprise, to coordinate the project with local authorities, to conduct an environmental impact assessment, while observing the strictest fire safety rules…

The next stage after the design was the implementation of construction and installation work – it was necessary to dismantle a concrete base up to 1.5 meters deep, and then equip a foundation slab for installing equipment with built-in technological pits for ventilation and equipment operation, a rail track for supplying products to the working areas of the chambers…

The painting area of ​​production is a rather energy-intensive area. Since to ensure high productivity and safe working conditions, it is required to provide a colossal airflow in the painting chamber – up to 100,000 cubic meters/hour, while heating the air to a delta of 35 ° C in painting mode and up to + 80 ° C in drying mode – such a spray booth, with electric air heating, consumes up to 500 kW/h of electricity. The abrasive blasting chamber consumes up to 12 cubic meters/min, 8 atm, compressed air while consuming up to 50 kW of electricity per hour. The total energy consumption of the painting area reaches 700 kW/h. Naturally, to provide such a volume of electricity, it was necessary to lay a separate power transmission line from the TP, with a length of 240 meters, and this was also included in the scope of work performed by our company within the framework of this project.

The scope of delivery of the equipment included: a painting and drying chamber, an abrasive blasting chamber, two self-propelled rail carts, abrasive blasting machines, airless high-pressure painting machines, a compressor room with receivers and air dryers, a set of lifting-mobile platforms for painting large-sized items, a cabin for storage and making paints…

Paint area

A painting and drying chamber and a dead-end type abrasive blasting chamber are located outside the main production area, adjoining it with a front wall with a gate. Both chambers have an internal size of 16180x6000x5500 millimeters, and together with rail trolleys, they can efficiently handle products with dimensions up to 15000x4000x5000 millimeters and weighing up to 20 tons! Both chambers have excellent energy efficiency, as they are hermetically sealed and made of sandwich panels with a fireproof filler – mineral wool, 100 mm thick. The spray booth has three rows of sealed energy-efficient LED lighting fixtures that provide at least 800 lux of illumination inside the cab, which allows for the best possible paint application on a wide variety of products.

A set of lifting-mobile platforms built into the spray booth allow operators to move quickly inside the booth and handle products up to 6 meters high. The platforms move in three directions – along the entire length along the walls of the chamber, along the entire height of the chamber, as well as from the wall at a distance of up to 1500mm. The platforms are driven by compressed air, which makes them explosion-proof and can be used in a spray booth environment.

The abrasive blasting chamber (KASO) has a system for the automatic collection and regeneration of shots and debris. The scraper floor system is responsible for collection and transportation, which consists of five longitudinal and one transverse line, which moves the shot to the elevator pit with synchronous translational movements. Further, the elevator raises the shot to a height of 7 meters, from where it enters the drum-type separator. In the separator, the shot is sifted and cleaned of large contaminating particles, and fine dust is removed through the dust extraction channels to the filter unit. After passing through the separator, the shot automatically enters the storage hopper in which the abrasive blasting machines are arranged. Thus, the abrasive blasting chamber provides a fully automatic collection, regeneration, and supply of shots for reuse – a closed cycle. The dust removal system is responsible for ensuring safe and comfortable working conditions in KASO, which is represented by two highly efficient filter and ventilation units FVU-18, they promptly remove the dusty gas-air mixture from the chamber, filter it and release it into the atmosphere.

The compressor station is represented by a high-performance screw compressor Remeza VK120, with a productivity of up to 16,000 liters per minute at 8 atmospheres of pressure, and effective installation with an air dryer – freezer, 4 compressed air receivers with a volume of up to 1000 liters each.

The set of equipment includes the Wiwa Airless 140032 RS/F Phoe Airless Painting Machine, the CLEMCO SCWB Shot Blasting Machine – 2452, 200 liters. with a full set of operator’s suit and personal protective equipment. And to ensure fire safety, the painting area is equipped with an automatic powder fire extinguishing system, fire alarm, and its connection to local fire extinguishing services.

Probably, the production of equipment was not the most difficult in the implementation of this project, it was much more difficult to correctly draw up the terms of reference, carry out the design, design development, coordinate all the processes and stages of implementation: construction, laying communications, fire safety… At the same time, observing the strictest security rules labor that operates at the enterprise LLC “ZLMZ”, PJSC “Zaporizhstal” and throughout the Metinvest Holding. And also find reliable contractors, coordinate and organize their work, plan everything and invest in the schedule.

This project gave our company invaluable experience in the implementation of a difficult and complex object, moreover, for one of the largest enterprises in Ukraine – Metinvest Holding! The implementation of such a project once again confirms the ability of our company to create and implement the most complex technological complexes for the painting department of any, even the most demanding Customer.

Painting and blasting chambers for Azovtekhgaz

At the end of February 2020, we received a request for a set of equipment including a painting and blasting booth for metal structures. The production base of the customer’s company is located in the city of Mariupol, Donetsk region. Thanks to a lucky coincidence, our specialists were nearby, in the city of Zaporozhye, promptly responded to the request and went to the customer’s site.
The customer company Azovtekhgaz LLC is engaged in the supply of technical gases, gas mixtures and gas welding equipment, as well as in construction and installation works in various areas of industrial construction. The maximum overall size of products to be processed in chambers is 12x3x3m. Shot-blasting and painting chambers will improve the quality of the paintwork of all metal products manufactured by the company.
The spray booth has two main modes of operation – painting and drying, with operating temperatures of 18-24 C and 20-70 C, respectively. The passage-type chamber has an internal size of 15x5x5m, two sets of sectional doors with an automatic drive are installed in the end walls. The air is heated using three high-performance gas burners, each with a power of up to 350 kW, and stainless steel heat exchangers, designed and manufactured by our company specifically for spray booths. Two side and two ceiling rows of high-performance four-lamp LED luminaires are responsible for lighting in the spray booth, while the illumination level inside the booth is at least 900 lux.

Azovtekhgaz

The main feature of this spray booth model is that it has the ability to work in zones. Three separate thermo-ventilation cabinets, in combination with a specially developed automation and control system, allow you to turn on and operate each zone separately from the rest. Thus, the camera has three zones 5x5x5m, and when painting oversized products, camera operators can use only one or two of the zones. Automation and control systems in this design are three times larger, more expensive and more complex than usual, but due to this, when operating the camera, the costs of electricity and natural gas are significantly reduced!
The abrasive blasting chamber has an internal size similar to the spray booth – 15x5x5m. The chamber has a sealed cabin made in the form of a prefabricated steel structure with sandwich panels. The inside of the cab is lined with an elastic soft material that protects the steel structures of the cab from damage by ricochet shots. The camera is illuminated by two rows of ceiling, located at an angle of 45 °, four-lamp LED luminaires, protected from possible mechanical damage by ricocheting shot. The chamber quickly and effectively cleans the dusty air that forms during the cleaning process; for this, it is equipped with a FVU-30 filter ventilation unit. FVU-30 is one of the models of filtering units developed by our company, it has a productivity of 30,000 cubic meters per hour, 30 cylindrical dust filters and an automatic filter cleaning system.
The blast chamber is equipped with systems for automatic collection and regeneration of abrasive material, dust and debris removal. There are special pits in the foundation of the chamber, which are covered with steel gratings. Shot and debris generated during cleaning is poured into these pits. During operation, they are automatically collected by scrapers and directed to the bucket conveyor pit. The scraper floor is driven by reliable electric drives, which guarantees a long and trouble-free operation of the entire system. After that, the shot that got into the pit of the bucket conveyor rises and goes to the shot regeneration unit – a vibration-type separator. The vibrating separator automatically separates the incoming material into three parts: the debris and impurities are discharged into the debris tank, the dust is discharged to the filtration unit, and the recyclable beads are automatically returned to the shot blasting machine. Thus, in the abrasive blasting chamber, a closed cycle of shot movement is created, while the collection and regeneration of the shot is carried out in a fully automatic mode. All parts and assemblies of the abrasive blasting chamber – FVU, scraper floor, bucket conveyor, vibratory separator are developed by our company specifically for use in abrasive blast chambers, are manufactured at our own production site in Kiev and have an increased degree of reliability and effective protection from damage.

ABRASIVE BLASTING CHAMBER FOR BADOR FROM TWEKO FACTORY

In 2018, we received a request for an abrasive blasting chamber from Nikolai Nikolayevich, the owner of the Bador company, which is engaged in the production of a variety of semi-trailers and bodies for vehicles. As a cabin for this chamber, the existing structure of the Customer with an internal size of 15x6x6m is used, and we installed a set of equipment for the automatic collection and regeneration of abrasive material, as well as a ventilation and dust removal system.
Automatic fraction collection is carried out using a slatted floor, which has 6 longitudinal modules 15 m long, and one transverse module, which is located in the middle of the longitudinal ones. Longitudinal modules scrape off abrasive and dust from the chamber floor and direct them to the transverse module, while the transverse directs the fractions to the paternoster elevator.
The fractions reuse system consists of a bucket conveyor elevator, fractions separator and storage. The assembled paternoster elevator has a height of 7500 mm, with the help of a gear motor and a belt with buckets, the paternoster elevator raises the fractions and dust from the excavation to a height of 7 meters, after which the fractions are poured to the separator. The separator collects large particles of contaminants and dust from the fraction which is suitable for further use and feeds the fraction into the storage hopper. The storage hopper is a capacity containing up to 1 m3 of fractions, through it the shot is fed to the abrasive blasting machines in semi-automatic mode.
The ventilation and dust removal system is presented in the form of a filter-ventilation unit with 27 filter cartridges. A powerful centrifugal ventilation unit, with a productivity of 27,500 m3 / h, ensures the active removal of dusty air from the chamber. The ventilation unit is equipped with an automatic system for cleaning filter cartridges using reverse compressed air flows.

COMPLEX OF EQUIPMENT FOR PAINTING

In 2015, we received a request for the development of a complex of equipment for painting and shot blasting cleaning of large-sized metal products. The complex should provide a full cycle of work on preparing products for painting – cleaning from scale, rust and other contaminants, followed by applying and drying the paintwork. We proposed to equip the painting area with an abrasive blasting chamber with systems for automatic collection, regeneration of shots and dust removals such as a filtering and ventilation unit.
In the process of manufacturing, the technical task for the complex of equipment for painting was also supplemented by the need to move products between the chambers, as well as to lift the products in the chambers for painting the bottom. To meet this request, we have developed and manufactured self-propelled rail trolleys with a built-in hydraulic lift. Rail trolleys have an overall size of 6×2 m and allow you to move products weighing up to 10 tons between the painting, drying and shot blasting chambers. As trolleys are used in the painting area they are explosion-proof and are driven by a low-voltage gear motor powered by built-in rechargeable batteries. Two out of five bogies have hydraulic lifts built-in, which allow you to lift the product to a height of 2 meters so that the operator can paint the bottom of the products.
The abrasive blasting chamber has internal dimensions of 12.5x6x5 m, the cabin is made of a steel framework with galvanized steel panels, on the inner side is coated with a protective rubber sheet which prevents the ricochet of the shot in the operator during cleaning, and the deformation of the chamber. The fraction collection system is implemented as an automatic scraper floor, which collects the fraction over the entire area of the chamber and supplies it to the fraction regeneration system. The regeneration system first raises the shot with the bucket elevator to a height of up to 6 meters, and then purifies it from large particles and dust which are not suitable for further use, and then supplies the purified shot to the bunker storage device which is connected to the shot blasting machine. The enclosure is thus provided with a closed fraction cycle, thereby significantly increasing the blast cleaning efficiency.
The painting chamber has internal dimensions of 12x6x5 m, and the drying chamber of – 10х4х4.3 m, which makes it possible to apply high-quality paint coating to the products and to dry them effectively, with minimal energy input. The drying chamber has two thermal ventilation cabinets with high-efficiency ventilation units, productivity up to 25,000 m³ each, air heating is carried out with the aid of electric heat exchangers, the total power consumed is 45-135 kW/h. The painting chamber has two inlet thermal ventilation cabinets and one dual exhaust ventilation cabinet, which provide an air flow of 70,000 m³ / h. Air heating is performed using two electric heat exchangers, the total energy consumption is 60-180 kW/h. Both chambers are equipped with multi-level filtration air treatment systems (cleaning class EU5), which, together with the supply and heating systems, provide intensive and uniform blowing of products, with clean, heated air to a predetermined temperature, which creates an optimal microclimate for applying and drying paintwork coverings inside the chambers.