Note: Descriptions are shown in the official language in which they were submitted.
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Background of the Invention
The present invention relates, in general, to method and appara- -
tus for carrying out heating operations which release flammable solvent
vapors, and more particularly to method and apparatus for drying solvent-
based paint coatings on articles of various form.
Solvent-based paints normally contain from 40 to 60 percent
organic solvents usually in the form of aromatic hydrocarbon compounds,
such as benzene, toluene, xylene and other high-flash napthas which are -
derived from coal-tar distillates and which are evaporated from the paint
coating during the drying process. Because these solvent vapors are
highly flammable and can form explosive mixtures when mixed with air,
. . .
they represent potential fire and explosion hazards. For this reason,
insurance and fire prevention regulations require that for safe operation
of drying ovens open to the atmosphere the solvent vapor concentration in
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the oven exhaust gases must be lower than 25 percent of the lower explo- `
sion limit (L. E.L.) thereof. To comply with these regulations therefore,
and independent of the drying process heat demand, the solvent vapors
evolved in such ovens must, before their exhaustion therefrom, be diluted
to 25 percent or less of their lower explosion limit. In conventional paint ``
20 drying ovens, this dilution is obtained by introducing into the oven at least
10, 000 cu. ft. of air per gallon of evaporated solvent. Prior to the en-
actment of recent pollution control regulations, these solvent-air mixtures
containing undesirable pollutants were discharged directly into the
atmosphere .
The heat required to operate such a conventional paint drying sys-
tem is used not only for heating the paint coated article to the required
paint drying temperature, usually from 200 to 600F., but also is used
up in heating the dilution air to the oven exhaust temperature. The added
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heat energy thus expended in heating the required large volume of diluMon
air represents a considerable proportion of the total fuel requirement
for the system and therefore a con~iderable added operating expense.
Because of the elevated levels of the pollutants contained in the
solvent-air mixtures exhausted from conventional paint drying ovens,
recently enacted governmental pollution control regulations no longer per-
mit the emission of these mixtures directly into the atmosphere. To com-
ply with these air pollution control regulations, therefore, it has been
necessary to equip paint drying ovens with some type of pollution abate-
ment equipment, the most common form of which has been a thermal
fume incinerator for incinerating the exhaust gases from the paint dry-
ing oven. Such thermal incineration of these oven exhaust gases normal-
ly requires temperatures between 1250F. and 1450F. In a typical fume
incinerator, the fumes are mixed with auxiliary fuel, e. g., natural gas,
and the mixture temperature is raised to lZ50-1450F. to cause the in-
cineration of the fumes. With proper design of the incinerator, the gas-
eous products of combustion are essentially clean, i. e., free of air
pollutants. The auxiliary fuel requirements for the incineration process
depend on the exhaust fume temperature and on the initial fume loading.
20 In most paint drying applications employing such exhaust gas incineration,
however, the fuel consumption for the paint drying operation increases
more than twice compared to that used in the conventional paint drying
system not equipped with a fume incinerator.
To reduce the fuel consumption of such incinerator-equipped paint
drying systems, it has been proposed to include a fume preheate~t in which
the exhaust gases from the incinerator are used to heat the fumes and
raise their temperature before entering the incinerator. However, the ad-
dition of such a fume preheater increases the capital cost for the system
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by an amount comparable to or higher than the cost of the incinerator it-
self. In many cases, economic considerations make it impractical to
raise the preheater efficiency beyond 50 to 60 percent, with the result that
the additional fuel consumption for the operation of the incinerator is still
substantial. A further proposal for reducing the fuel consumption still
further has been to employ a liquid-to-gas heat exchanger to recover ad-
ditional heat from the e~aust gases leaving the fume preheater. 13ut -
such a system is considerably more expensive and its use is limited to
very large installations. Even with such an elaborate heat recovery sys-
10 tem, however, the fuel consumption is higher than the simple convention-
al system without fume incineration equipment.
Many small and medium scale paint drying installations cannot
justify from an economic standpoint the use of a complete heat recovery
system, with the result that they have to use considerably more fuel than
in the past in order to operate the required pollution abatement equipment
or incinerator. Moreover, the present fuel supply shortages and the con-
tinuously rising fuel costs are threatening the paint drying industry with
higher production costs, insufficient fuel allocations and production cut-
backs or interruptions. As alternatives to the use of solvent-based paints,
20 the use of powder coatings and water-based paints is being considered as
a way of reducing or eliminating air polluting emissions and hence the ad-
ditional fuel consumption in the incinerator, but the use of any one of ;
these two alternatives still requires substantial fuel usage in the drying
or heating oven. Moreover, so far as known, none of these alternatives
has been tried as yet on a large scale so that their ultimate use in large
scale coating operations may not occur for a considerable time.
Summary of the Invention
As mentioned hereinabove, conventional solvent-based paints
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contain from 40 to 60 percent or higher of organic solvents which are
highly inflammable and have heating value of 120, 000 to 140, 000 Btu
per gallon of solvent. These paints are customarily applied as a thin
coating or film on the article or object to be painted, the film thickness
in most applications being of the order of 0. 5 to 2 mils or thereabouts.
During the drying process most of these solvents are evaporated, and
the pigments of the paint form a protective coating on the article. The
heating value of the solvent vapors evaporated during the paint drying
process is usually many times more than the fuel requirements in a
typical paint drying oven. Accordingly, a paint drying system designed
to take advantage of this heat energy of the solvent vapors, while main-
taining the basic requirements of safety, pollution free exhaust emissions
and unchanged coating or product quality, will provide a drastic reduc-
tion in the fuel demand of the paint drying industry.
In conventional paint drying systems which operate with oven at-
mospheres below the lower explosion limit, the dilution air which must be
added to the solvent vapors before exhausting them from the oven in order
to comply with safety regulations uses up a major portion of the total heat
requirement for the system. Moreover, bringing the exhaust gases to an
incineration temperature of 1250 to 1450F. to comply with air pollution
regulations can more than double the heat requirements of systems not
provided with oven exhaust incineration means. By eliminating or reduc-
ing the dilution air without endangering the safety requirements of the
paint drying system, a large part of the intrinsic heat energy in the sol-
vent vapors released from the paint on drying can be utilized for heating
the drying oven and the painted article therein to be dried. In the design
of such a system, however, considerations relating to safety and perfect
combustion req~ire an understanding of the fundamentals of the ;
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flammability characteristics of gas mixtures, such as are formed in
paint drying ovens, by reference to the established flammability curves
therefor. These curves show that mixtures of common flammable gases
including hydrogen, carbon monoxide, hydrocarbons and vapors of com-
mon paint solvents, with inert gases such as nitrogen, carbon dioxide and
water vapor, are nonflammable if the oxygen concentration in the mixture
is less than about 5 percent. Accordingly, and as an alternative to the use ~ -
of large quantities of dilution air to control potential explosion hazards,
the gas-solvent vapor mixture formed in paint drying ovens during the dry-
ing operation will remain nonexplosive if an atmosphere with a low oxygen
content, or an inert atmosphere with essentially no oxygen content, is
maintained in the ~ven during the solvent evaporation from the paint coat-
ing. In this way, it is not necessary to use any dilution air at all because
the gas-solvent mixture is outside and considerably away from the ilamma-
bility region, i. e., it is above the upper explosi~3n limit (U. E. L. ) thereof.
While, from a safety standpoint, the volume ratio of inert gases to the
solvent vapors may in such gas be any value, in most instances the required
volume of inert gas per gallon of evaporated solvent is much less than the
dilution air required in conventional paint drying systems.
The nonexplosive gas-solvent mixture or rich fumes exhausted from
the drying oven can be utilized to supply all the heat required for the paint
drying operation by incinerating the oven exhaust gases, under stoichio-
metric conditions, in an incinerator to convert them into off-gases of sub-
stantially inert character and high temperature, e. g., from 1400 to 1650F.
or thereabouts. Because of their inert character, these hot exhaust gases
from the incinerator then can be recycled, after cooling, back into the
paint drying oven to not only supply thereto all, or if desired only a part of
the heat required for the paint drying operation but to also supply thereto
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the required amount of inert gases to assure the maintenance in the oven of
a gas-solvent vapor mixture above the upper explosion limit thereof at all
times during the paint drying operation. Since the volume and heat energy
of the exhaust gases generated in the incinerator are substantially greater
than that required for the paint drying operation in the oven, only a part of
the total volume of these exhaust gases need be recycled back into the oven.
In view of their inert and therefore nonpolluting character, the other part
of these exhaust gases can be vented directly to the atmosphere without any
polluting effect thereon. The portion of the hot incinerator off-gases re-
cycled to the oven can be cooled to the lowered temperature required for
the paint drying operation in the oven in a suitable heat recovery system
or heat exchanger such as a water or an air heater, or a low pressure
steam boiler, or a metal preparation section of the article coating line.
Thus, the incinerator is used as a means of energy recovery and serves
the multi-purpose function of an inert gas generator, a heat generator or
burner, and as pollution abatement equipment. Moreover, the incinerator
does not require any auxiliary fuel for its normal operation except for the
v~ry small amount needed to operate pilot burners to maintain the required
ignition condition~ in the incinerator for assuring the complete combustion
20 of the solvent vapors contained in the oven exhaust gas mixture introduced
into the incinerator.
It is an object of the invention, therefore, to provide a system for ;
drying solvent~based paint and other solvent containing coatings which is
of increased thermal efficiency.
Another object of the invention is to provide a system for drying
such solvent-based coatings which not only is of improved thermal effi-
ciency but also is characterized by pollution-free emissions.
Still another object of the invention is to provide a system for ;
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dr ing solvent~based coatin~s which is substantially self-
! a~VpPortins in respect to its fuel energy requirements.
A further object of the invention is to provide a system
for drying such solvent-based coatings in a substantially oxygen-
free or low oxygen content inert atmosphere maintained well above
the upper explosion limit at all times during the drying operation
and complying with standard fire safetY regulations therefor.
A still further object of the invention is to provide
a system for drying such solvent-based coatings in which the
latent heat energv in the solvent vapors evaporated from the
coating during the drying operation is used to supply all or
part of the heat required for such operation.
Another object of the invention is to provide a system
for drying such solvent-based coatings in which the solvent
vapors evaporated from the coating during the drying operation
are incinerated in a manner to produce substantially oxygen-free
or low oxygen content inert gaseous combustion products for "
recycling back into the drying oven to supply an inert atmosphere
therein.
Still another object of the invention is to provide
a system for drying such solvent-based coatings which does not ~;~
require the addition of any dilution air to the gases exhausted
I from the drying oven during the drying operation in order to '!'' ' '
maintain them outside their explosion limits so as to comply ~;
with standard fire safety regulations. -
A further object of the invention is to provide apparatus
for effectively carrying out the drying of solvent-based paint
and other such coatings in accordance with the above referred
to systems.
One aspect of this invention is defined as a method of
drying solvent-based coatings on articles moving through a drying
chamber by means of exhaustgasescoming from a cambustion apparatus
having an intake in fluid communication with a gaseous exhaust
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duct in the dryin~ chamher whereby a furnace atmosphere generated
hin the drying chamber is drawn into the combustion apparatu.s,
the method comprising the steps of: injecting combustion air into
the combustion apparatus at a fixed rate sufficient to mix stoi- :
chiometrically with the furnace atmosphere drawn from the exhaust
duct when the drying chamber is operating under constant load;
initially mixing, during startup, a gaseous fuel from an auxiliary
burner in stoichiom~tric proportions with the combustion air;
igniting the gaseous fuel and the combustion alr in the combustion ~ ',
apparatus b~ means of at least one pilot burner to pro~uce an ,
inert type,gas mixture possessing not more than five percent
oxygen by content; circulating at least a portion of the inert
gas mixture leaving the combustion apparatus through a heat
exchange mechanism to cool same to a predetermined value; piping .
at least a portion of the inert gas mixture leaving the cooling ,,~;
mechanism into the drying chamber to purge same; introducing the ': ,
articles through an article inlet end into the drying chamber to ';
produce a furnace atmosphere containing solvent emissions and
removing the articles through an article outlet end of the chamber; ~,
continuously removing a first portion of the furnace atmosphere
through the exhaust duct and burning the removed solvents in the
combustion apparatus to continuously produce an inert type off- '
gas; sensing the temperature of the off-gas to regulate the flow
of fuel to the auxiliary burner to insure that the off-gas poss- ''~
esses no more than five percent oxygen by content; circulating
a portion of the off-gas through the heat exchange mechanism to .
cool same to a predetermined temperature; introducing a portion
of the cooled off-gas to the dr~ing chamber to insure that the
furnace atmosphere is outside the explosive range; exhausting
a second portion of the furnace atmosphere from the dr~ing chamber
through a vent; recirculating the second portion of the furnace
atmosphere into the drying chamber after mixing'same with the
portion of inext type off-gas being circulated into the drying . :.
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chan~er; controlling the flow of the off-gas to produce a sliyht
pressure in the drying chamber; circulating a portion of the
inert type off-gas downstream from the heat exchange mechanism
` into a plenum arranyement at the article inlet end and the
article outlet end; and, ejecting the inert type gas mixture
. from the plenum arrangement in a plurality of gaseous streams
directed generally normal to the flow of the articles at a pressure
. .
: sufficient to establish gas flow patterns through the article
inlet andoutlet ends whereby the overpressure is maintained and
the furnace atmosphere is substantially sealed.
Another aspect of this invention is defined as an
apparatus for drying solvent-based coatings on articles, the
apparatus comprising: a dr~ing oven having a drying chamber, an
article inlet opening, an article outlet opening, a gaseous inlet
opening for injecting a furnace t~pe gaseous atmosphere into the
~ oven, an exhaust outlet opening for removing a first portion of
: the furnace atmosphere, and a vent for removing a second portion
of the furnace atmosphere; combustion means in fluid communication
with the gaseous exhaust outlet for burning furnace fumes exiting
~ 20 therefrom to produce an inert type off-gas mixture which contains
;' not more than fi~e percent oxygen by content; the combustion means
including combustion air supply means preset to deliver a fixed
quantity of combustion air to the combustion means to achieve
approximately stoichiometric combustion when the apparatus is
. operated under constant load, pilot burner means to ignite the
combustion air with the exhaust furnace fumes to produce the
inert type off-gas mixture, auxiliary fuel means effective during
startup of the apparatus to mix with the combustion air in the
~: combustion means to produce an inert type off-gas suitable for
0 purging the drying chamber and effective during normal operation
~ of the apparatus to control the oxygen content within the five
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percent limit in the inert off-gas mixture, and temperature control : . :
means associated with the combustion means for controlling the fuel
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quantity supplied the comhustion means by the auxiliary fuel
,n2Q~s; recycle conduit means for recycling at least a portion
of the inert gas mixture from the combustion means to the gaseous
inlet opening in the drying chamber; the recycling means including
a heat transfer mechanism for reducing the temperature of the :
inert off-gas mixture to a predetermined value, first conduit
means upstream of the heat transfer mechanism for venting a
portion of the inert off-gas mixture directly to the atmosphere
as nonpolluting emissions, second conduit means in fluid communi- ::
cation with th~ gaseous inlet of the drying chamber for conveying
and mixing a second portion of the inert type off-gas mixture :
with the solvents emitted from the coatings to produce a furnace
gas atmosphere which is above the upper explosive limits of the ; :~
atmosphere at all times during the drying the coatings; recircula-
ting means including a third conduit in fluid communication with
the vent for circulating a second portion of the furnace atmosphere
with the inert type gaseous mixture whereby the heat sensibility : :~
of the furnace mixture is conserved and temperature uniformity
of the urnace atmosphere is promoted; pressure means for main-
taining the drying chamber at a slight overpressure; aerodynamic
sealing means at the article inlet opening and the article outlet ~
opening directing a plurality of streams of the inert type off- . :
.,
gas mixture in a direction generally normal to all surfaces of
the articles at a flow rate sufficient to establish gas flow
into the drying chamber to maintain the drying chamber substantially .
sealed from the outside atmosphere; and, the recycling means
including a fourth conduit supplying the inert gas mixture to
the aerodynamic seal means.
Further objects and advantages of the invention will
appear from the following detailed description of species .
thereof and from the accompanying drawings. .
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~e~ Descripti.on of the Drawin~s
Figure 1 is a vertical cross-sectional view, partly
schematic, of a paint drying system according to the invention;
Figure 2 is a flow chart of the basic system shown
in Figure l;
Figure 3 is a flow chart of a modified paint drying ~
7 system ~ :
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according to the invention; and
Figure 4 is a vertical cross-sectional view, on an enlarged scale,
of one of the aerodynamic seals which are located at the article inlet and
outlet openings in the drying oven shown in Figure 1.
Description of the Preferred Embodiments
In the drawings, the invention is therein illustrated as embodied
in a system for the continuous drying of solvent-based paint coatings on -
metallic strip stock such as metallic coiled strip. It should be under-
stood, however, that the invention is applicable as well to the drying of
solvent-based paint coatings on articles of various other types such as,
for example, automobile bodies, metal cabinets for household appliances,
etc., and also to other heating processes in which high Btu vapors are
released as in chemical coating, pyrolysis of carbonaceous material,
carbon baking operations, and resin coating processes.
Referring to Figure 1, there is shown at 10 an oven in which heat-
ing operations are to be carried out which result in the release of flam~
mable vapors of high Btu content, in the particular case illustrated the
heating of metallic strip stock mat.erial 11 such as steel or aluminum
strip coated with a l~er or film 12 (Figure 4) of a solvent-based paint on
one or both sides. In the exemplary continuous metallic strip paint coat- ~i
ing process as shown in Figure 1, the metallic strip material 11 is un-
coiled from a supply roll or coil 13 thereof as by means of a pair of feed
rolls 14 between which strip 11 passes and from which it is then dipped or
immersed in a bath 15 of solvent-based paint contained in a coating tank 16
to form coating 12 on the strip. It should be understood, however, that ~ -
coating 12 of paint on the strip material 11 could be applied thereto by
methods other than the illustrated dip-coating method, e. g., by spraying,
rolling, etc. From the coating tank 16 the coated strip 11 passes between
_ 9 _ ;
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and is supported by a pair of squeegee rolls 17 which squeeze the excess
coating material from the strip so as to leave the desired thickness film
or coating 12 thereon which, in the case of conventional paint coatings, is
usually from 0. 5 to 2. 0 mil thickness. The coated strip ll passes from
squeegee rolls 17 into the interior or drying chamber 18 of oven 10
through an inlet or entrance opening 19 in an end wall 20 of the oven and
then, after the drying of coating 12 on strip 11, out of oven chamber 18
through an outlet or exit opening 21 in the other end wall 22 of the oven.
The emerging strip 11 from oven 10 and on which coating 12 is now dried
10 passes between and is supported by a pair of id]er rolls 23 and is then
coiled on a take-up roll 24. Oven chamber 18 is supplied with a heàted at-
mosphere at the required temperature for the particular drying operation
or other heating operation to be carried out therein, e. g., a temperature ~ -
in the range of from about 200 to 600F. in the case of conventional sol-
vent-based paint coatings 12 to be dried.
As mentioned hereinabove, where any heating operation carried out ^~
in an oxygen-containing atmosphere in an oven results in the evolution of
vapors in the oven which are highly flammable and of explosive character,
such as the solvent vapors which are evaporated from solvent-based paint
20 coatings 12 during the drying thereof, the applicable insurance and fire
regulations require that for safe operation of the oven the solvent vapors
evolved therein must, before the exhausting thereof from the oven, be -
diluted to 25 percent of, i. e., well below, the lower explosion limit
(L. E. L. ) of the solvent vapor-containing gas mixture formed in the oven
during the heating operation. In conventional paint drying ovens, this
dilution is obtained by introducing into the oven 10, 000 cu. ft. of air per
gallon of evaporated solvent. Because this dilution air introduced into the
oven must, of necessity, be also heated to the temperature required for the
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heating operation to be performed in the oven, the added heat ener~y thus ;
expanded in heating the dilution air represents a considerable proportion
of the total heating fuel requirement of the oven and therefore a consid-
erable added operating expense.
In accordance with the invention, the need for and added expense
of heating such dilution air is entirely eliminated by carrying out the paint
- drying or other heating operation to be performed in the oven in a substan-
tially oxygen-free or low oxygen content inert atmosphere which is above
the upper explosion limit (U. E.L. ) of the particular gas mixture formed in
the oven during the heating operation instead of below the lower explosion
limit (L.E.L.) of such gas mixture as has been customary practice here-
tofore. The flammability characteristics of any gas mixture can be deter-
mined by reference to the established flammability curves for various gas
mixtures. These curves show that a mixture of common flammable gases
including hydrogen, carbon monoxide, hydrocarbons and vapors of common '-
solvents such as employed in conventional solvent-based paints, with inert ;
gases such as nitrogen, carbon dioxide and water vapor, is nonflammable
if the oxygen concentration in the mixture is less than 5 percent. For the
purposes of the invention, therefore, oven 10 is supplied with a substan-
20 tially inert gas atrnosphere having an oxygen concentration of less than
5 percent and preferably less than 2 percent. The inert gas atmosphere
can be suppliad to oven 10 from a separate source of supply thereof. Pre-
ferably, however, and to realize the fullest benefits of the invention from
an economic standpoint, the inert gas atmosphere supplied to oven 10, as
well as the heat required therein for the paint drying or other solvent
vaporizing heating operation conducted in the oven, is supplied in the man-
ner shown by the flow chart in Figure 2, by the exhaust or off-gases from
an incinerator 25 in which the mixture of inert gas and solvent vapor
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exhausted from oven 10 is incinerated in a manner as described herein-
after. At least a part of these off-gases, after cooling to the temperature
required for the paint drying or other heating operation to be performed
in oven 10, is recycled back into the oven to supply the inert gas atmos-
phere and all or part of the heat required therein. Thus, the paint drying
or other solvent vaporizing system according to the invention may be sub-
stantially self-supporting in respect to its fuel energy requirements.
To maintain the desired low oxygen concentration in the oven at-
mosphere at all times during the continuance of the paint drying or other
heating operation carried out in oven 10, it is necessary to isolate the
drying chamber 18 of the oven and thus the atmosphere therein from the
ambient atmosphere to prevent leakage of air into the oven. To this end,
the walls of oven 10 are made of proper design to be substantially air tight
in themselves. Thus, as shown in Figure 1, end walls 20, 22, side walls i
26 and top and bottom walls 27, 28, respectively, may be formed as a sheet
metal shell or casing 29, the inner side of which may be provided with a
lining 30 of a suitable heat refractory material such as, for example,
ceramic fiber type block insulation. Further assurance against leakage of
ambient air into oven chamber 18 is afforded by maintaining the inert gas
20 atmosphere therein at a slight overpressure of, for example, 0. 05" w. c.
(water column) or so. Also, where, as in the particular paint drying oper-
ation illustrated, the work to be processed in oven 10 is continuously ad-
vanced into and out of the oven through inlet and outlet openings 19, 21
therein, the isolation of oven chamber 18 from the outside atmosphere re-
quires that these openings 19, 21 also be sealed off from the outside atmos-
phere. For this purpose, oven 10 may be formed at its inlet and outlet
openings 19, 21 with aerodynamic seals 31 of suitable form.
As shown more particularly in Figure 4, where the work to be
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processed in oven 10 is in the form of a continuous strip such as the paint
coated metallic strip material 11, or in the form of articles conveyed into
and out of th~ oven on a conveyor belt or similar such means, aerodynam- ;
ic seals 31 may in such case be formed by curtains or screens 32 of inert
gas directed ~ormal:.to and against the opposite flat sides of strip material
11 or conveyor means immediately outside each of the openings 19 and 21
in the oven. For gas screens 32 to be effective to seal off the openings
19, 21 from the outside atmosphere, inlet and outlet openings 19, 21 in :
oven walls 20, 22 may be in the form of narrow rectangular shaped slots
about 6 inches high, for example, and wide enough to accept, with a slight ~ -
clearance at each side, the maximum width strip material ll or conveyor .
to be advanced through the openings. Inert gas screens 32 may be directed
against advancing strip 11 or work carrying conveyor from respective
pairs of plenums 33 and 34 mounted on the outside of oven end walls 20,
22 at locations immediately above and below inlet and outlet openings 19 -
and 21 so as to be positioned on opposite sides of advancing strip 11. j:
:Plenums 33 and 3ds are of an extent conforming to the width of inlet and . :
outlet openings 19, 21 in oven walls 20, 22 and they are provided with
opposed flat plenum outlet plates 35 of perforated form, and disposed
parallel to and facing strip 11, to provide outlet openings for the inert gas . . .
forming gas stream curtains 32. Plenum outlet plates 35 may have a
dimension longitudinally of advancing strip 11 suitably around 6 inches
or so, and they may be spaced apart around 9 inches or thereabouts so
as to be eaeh spaced approximately the same distance of around 4-1/2 in~
ches or so from their respective side of advancing strip 11. Perforated
outlet plates 35 may have small diameter gas discharge or outlet holes
(not shown), the centers of which are spaced apart a distance of two out- :
let hole diameters and are arranged in staggered pattern to provide
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approximately 33 percent open surface area in plates 35. To prevent
leakage of the sealing-off gas streams 32 at the side ends of the space
between plenums 33, 34, end plates 36 bridging the plenums at their re-
spective ends and closing off the space therebetween are provided on the
plenum s .
The inert gas for plenums 33, 34 is supplied thereto by respect-
ive gas inlets or duc~s 37 which open into the plenum chambers and are
connected to a suitable source of inert gas which, in accordance with the
invention, may be the exhaust gases from incinerator 25. Sufficient in-
lets 37 to each of plenums 33, 34 should be provided to prevent uneven gas
distribution therein. Satisfactory results are obtained in this respect with
one side inlet 37 per foot of extent of the plenum along the width of the re- -.
spective slot-shaped inlet or outlet opening 19, 21. With the particular
dimensional openings 19, 21 and plenums 33, 34 as described above, the
quantity of inert gas required to be supplied to plenums 33, 34 to produce
` an effective aerodynamic seal 31 at oven openings 19, 21 is much less than
the off-gas by-products from incinerator 25. A sufficient excess of such .~.
inert off-gases from incinerator 25 is therefore available at all times to
supply the needed atmosphere for plenums 33, 34 to maintain aerodynamic -
seals 31 at inlet and outlet openings 19, 21 of oven 10.
In the operation of aerodynamic seals 31, the inert gas streams 32
discharged from plenums 33, 34 in directions normal to advancing strip 11,
after impinging on the strip, then turn and proceed along and more or less
parallel to strip 11 as indicated by the arrows in Figure 4, part of the gas
stream flowing inwardly into oven 10 and the other part flowing outwardly
thereof. This flow pattern operates to effectivelyiprevent outside air from
entering oven 10 through oven inlet and outlet openings 19, 21 as well as to
prevent the inert oven atmosphere from escaping to the outside atmosphere
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through these openings.
For proper operation of the illustrated paint drying operation, paint
coated strip 11 is advanced through heated oven chamber 18 at a rate, de-
pending upon the specific operating temperature of the oven atmosphere and
the thickness and particular composition of paint coatings 12, such as will
assure the substantially complete drying of paint coatings 12 on the strip
before the exiting thereof from oven chamber 18 through oven outlet open-
ing 21. During this paint drying operation, the solvents in paint coatings
12 are evaporated therefrom and the resulting solvent vapors mix with the
inert gas atmosphere maintained in oven chamber 18. Because this gas- i-
solvent vapor mixture is maintained below approximately 5 percent oxygen
content at all times during the continuance of the paint drying operation, it
therefore is above the upper explosion limit and outside the flammability
region of the flammable components thereof and thus can be directly ex-
hausted safely from the oven 10 without the need of diluting it with any air
whatsoever to comply with insurance and fire regulations such as has been
customary practice heretofore with prior conventional paint drying sys-
tems. As shown, the inert gas-solvent vapor mixture is exhausted from
oven chamber 18, preferably~atia region of the roof thereof near or at the
back or outlet end of the oven, through an exhaust duct ~3~8~'(Figure 1) and
as shown by the flow line 38a in the flow charts of Figures 2 and 3. The ;
gas-solvent vapor mixture is suitably exhausted from oven chamber 18, as
. . .
by means of an 0xhaust pump or fan 39 in duct 38, at the required rate to
maintain the solvent vapor concentration in the oven atmosphere at the de-
sired level. In this regard, while from the viewpoint of safety require-
ments the volurne ratio of inert gases to the solvent vapors in the oven at-
mosphere can assume any value, the vapor condensation and other consid-
erations may require that this ratio be maintained below a definite -
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numerical value. In most cases, however, the required volume of inert
gas per gallon of the evaporated solvent is in any event many times less
than the dilution air required in conventional solvent-based paint drying
system s .
The oven atmosphere may be maintained at the aforementioned
slight positive or overpressure of around 0.05 inch w. c. by a conventional
pressure controller 40 (Figure 1) which is actuated by a pressure measur-
ing unit 41 in oven chamber 18. Pressure controller 40 is arranged to con- i
trol the position of either a damper 42 in gas exhaust flue 38 from oven
chamber 18 or a damper 43 in the inert gas supply intake 44 therefor.
The inert gas-solvent vapor mixture or so-called rich fume ex-
hausted from oven 10 is, in accordance with a further aspect of the inven- -~
tion, introduced into a special design incinerator 25, known as a rich fume
incinerator, where the rich fume is incinerated at a temperature of at
least 1400 F. and under approximately stoichiornetric conditions to convert
the rich fume into clean, i. e., nonpolluting, inert gaseous products of com-
bustion or off-gases such as nitrogen, carbon dioxide and water vapor and
having an oxygen concentration of less than about 5 percent, preferably
about 2 percent in the particular paint drying process illustrated, such as
20 are permissible to vent to the atmosphere under existing pollution control
regulations. For the purposes of the invention, rich fume incinerator 25
may be of the type described and claimed in cop~ending application Serial
No. 168, 372, K. H. Hemsath and A. C. Thekdi, filed April 10, 1973 and
assigned to the assignee of the present application. As therein disclosed,
incinerator 25 comprises in general a stack 45 (Figure 1) which is lined on
the inside with refractory bricks in order to preserve heat and into which
the rich fume exhausted from oven 10 is discharged. Disposed about and
above generally c~rlindrical stack 45 is a housing 46 having a lower
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~(~42Z(~l
chamber 47 and an upper or combustion chamber 48, the housing also
being lined with refractory material. Lower chamber 47 has a restricted
cylindrical passageway 49 extending upwardly and opening into upper cham-
ber 48 and terminating a short distance above the upper end of stack 45
with which it is concentric and which it closely surrounds to form there-
between a narrow annular air supply channelway 50. Gombustion chamber
48 is abruptly widened at the upper end of restricted passageway 49, as by
means of the step shoulder 51 in the wall of chamber 48, to provide flame
stabili~ation means for promoting the complete combustion of the rich
fume and pump air mixture within the combustion chamber. Lower cham-
ber 47 also has an opening 53 for an air supply pipe 54 provided with a
manual valve 55. Air supply pipe 54 provides the required quantity of pump
air for the approximate stoichiometric combustion of the rich fume in the
upper or combustion chamber 48 of housing 46. The pump air directed into
the lower end of combustion chamber 48 from restricted annular channel-
way 50 is discharged into the combustion chamber at a velocity grea~er
than that of the rich fume exhaust discharged thereinto from the stack and ;
thus acts as an air pump to aspirate into, and enhance the discharge or `~ ;
emission of the rich ume from stack 45 into the combustion chamber.
20 Additionally, the pump air from annular channelway 50 promotes uniform
mixing thereof with the rich fume discharged from stack 45 so as to better
. ~ . . ,
assure the complete combustion in combustion chamber 48 of all the com-
bustibles in the rich fume introduced thereinto from oven chamber 18. ~
Upper or combustion chamber 48 of incinerator 25 is provided at ~ ~ ;
its lower end, at the region of the intermixing therein of the pump air
from channelway 50 with the rich fume from stack 45, with a number of
pilot or auxiliary gas burners 56 directed tangentially to the combustion
chamber and operated with air and natural gas mixtures proportioned for
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approximate stoichiometric combustion thereof. Pilot burners 56 provide
a pilot flame or ignition source in combustion chamber 48 and assist in
maintaining the combustion chamber at the required temperature of at
least about 1400F., and preferably about 1650F., for assuring the
complete combustion or incineration therein of the combustibles in the :rich
fume discharged thereint~ from stack 45. The supply of combustion air
and gas to pilot burners 56 is preset by manual adjustment of valves 57
and 58 in air line 59 and gas line 60, respectively, to provide the ignition
source for the rich fume-pump air mixture introduced into the incinerator.
Since the solvent concentration in the exhaust gases or rich fumes from
oven 10 is, in the process according to the invention, considerably higher
than that in conventional paint drying systems because of the nonrequire- -
ment for the addition of any dilution air to the oven exhaust gases, the heat
released by the solvent vapor combustion in incinerator 25 is ordinarily
high enough to itself bring the fume-air mixture in combustion chamber 48
to the required incineration temperature of from 1400 to 1650F. Thus,
for the normal operation of the paint drying system according to the inven-
tion, incinerator 25 does not require any auxiliary fuel except for the very
9mall amount for a pilot flame from burners 56. The fuel réquirement of
20 oven 10 is additionally lowered, compared to that required by conventional
systems, because the inert gas heat load is much less than what is required
for the conventional dilution air paint drying systems.
To permit the use of the off-gases from incinerator 25 as the
source of supply for the low oxygen content atmosphere, i. e., no more
than about 5 percent oxygen content, required to be maintained in oven
chamber 18 for the practice of the invention, it is therefore necessary that
these incinerator off-gases contain not more than about 5 percent oxygen.
Since pilot burners 56 in incinerator 25 are operated at approximately
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2~
stoichiometric air-fuel ratio, they release little if any oxygen into the off-
gases from the incinerator. However, the solvent vapors in the rich
fumes introduced into incinerator Z5 from drying oven 10 need oxygen for
their combustion in the incinerator, this oxygen being supplied by the
pump air introduced into lower chamber 47 of the incinerator. The sol-
vent concentration in the gas mixture introduced into incinerator combus-
tion chamber 48 is maintained in such a way that the heat generated by the
perfect, i. e., stoichiometric combustion of the solvent vapors in this nli;x-
ture is enough to raise it to at least the 1400 to 1650F. temperature re-
10 quired to be maintained in the combustion chamber for the complete com-
bustion of the solvent vapors. To assure that the off-gases from incinerator
25 normally contain no more than about 5 percent and preferably around
2 percent oxygen content, the pump air supply to the incinerator is preset .- ~ :
by manual valve 55 in accordance with the design solvent vapor emissions
from oven 10.
For maintaining the oxygen content in the flue or off-gases from
incinerator 25 at the desired low set value, e. g., 2 percent, the electrical
',!., ~
signal from a temperature controller means can be used for this purpose.
The temperature controller means may comprise a thermocouple 61 in com-
Z~ bustion chamber 48 connected by a lead 6Z to a temperature measuring andrecording instrument 63. The signal from temperature measuring and re-
cording instrument 63 is fed through a lead 64 to a fuel controller unit 65
which then actuates the valve 66 in an auxiliary gas inlet 67 to the rich
fume stack 45. As previously stated, pump air supply 54 to incinerator Z5
is maintained constant for a given type of load in oven 10. This constant
flow of pump air is pre-established by design conditions of solvent vapor -
emissions from oven 10. When the solvent concentration in the rich fume
from oven 10 decreases, the temperature of oven 10 also drops with
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ZZ~ .
correspondingly less solvent evaporated therein, causing the oxygen
concentration in the incinerator flue products to rise. When this occurs,
the signal from the temperature controller means 61-63 will cause the
fuel controller unit 65 to open the auxiliary gas supply valve 66 so as to
add more gas fuel and thus more heat to the incinerator 25 by its com-
bustion with the available excess oxygen therein and so reduce the oxy-
gen content in the incinerator flue products. Since the heat release from
the auxiliary fuel replacing the drop-off in the amount of the solvent va-
pors in the rich fumes, and the oxygen requirement for the oxidation or
10 combustion of the solvent vapors and auxiliary fuel are all linearly pro-
portional, the rate of temperature rise in the incinerator combustion
chamber 48 and corresponding flue products therefor will be substantially
the same. ~ conventional type oxygen indicator 68 with a high-low limit,
e. g., 0 to 5. 0 percent oxygen content actuating range, may be used for
the purpose of providing an electrical signal for actuating an alarm when
the oxygen concentration in the incinerator flue gases drops below the
set oxygen concentration limit, in which case an operator will then inves-
tigate the possible problems in the system, such as insufficient pump air.
When the oxygen indicator 68 senses an oxygen concentration above its
20 high limit oxygen concentration setting, the entire system is then shut down
by the automatic closure of all system emergency shut-off gas valves
(not shown) which are actuated by the oxygen indicator 68. In this case,
the entire oven, incinerator and gas recirculation system is automatically
purged with an adequate supply of an inert atmosphere such as nitrogen
for safety against explosion hazard. Under normal operating conditions,
however, including changeover of the paint coated strip 11 or breakage
thereof, the fuel supply to the auxiliary gas inlet 67 will be enough to re-
duce the oxygen percent in the incinerator flue gases below the maximum
set limit. ,;~
. : ' ..
The incineration of the rich fumes from the oven 10 in incinerator
25 in the manner according to the invention as described above results in
the formation of so-called clean incinerator flue or off-gases such as
nitrogen, carbon dioxide and water vapor which are of inert and nonpol-
luting character and which therefore are permissible to vent directly to
the atmosphere under present pollution control regulations. In accord-
ance with a further aspect of the invention, however, these off-gases or
by-products from incinerator 25, because of their inert and substantially
oxygen-free composition, i. e., containing no more than about 5. 0, and
preferably around 2. 0 percent oxygen in this particular case, are recy-
cled at least in part back into oven chamber 18 by recycling means com- `
prising exhaust flue 69 to supply to the oven chamber the inert gas at-
mosphere as well as the heat required for the conduct of the particular ~`~
solvent-evaporating operation to be carried out therein, such as the
illustrated solvent-based paint drying operation. Although the recycled
portion of the off-gases may be enough to supply only a part of the total
heat and total inert gas requirement of oven 10, it is preferable from
economic con~iderations to employ a sufficient amount of the off-gases
from the incinerator to supply all of the total heat and inert gas require-
ment of oven 10.
Inasmuch as the flue or off-gases exiting from incinerator 25
through flue 69 are normally at a temperature in excess of 1400 F. which
is considerably above the 450 to 600F. temperature required in oven
chamber 18 for the paint drying or other solvent-evaporating operation
carried out therein, the off-gases to be recycled back into oven 10 there-
fore must first be cooled down to such lowered oven operating temperature ;~
as by passage of the gases through one or more suitable heat recovery
systems or heat exchangers 70 of the recycling means, such as a water
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or air heater, Ol a low pressure steam boiler, or a heater for a metal
preparation solution employed to prepare metal strip 11 for the applica-
tion of paint coating 12 thereto. The heat thus recovered in heat exchan-
ger 70 can be advantageously employed, as a further economic benefit
of the process comprising the invention, for various supplementary
heating operations.
The flue gases cooled in heat exchanger 70 are exhausted there-
from and discharged, as by a recirculating fan 71, into inert gas intake
44 of oven 10 to thereby supply the inert gas atmosphere for oven cham-
ber 18. As shown in Fig. 1, gas intake 44 may be formed with a mani-
fold 72 from which the inert gases from incinerator 25 are distributed to,
and introduced into oven chamber 18 through a series of gas inlet or sup-
ply openings 73 in sidewall 26 of oven 10. Before their introduction into
oven 10, however, the cooled flue gases from heat exchanger 70 are
preferably first mixed with some of the existing inert gas atmosphere in
o'ven chamber 18 for the purpose of assuring better temperature homo-
geneity of the inert gas atmosphere introduced into oven chamber 1~ with
that present therein during the operation of the system. This intermixing
may be achieved by exhausting a portion of the inert gas atmosphere from
oven chamber 18 through an exhaust opening 74 in sidewall Z6 of oven 10
and conveying the so-exhausted oven atmosphere through a duct 75 into a
suitable mixing means 76 where it is mixed with the cooled inert flue
gases from heat exchanger 70. The resulting gas mixture is then circu-
lated by fan 71 into oven chamber 18 through manifold 72 and gas supply
openings 73 in oven wall 26. The portion of the cooled inert off-gases ;
leaving heat exchanger 70 that is not recycled back into oven 10 may be
supplied to plenums 33, 34 for the production of the aerodynamic seals
31 at the article inlet and outlet openings 19 and 21 of oven 10. Manually
;
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ZO~ ..
set dampers 77 and 78 in respective ducts 79 and 80 which supply the
recirculated cooled inert gases from heat exchanger 70 to oven 10 and
aerodynamic seals 31, respectively, are employed to properly balance
the flow of the of~-gases from incinerator 25 to seals 31, to the atmos-
phere, and recycled to oven 10.
Fig. 3 illustrates a modification of the invention wherein all the
off-gases from incinerator 25 are first passed through one or more heat
exchangers 70 before the unused portion thereof not employed for the heat
requirements of oven 10, or for seals 31, is vented to the atmosphere.
10 In this way, heat recovery from all the incinerator off-gases may be ob-
tained instead of just from the unvented portion thereof. In the particular
case illustrated, the heat recovered in heat exchanger 70 is shown as being
conducted through a duct 81 to a metallic strip preparation section 82 of
the illustrated strip paint coating line, such as for heating a metal prepa-
ration solution used to prepare metallic strip 11 for the application of
paint coatinge 12 thereto. Thus, a further reduction in the total heat re-
quired for the paint coating and drying system i9 obtained.
In the start-up of the paint drying or other solvent vapor releasing
process according to the invention, oven 10 must first be purged of atmos-
20 pheri`c air. For this purpose, any inert gaseous medium such as, for ex-
ample, nitrogen, steam, or combustion products from burners 56 and
auxiliary fuel 67, can be used to purge oven chamber 18. An oxygen indi- `
cating device should be used to indicate when the oxygen content of the oven
atmosphere is less than the maximum permissible concentration thereGf
of no more than 5.0 percent, e. g., about 2.0 percent, before starting
the introduction into oven 10 of the work to be processed therein. Oven
seals 31 are activated before metallic strip 11 or other work conveyor is
started into the oven. Burners 56 and auxiliary fuel 67 in incinerator 25
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~L~4~
will supply the heat for bringing the system to the required oven and
incinerator temperatures and the inert atmosphere to oven seals 31.
Auxiliary fuel 67 will be required during start-up due to the addition to
incinerator 25 of the constant and pre-set amount of pump air through
supply pipe 54 provided with manual valve 55. The incinerator tempera-
ture controller means 61-63 will adjust the fuel input rate to auxiliary
fuel inlet 67. Once the operational conditions are settled, metallic strip
11 or the work conveyor is started into oven 10.
The economic advantages of the paint drying system comprising
the invention will be readily apparent from a comparison of its require-
ments of fuel, air and other utilities with those of a conventional solvent-
based paint drying system in which the drying oven is operated with an
atmosphere below the lower explosion limit of the gas mixture formed in
the oven during the drying operation instead of above the upper explosion ;-
limit thereof as in the process according to the invention. For example,
in a conventional system used for comparison purposes and including a
fume incinerator, a preheat recuperator, and a heat transfer liquid
medium for total heat recovery, the gas consumption thereof is approxi-
mately 41, 000, 000 BTU per hour, and the heat transfer rate to the work
is aFproximately 7, 000, 000 BTU per hour. For the same heat demand
in the paint drying oven 10, a properly designed paint drying system ac-
cording to the invention reduces the fuel consumption to less than
5, 000, 000 BTU per hour or only 12 percent as much fuel requirement.
The fresh air requirements of the system according to the invention are
only 200, 000 s. c. f.h. (standard cubic feet per hour) or about 13 percent ;~
of the 1, 500, 000 s. c. f. h. required by the conventional system. In ad-
dition, the lower fume volume of approximately 525, 000 s. c. f.h. for the , ;
process cornprising the invention compared to the 1, 300, 000 s.c.f.h. for
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. '
the conventional system makes it possible to employ smaller size
exhaust fans, piping, and the incinerator itself, thus further effecting
economies in the form of reduced cost for the required eequipment. --
Insofar as the quality of the finished paint coating is concerned, '
comparative tests of thermosetting type paint samples indicate that the
composition of the atmosphere in the drying oven 10 does not have any
effect on the finished paint properties or color characteristics. As a
matter of fact, the inert atmosphere employed in paint drying oven 10
in accordance with the invention retains the paint qualities when the paint
is exposed to such inert atmosphere for a long time, whereas with high
oxygen-containing atmospheres such as are employed in the drying ovens
of conventional paint drying systems the paint pigments are oxidizied and
become darkened. Thus, if anything, the drying of solvent-based paint
coatings in inert gas atmospheres in accordance with the invention
actually results in better paint finishes and quality.
~, i ,
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