Application of Kaolin in the Production of Water-based Coatings

Application Analysis

The application of calcined kaolin in water-based coatings can greatly reduce the production cost of coatings, and the research and development of water-based coatings can consume part of the finished kaolin products and substandard products, which not only reduces the production cost of coatings, but also increases the economic benefits of kaolin.

Production Process

The production of conventional latex paint is divided into two major processes: dispersion and stirring.

The purpose of this experiment is to improve the dispersion efficiency and shorten the dispersion time during dispersion

When dispersing at high speed, the inorganic thickening powder is generally put in first, pre-dispersed for 30 minutes, and the powder is added to disperse for 30 minutes after passing the inspection

At the same time, each ton of latex paint can save half an hour of power consumption.

This experiment has been tried on the production line, and the effect is remarkable, the operation is convenient and fast, if it is checked and approved according to the annual production volume, it can not only save energy and reduce consumption, but also can produce quickly and deliver timely, which can bring certain benefits to customers.

Production formula process

As the most important white pigment and filler in the production process of water-based coatings, titanium dioxide mainly provides tinting strength and covering power.

The application of kaolin in water-based coatings plays a key role in reducing the cost of water-based coatings

Kaolin is clay with kaolinite as the main component.
It is an inorganic silicate with crystal water.
It is soft and slippery, and is easy to disperse in water
.
Calcined kaolin is prepared from high-quality kaolinite through selection, grinding, impurity removal, calcination and other processes
.
It is characterized by high whiteness, good dispersibility, and strong covering power, which can replace part of titanium dioxide
.

Through experimental demonstration, the application of kaolin in coatings improves the opacity of the paint film, and improves the optical properties, wear resistance and stability of the paint
.

During the debugging process, the covering power of the latex paint film with the addition of calcined kaolin is generally improved.
Of course, this situation does not exclude the dilution effect of calcined kaolin on titanium dioxide, but the important thing is that after adding calcined kaolin, the porosity of the coating film is very large.
In addition, the water dispersion of ultrafine particles of calcined kaolin has a strong refraction effect on light, so after adding calcined kaolin, the wet paint film is also partially covered
.

With the increase of the amount of calcined kaolin, the covering power of the dry film of the coating is obviously improved, the water resistance and alkali resistance have no obvious changes, and the scrubbing resistance is improved to a certain extent.
The system has a special meaning
.
Secondly, with the increase of the amount of calcined kaolin, the amount of titanium dioxide can be appropriately reduced, and the production cost can be reduced without affecting the covering power of the paint film
.

Production equipment

The equipment and process design of the new project breaks the traditional design concept, uses natural science, and combines the actual situation.
In the case of a fixed space in the workshop, a three-layer platform-type production process is adopted to maximize the use of the effective space, and the platform-type structure enables the equipment to interact with each other.
Connected in parallel as a whole, the operation radius is shortened, and it is beautiful and neat
.
The overall equipment is divided into pure water unit, auxiliary batching station, negative pressure conveying unit, horizontal real stone paint production section, aseptic production of water-based interior wall latex paint, exterior wall latex paint production section, water-based industrial paint production section, 7 major sections including VOC adsorption tower, sewage treatment station, dust collection and environmental protection unit
.
Each section is connected to each other and can be started independently or used in series
.

(1) Pure water unit, the daily production of pure water is 10t for production use.
Compared with domestic water, pure water is not easy to produce mildew in coatings.
Most of the mineral ions are filtered out, which can make the product performance more stable and long-term storage
.

(2) The latex paint and real stone paint equipment all adopt the self-weight cutting process at the top of the dispersion kettle; the traditional feeding method is negative pressure suction, and the material is fed through the bottom of the dispersion kettle
.
The specific operation is to first use a negative pressure unit to pump the dispersion kettle into a vacuum state, so that the negative pressure in the kettle is generally maintained at 0.
06MPa to form an internal suction, open the valve connecting the feeding hopper and the dispersion kettle, and use the negative pressure suction to inhale the material into the in the dispersion kettle
.

Due to the limitation of the production process, the production water and additives have been put into the kettle before the material suction, and the material must be sucked from the bottom.
Therefore, if the valve is not well controlled, the water emulsion will flow back into the pipeline at the bottom of the dispersion kettle, and the cleaning is cumbersome, and it will not be used for production.
bring a lot of inconvenience
.
The new equipment is changed to top self-weight feeding, which means that the feeding platform is built on the equipment, the feeding hopper is connected to the dispersion kettle, and the material falls directly into the dispersion kettle by its own gravity.
Completed, it not only saves the feeding time, but also does not need auxiliary equipment such as negative pressure pump, which saves a part of the electricity bill
.

Example of old equipment: It usually takes 45 minutes to produce one ton of latex paint in the feeding section.
At least 2 operators are required to complete each feeding, one feeding and one controlling the valve to prevent the negative pressure in the kettle from being insufficient to form backflow; while a negative pressure pump It is usually 22kW.
It is turned on for 45min when feeding, and the power consumption is about 16.
5kW·h.
According to the production level value of 0.
5 yuan/kW·h, a cost of 8.
25 yuan is incurred
.

The newly designed feeding method can complete the feeding task with only one feeding worker, and there is no need to worry about the situation that the negative pressure is not enough for the backflow of the water and emulsion.
The newly designed equipment can complete the feeding in only 20 minutes, because the dispersing kettle must be started during feeding to prevent Material press, the power of a 1t dispersion kettle is 30kW, and the production of new equipment can save 20min of dispersion time, so it can save 10kW·h electricity, about 5 yuan in electricity costs, plus 8.
25 yuan saved by the negative pressure unit, per production 1t of latex paint can save 13.
25 yuan, and according to the annual output of 3,000t of latex paint, it can save about 40,000 yuan per year
.

(3) The main production process of the old real stone paint kettle equipment is divided into two parts.
One is to disperse the water emulsion with a floor-type disperser, and then use a forklift to lift the dispersed water emulsion cylinder and put it into the horizontal stirring kettle.
Use a forklift to pick up the colored sand and manually throw it into the stirring kettle.
Take the existing 30t real stone paint stirring kettle as an example
.

It takes at least 3 days to produce and pack 30t of real stone paint: 1.
5d to disperse the water emulsion, 6h to cast colored sand, and 1d to pack; and the new production line is changed to a linked production mode, equipped with a 5t large water-emulsion dispersion kettle, and the pneumatic diaphragm pump is connected to the 30t real stone paint for stirring The kettle, the water emulsion is formed at one time, and the pump is pumped into the 30t stirring kettle.
For sand feeding, the colored sand is first lifted to the feeding platform on the third floor by a hoist, and then lifted to the feeding port by a small crane, which saves time and effort.
The current equipment only takes 3 hours to complete the sand feeding and 12 hours to disperse the water emulsion.
The current equipment only takes 5 hours to complete the packaging time, and the previous 8 hours packaging time is now switched to a filling machine.
When three feeding ports are packaged at the same time, 3 tons can be packed in 20 minutes.
, 30t only takes 3.
5h to complete
.
In the case of joint operation, the production and packaging of 30t can only be completed in 12h
.

economic benefits

(1) Assuming the implementation of the project, the annual production of 10,000t of water-based environmental protection paint and 3,000t of latex paint can create a turnover of 24 million yuan and a profit of 7.
2 million yuan a year
.
7000t of real stone paint can create a turnover of 31.
5 million yuan and a profit of 9.
45 million yuan each year, with an annual increase of 16.
65 million yuan in total profit
.

(2) Calculated according to the annual production capacity of 3000t, each ton of water-based paint can save about 25kg of 2.
5% titanium dioxide, and need to add 50% of kaolin to about 50kg
.
According to the current market average price of chemical materials, the price of rutile titanium dioxide is 19 yuan/kg, and the price of coating-grade kaolin is 1.
8 yuan/kg.
It can be calculated that producing 1 t of paint can save 475 yuan of titanium dioxide and increase the cost of 90 yuan of kaolin
.