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Ystral Conti-TDS - A new Dispersion Technology in Lacquer and Paint Production Dr. Hans-Joachim Jacob | 用于涂料生产的一种新型分散技术 — 德国ystral公司的Conti-TDS Dr. Hans-Joachim Jacob |
Dissolvers were invented in the middle of the last century and have survived in lacquer and paint production until today. They have too many disadvantages, limitations and negative effects on the final product. | 高速分散机发明于上世纪中叶且仍在当今涂料的生产上使用。此类设备存在太多缺点和制约，对成品产生负面影响。 |
The ystral Conti-TDS - a new and advanced dispersion technology - has started to displace traditional High Speed Dissolvers in Lacquer and Paint Production. This new technology enables enormous reductions in production costs and process times. Additional effects are a higher degree of dispersion, improved quality and raw material savings. The energy consumption is reduced to about 30% compared to the old dissolver technology. | 德国ystral公司的Conti-TDS 是一种新型的、先进的分散技术，已开始在涂料生产上替代传统的高速分散机。这项新技术能够极大的降低生产成本和减少加工时间，达到更高水平的分散度，改善产品品质和节约原料等的附加效果。相比之下，这项新技术的能耗降低至只有传统高速分散机的30%左右。 |
Ystral Conti-TDS | 德国ystral Conti-TDS 这项新技术灵活性高并且可以根据需要容易的扩展。与同样产能的传统高速分散机相比，投资成本要低40%以上。 |
Dispersion is the most important process in lacquer and paint production and has the highest influence on the quality of the final product. The better the dispersion the higher is the efficiency of the dispersed pigments, extenders, rheology modifiers and all other functional additives in the final coating. Traditional high speed dissolvers are simple free rotating discs with up- and down-bent teeth at their circumference. Due to the wide distance between the rotating dissolver disc and the static wall of the vessel the shear gradient is very low: just about 50 reciprocal seconds. To create shear forces with such a low shear rate a dissolver needs a very high viscous liquid or at least a shear thickening or dilatant rheology. Lacquers and paints have exactly the opposite rheology: they are low viscous, shear thinning and thixotropic. A dissolver cannot create significant shear in a low viscous lacquer or paint. To shear with a dissolver the viscosity has to be increased extremely. For that reason the dissolver process starts with more thickeners than required and just a part of the liquids to get a higher viscosity. This is completely paradox since the most ingredients which have to be dispersed are very fine powders (pigments, silica, fillers and extenders). Making a liquid extra high viscous before adding finest powders is absurd. The higher the viscosity the worse is the wetting and dispersion of fine powders. A high viscous liquid will not get into smallest capillaries and cannot wet fine particles as fast and complete as a low viscous liquid. The consequences are stable agglomerates, low qualities, extra-long dispersing and milling times, heat generation and a waste of energy. Adding thickeners at begin of the process is negative for another reason: Most thickeners are shear-sensitive polymers. During dispersion the polymers get partially destroyed. Their effect goes down in an uncontrolled manner. For that reason you have to add more thickeners than required and you get uncontrolled and unpredictable viscosity levels at the end of the dissolver process. Finally you have to adjust the viscosity again. In other industries dissolvers have disappeared since years. Now the dispersion technology in lacquer and paint production has started to change to Conti-TDS – worldwide.
| 分散是涂料生产中最重要的工序，其对成品品质的影响最大。分散的效果越好，最终涂层中分散的颜料、填充剂、流变改性剂和所有其他功能添加剂的效率就越高。 传统的高速分散机是简单的自由旋转的圆盘片，其圆周上有向上和向下弯曲的齿。由于转动的分散盘与容器的静态壁之间的距离较宽，剪切速率非常低：大约只有50S-1 。在如此低的剪切速率下产生的剪切力，高速分散机需要很高粘度的液体或至少产品具有剪切增厚或膨胀的流变特性，然而涂料具有与之截然相反的流变性:它们是低粘度的、具有剪切变稀和触变性。高速分散机无法在低粘性油漆或涂料中产生显著的剪切效应。利用高速分散机进行剪切分散，必须极大提高产品的粘度。因此，高速分散机的分散过程从一开始就需要加入比需要的更多的增稠剂，且仅加入部分液体以获得更高的粘度。 这实际上是完全矛盾的，因为必须被分散的大多数的添加成分都是些非常精细的粉料 (颜料、硅土、填料和填充剂)，在添加微细的粉料之前先将液体制备成高粘度是很荒谬的。粘度越高，对微细粉料的润湿与分散就越差。高粘度的液体无法进入最小的毛细管，无法像低粘性液体一样快速和完全的润湿颗粒。其后果导致稳定的团块，品质低，分散和研磨时间加长，产生热量并且浪费能量。 在分散开始时添加增稠剂有负面作用的另一个原因：大多数的增稠剂是剪切敏感的聚合物，在分散过程中，聚合物会有一部分受到破坏，它们的功效以不可控的方式下降。因此，增稠剂的添加必须比必要的更多，当高速分散结束时，得到的是无控制的和不可预测的粘度。最后，粘度必须再调整。 在其它行业，高速分散机已消失多年。如今油漆和涂料生产的分散技术已开始在全球范围内向Conti-TDS转变。 |
Conti-TDS Technology | Conti-TDS技术 |
Ystral Conti-TDS Technology is based on an inline dispersing machine which is able to induct and disperse powders into liquids under high speed and vacuum. The machine is installed outside the process tank and recirculates the liquid with high speed. Additional pumps are not required.
德国ystral公司Conti-TDS 技术是基于一种在线分散机，能够在高速运转和真空下导入粉体，使粉体分散至液体中。该机器安装在工艺混合罐外部，让液体以高速打循环，无需额外的泵。
Picture 1: ystral-Conti-TDS with process tank and big-bag station
图 1：ystral-Conti-TDS 连接循环罐和大袋解包站
The core of the machine is the dispersing chamber equipped with high shear tools. In the high-shear dispersing zone it creates a shear rate of 50.000 reciprocal seconds. This is 1000 times higher shear compared to the dissolver. High liquid viscosities or additional thickeners are not required. Exactly in this zone the machine creates a very strong vacuum. With this vacuum it inducts powder directly from bags, bag tipping stations, hoppers, drums, containers and big bags into the liquid. No vacuum tank and no vacuum pump is required which pulls uncontrolled amounts of powder or effluent vapor out of the liquid into filters or exhaust systems as it happens in vacuum dissolvers. The induction is dust-free because 100% of all the powder goes into the liquid. Dust pollution of the working area is completely avoided. The powder is inducted into the recirculating liquid loop and arrives in the vessel as a liquid dispersion. No dust appears above the liquid; no partially wetted agglomerates and crusts are built up above the liquid surface and then fall into the liquid and reduce product quality, a common problem with dissolvers. | 机器的核心是内部装配有高剪切部件的分散腔。在该高剪切分散区能产生50’000S-1的剪切速率。这个剪切速率比高速分散机高1’000倍，不需要提高液体粘度或额外添加更多的增稠剂。 在此分散腔内机器能产生一个很强的真空，利用这个真空，机器可以直接从袋子、包袋的倾倒站、粉料斗、各种桶、容器和大袋中吸入粉体，使粉料进入液体。不需要将混合罐抽真空，也不需要加真空泵，带抽真空的高速分散机会带走无法控制的粉体量或使液体中产生的废蒸汽进入过滤器或排气系统。粉体吸入是无尘的，因为100%的所有粉料都会被导入液体中，从而杜绝了工作区域的粉尘污染。 粉末被吸入液体的循环回路，成为液状分散体到达容器。不再有粉尘出现在液体之上; 不再出现局部浸湿的团聚体和结壳积聚在液体表面后又落入液体中和品质降低这些高速分散机的常见问题。 |
Picture 2: ystral Conti-TDS with liquid and powder connections
图2：ystral conti-TDS 与液体和粉体连接
The dispersion of the powder into the liquid is always done under equal, constant and controlled conditions, independent from the speed of the operator. The product quality is absolutely reproducible, even for different batch sizes.
将粉料分散至液体中始终是在相同的、连续的并且是受控的条件下完成的，与操作人员的动作快慢无关。产品质量可完全重复再现，即便对于不同大小的批量。
Constant quality has been one of the biggest problems with dissolvers. Particle size, color strength, viscosity, matting effect and film formation are influenced by the way how the operator has added the powder. The quality changed from batch to batch, from operator to operator. Slower powder addition caused longer process times, higher temperatures, lower viscosities. Faster addition caused more agglomerates and further processing time, longer shear, higher temperatures and lower viscosity. Dissolver batches always had to be quality checked – adjusted – checked and adjusted again. These steps took time and blocked the process tanks during waiting for the QC results. | 达到恒定的品质一直是高速分散机存在的最大问题之一。颗粒度、色强度、粘度、消光效应和成膜效果都受到操作者添加粉料方式的影响。从批量到批量，从操作员到操作员，品质都在变化。较慢地添加粉体导致加工时间过长，温度更高，粘度更低；较快地添加粉体又会导致更多的结块和进一步延长加工处理时间，更长时间的剪切，更高的温度和更低的粘度。高速分散机的批量总是必须经过质检- 调整- 再质检和再调整。这些步骤花费时间，等待QC结果的时间阻挡了工艺混合罐。 |
Some Results with Conti-TDS The Conti-TDS produces absolutely constant qualities. The viscosity is constant. And thickeners are not destroyed – what means that often up to 20% of the thickener can be taken out. This is the amount which is typically over dosed and destroyed by the long dissolver process. Picture 3 shows a typical particle size distribution for the induction and dispersion of titanium dioxide.
Immediately after induction the result is already much better than reference samples produced with Dissolver and Mill. The medium particle size is already 0.46 µm. 99,9 % of the particles are below 2 µm. Not any oversized particle is visible. The distribution is very narrow. After 120 sec additional dispersion the medium particle size goes down to 0.38 µm. 100 % are below 2µm and 98% are below 1µm.
The color strength of the titanium dioxide dispersions produced with Conti-TDS is always much higher. For that reason the amount of Titanium Dioxide may be reduced with even better performance than dissolver dispersions. Titanium dioxide is the most important pigment in lacquer, paint and ink production. It covers more than 59% of the global pigment demand. The prices for titanium dioxide are rising since 2009. Companies which are using the Conti-TDS for titanium dioxide are reporting about enormous savings. They save time, energy and a significant amount of raw material because of the better dispersion. But even all other pigments, matting agents, extenders and fillers are dispersed faster and with better results – for all water born and solvent born lacquers, paints and printing inks.
Installation and Operation The machine is installed in recirculation with a process tank. This way it operates independently from vessel size and filling level. To double the capacity with minimum additional costs one machine is often installed between two vessels (picture 4). You need just one machine, one control system and one powder addition point to double the production output. |
Conti-TDS的一些结果 Conti-TDS可以生产出完全均一恒定的质量。粘度是恒定的，增稠剂也不会被破坏，这意味着通常高达20%的增稠剂可以省去，这个数量也是通常被过量添加和被高速分散机长时间溶解所破坏的量。
图3显示了钛白粉的吸入和分散的典型粒径分布 图 3：钛白粉被吸入后分散30秒、60秒和120秒的粒径分布
在粉体被吸入后可即刻获得比高速分散机和磨机生产的参照样品好得多的结果。中粒径已达到0.46µm。99,9%的粒子小于2µm。没有任何大的粒子可见，粒径分布很窄。经120秒延时分散后中粒径下降至0.38µm，100%小于2µm和98%小于1µm。 使用Conti-TDS 生产的钛白粉分散体的色强度总是要高很多。因此，与高速分散机相比，即便减少钛白粉的用量都能达到更好的品质性能。 钛白粉是生产油漆、涂料和油墨最重要的颜料。它覆盖了全球颜料59%以上的需求。钛白粉的价格自2009年以来就处于上涨。使用Conti-TDS加工钛白粉的厂家的报告了他们巨大的节省。因为这种更好的分散，他们节省了时间、能耗以及大量的原料。 然而所有其它颜料、消光剂、填充剂和填料，都能被分散得更快，达到更好的效果—对于所有水基和溶剂基的油漆、涂料和印刷油墨。 安装与运行 机器安装在与一台工艺罐的循环连接的回路中。如此，机器的运行不受罐体大小和罐的料位影响。以最小的花费让产能翻番的办法经常是将一台机器安装在两台工艺罐之间（如图4）。你只需一台机器、一个控制系统及一个粉料加料口就能让产能翻番。 |
Picture 4: Conti-TDS-5 between two process tanks
图4：两台工艺储罐之间的 Conti-TDS-5
During production in one vessel the other vessel is discharged from the last batch and filled with the liquid for the next batch already. In the average 50 seconds after finishing the powder induction the required particle size is reached and the product is ready to transfer. When the batch is ready to discharge the machine automatically switches over to the second tank and starts the process there. This way it is possible to produce up to 20.000 kg finished paint per hour with just one machine, even in a continuous and uninterrupted production.
All Conti-TDS systems have an integrated and paint industry approved automatic cleaning unit. To keep the process system always clean every single batch includes a cleaning step. A part of the process liquid is added through the cleaning heads and keeps the tank and all relevant parts clean. Even if the following batch is the same product the vessel is cleaned automatically. Additional cleaning with extra liquid is possible if there is a product change between incompatible materials or different colours. Inside the process tanks there are high effective jet stream mixers installed which are moving and turning the liquid vertically. These mixers provide an instantaneous homogeneity. This is important because of the high speed powder addition. Simple agitators with mainly horizontal rotation are not able to mix the liquid homogenously and fast enough.
Economic Advantages and Flexibility Additional to the technical advantages there are obvious economic advantages with this new Conti-TDS-technology as well. The production costs of paint are typically reduced to below 10% compared to the dissolver process. Additionally, a significant reduction in raw materials is possible because of better dispersion, higher color strength and less thickener demand. A reduction of the production times to below 20% is typical. Consequently, energy savings down below 35% are reported as well. Generally the Conti-TDS guarantees higher product quality, much higher flexibility in the production and a much higher level of safety. The foot print of a Conti-TDS system is just some square meters. Because of the much faster process one Conti-TDS can always replace a number of dissolvers – on a very small space. Investment costs are much lower. For a new installation the investment costs are about 60% lower compared to conventional dissolvers. The return of investment is often shorter than 6 months. Another advantage is the short realization time: Normally it takes just between half a year and one year from the decision to the production. Today flexibility is getting more and more important. With such a system it’s possible to produce very effectively different formulations and variable batch sizes. Because of the compact design it is easy to expand the capacity if required in future. Since the machine is working independently from the vessel size it is possible to enlarge the process tanks in future if required. Therefore just the process tanks and their mixers are exchanged – nothing else. The core of the system – the Conti-TDS and the automatic control - remains untouched. The machines are already used in all fields of the industry in an extremely wide field of applications. All types of products, all viscosity ranges and all types of raw materials are processed. If there are completely new demands in future it is easy to restructure the process. The final product quality of the produced lacquers and paints is at least equal, in most cases are better than using traditional dissolvers.
| 当生产还在一台循环罐中进行时，另一台循环罐已排空上一个批量并完成下一个批量液体的加料。粉料吸入结束后的平均50秒内，所要求的粒径已达到且产品已准备好转移。当本批量的产品准备排料时，机器自动切换至第二台循环罐开始生产，如此只用一台机器就可达到每小时生产20’000kg的成品涂料，即便是以连续不间断的方式生产。
所有的Conti-TDS系统都有经涂料行业证实的集成的自动清洗装置。为了保持工艺系统的洁净，每个批量都包含一个清洗步骤。配方中的部分液体通过清洗喷头加入，保持循环罐和所有相关部件的清洁。即使下一批是相同的产品，循环罐也会被自动清洗。如有不兼容的原料或在不同颜色之间进行产品更换，则可以追加液体进一步清洗。
工艺罐内装有高效的捷流混合器，它能垂直推动和上下转动液体。这些混合器起到瞬间均混的作用。这一作用非常重要，因为粉料是高速吸入的。以水平方向旋转为主的简单搅拌器不能做到均匀混合的，也不足够快。
经济优势和灵活性 除了技术优势外，新型的Conti-TDS技术也具有明显的经济优势。与高速分散机工艺相比，涂料的生产成本通常降低到10％以下。此外因为更好的分散、更高的着色强度和需要的增稠剂更少，可显著减少原料用量。典型的是将生产时间缩短到原来的20％以下。据用户的报告能耗节省至不到原来的35％. 通常Conti-TDS保证达到更高的产品质量、更高的生产灵活性和更高的安全水平。 一台Conti-TDS的占地面积只有几平方米。由于更快的加工速度，一台Conti-TDS 能够在非常小的空间上替代好几台高速分散机。
投资费用相对低许多。对于一条新的装置，与几套传统高速分散机相比，投资成本大约不到其60%。投资回报一般不超过6个月。另一个优点是项目建成时间短：通常从决定到投产运行只需要半年到一年的时间。 今天灵活性越来越重要。采用这样的系统，可以非常有效地生产不同配方的产品和各种大小的批量。由于设计紧凑，很容易实现未来扩产的需要。
由于机器的操作不受工艺罐大小的局限，可根据未来需要扩大工艺罐，只需更换工艺罐和罐内的混合器，再无其它，而装置的核心机器 Conti-TDS及自动控制系统 – 维持不变。
该系列机器已在各行各领域中得到了极为广泛的应用。所有类型的产品、所有粘度范围和各类型的原料都被加工过。如果未来出现全新的需求，工艺的重组也很容易。 生产的油漆和涂料的成品至少能达到相同的质量，绝大多数情况下比传统高速分散机所达到的质量更好。 |
Dr.-Ing. Hans-Joachim Jacob, Process- and Application Engineering
Hans-Joachim Jacob工程学博士，工艺与应用工程
· Studies at the Dresden University of Technology 1981 to 1986 in Mechanical Engineering
1981至1986年就读德雷斯顿技术大学机械工程
· Since 1990 at the company ystral gmbh maschinenbau + processtechnik
自1990年 就职于德国ystral公司机械制造工艺+过程技术部
· Senior process engineer and customer application specialist
高级工艺工程师及客户应用专家
· Special expertise: Mixing, Emulsifying and Powder dispersion into liquids
专业知识：混合、乳化剂及粉体在液体中分散
如想了解更多请联系：
伊思创（北京）工艺技术有限公司
北京市朝阳区东三环北路8号亮马河大厦二座7层706室, 100004
For more information pls contact:
Ystral (Beijing) Process Technology Co., Ltd.
Landmark Tower 2, Unit 0706, 8 North Dongsanhuan Road
Chaoyang District, Beijing 100004 P.R. China
Phone: +86-10 6501 8070
Mobile: 13811270857
Email: ystral.china@ystral.com
www.ystral.com
