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Eisenmann presents an electrostatic separation system for paint overspray
 Boost efficiency, save energy, avoid CO2 emissions – these are today's strategies for successful and sustainable production, particularly in challenging times. With E-SCRUB, the plant engineering specialist Eisenmann operating on an international level now presents an electrostatic separation system for paint overspray that implements precisely these strategic aspects. The objective was clear: a separation system that benefits the environment, saves resources, cuts operating costs, is robust, reliable and easy to use and can be retrofitted without difficulty in existing plants.
"I am delighted to say that we have achieved these goals with E-SCRUB and can now offer our customers a highly efficient, environmentally beneficial and economical solution for their painting systems," says Dr. Kersten Christoph Link, chief technical officer of Eisenmann AG.
 Basic functional principle of E-SCRUB
With E-SCRUB, the air in the spray booth is specifically routed to guide the surplus paint mist (overspray) produced during the painting process via funnel-shaped run-off surfaces known as flood sheets into the new electrostatic separation system. Part of the overspray is immediately bound by separating agent on the flood sheets which transports the paint particles into a collecting pan at the bottom.
Most of the overspray is diverted into so-called separating modules at the bottom of the flood sheets. These high-voltage modules are fitted with positively charged separating plates which are also rinsed with separating agent in a circulating system. High-voltage wires additionally run horizontally between the separating plates inside the module. Paint particles in the circulating air stream become negatively charged as they pass the high-voltage wires and are attracted by the positively charged separating plates. Here too, the paint particles are bound by the separating agent and discharged into the collecting pan at the bottom.
Due to the chemical composition of the separating agent, the bound paint particles combine in the collecting pan to form solid agglomerates which can be removed and disposed of without difficulty.
 Energy-efficient and environmentally beneficial
E-SCRUB combines maximum separating efficiency with minimum pressure loss, permitting operation with 95 percent recirculated air. Compared with a conventional wet scrubber section, this results in distinct energy savings of up to 78 percent and a corresponding reduction in CO2 emissions. In addition, E-SCRUB requires up to 87 percent less water and considerably less chemicals. The electrostatic system switches on and off in accordance with production, yielding further energy savings.
 Separating efficiency is maximized by electrostatic charging and binding the overspray in the separating agent. The clean air regulation "TA Luft" permits maximum dust emissions of 3 mg/m3 – with E-SCRUB, this value can be reduced to 0.3 mg/m3. In combination with recirculation of the air, this consequently reduces particulate emissions up to 100-fold.
Quality and reliability in production
By eliminating complex mechanical filter systems, E-SCRUB ensures constant flow rates without pressure fluctuations – an essential prerequisite for optimum production conditions and high quality coatings. In operation, E-SCRUB is characterized by considerably lower noise levels and easy servicing.
Simple retrofit, rapid amortization
Another advantage of E-SCRUB is that it can be retrofitted quickly and simply in existing plants. Moreover, E-SCRUB requires considerably fewer plant components than a conventional wet scrubber system.
 E-SCRUB from Eisenmann is the energy-efficient, environmentally beneficial and cost-cutting alternative to wet and dry separation in spray booths. It cuts operating costs significantly, thus ensuring rapid amortization of the investment costs.
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