FIELD OF INVENTION
The invention relates to industrial coating material comprising processed paint
sludge, composition comprising paint sludge treated with regeneration chemicals and a
process for converting the paint sludge into industrially reusable paintlprimer, wherein
the process saves time and energy by cutting down energy intensive and time consuming
steps.
BACKGROUND AND PRIOR ART
Disposing of paint sludge is an issue that persists in the paint industry. It is
hazardous to dump such waste in the open environment as it would result in toxicity to
the environment and ground water. This sludge is not biodegradable or degrades at a slow
rate.
Indian Patent No. 247640 relates to a process using such paint sludge for making
reusable raw material for paints. However, the process of this patent requires transferring
the sludge to the mill after washing and thereafter treating the paint sludge into ball mill
or bead mill which is time and energy consuming and comprised of increased quantity of
paint sludge and thereby increased waste resulting in more time and energy for washing
and recycling.
In pursuit to make the process more eco-friendly by reduction in energy and time
consumed for recycling and for increasing productivity of the process employed in
converting paint sludge into reusable paint or primer the process of the present invention
was developed for processing the industrial paint sludge as raw material for producing
reusable industrial paintslprimers with better properties.
Accordingly, there is a need for improved process for recycling and converting
the paint sludge for optimum use to produce reusable paintslprimers.
Accordingly, the present invention relates to a modified process for recycling
1 1 paint sludge into reusable painuprimer. Also, new modified type of resins have been
introduced in the chemical composition to obtain enhanced paint properties.
OBJECT OF THE INVENTION
An object of the present invention is to provide an industrial coating material
comprising processed paint sludge.
Another object of the present invention is to provide a modified process with low
energy consumption and highest efficiency for preparation and conversion of paint sludge
into industrially usable painuprimer.
Still another object of the present invention is to provide a composition paint
sludge and regeneration chemicals as raw material for industrial coating material.
SUMMARY OF THE INVENTION
The invention relates to an industrial coating material comprising
processed paint sludge, composition comprising paint sludge and regeneration chemicals
and also a process for converting the paint sludge into industrially reusable paintlprimer,
wherein the process saves time and energy by cutting down energy intensive and time
consuming steps.
One of the embodiments of the present invention provides an industrial coating
material comprising a processed paint sludge obtained by treating the paint sludge with
regeneration chemicals wherein the paint sludge is varied in the range of 40-70%.
Yet another embodiment of the present invention provides regeneration chemicals
comprising of surfactants in the range of 0.05 to 0.17%, solvents in the range of 1 to
16%, resins in the range of 3 to 31%, pigments in the range of 0.5 to 12%, solvents in the
range of 0.8 to 30% and additives in the range of 0.1 to 0.6% depending on the total
formulation
- 2 " . \ -
CC
t
In one of the embodh f ;ke' present invention the paint sludge is selected
from the group consisting of amino alkyl based paint sludge, epoxy paint sludge, acrylic
based paint sludge, polyester melamine based paint sludge, aminopolyester paint based
sludge, thermosetting acrylic sludge, urea formaldehyde, silicon or modified silicon
based paint sludge and acrylated alkyl paint sludge or mixtures thereof.
In a still another embodiment of the present invention, the resin is either a Quick
Drying alkyd (QD) Resin, Melamine Formaldehyde (MF) Resin, Epoxy Resin or a
combination thereof wherein the quick drying alkyed resin is based on coconut oil, soya
oil, linseed oil, CNS oil or rapeseed oil.
In still further embodiment of the present invention, the pigment is selected from
the group consisting of china clay, barytes, calcite, zinc oxide, zinc chromate, talcum,
silica powder (micropulverised), titanium dioxide, carbon black or any other conventional
pigments or conventional coloring agents.
In yet another embodiment of the present invention, the solvents are selected from
the group consisting of methanol, xylene, toluene, or iso butanol.
In a further embodiment of the present invention, the additives are selected from
the group consisting of anti-setting agents, anti-corrosion additives, thickening agents,
dispersing agents, anti-oxidants, plasticizers, bonding agents, gloss improvers, drying
agents and any other conventional property enhancing additives.
Another embodiment of the present invention provides a process for the
preparation of a composition for conversion of paint sludge into reusable paint wherein
the process comprises of:
(a) collecting paint sludge;
(b) subjecting the paint sludge to homogenization or dispersion followed by
washing with demineralized water and addition of surfactant in a pug mill;
(c) subjecting the homogenized paint sludge obtained at the end of step (b) to
coarse filtration to remove particles larger than +lo0 mesh therefrom;
G E3 - L 1 \ 1 w s
(d) subjecting the filtlred sludge to chemical blending or regeneration chemicals
with continuous stirring in the pug mill;
(e) subjecting the mixture of step (d) to milling or grinding to obtain a particle
size of +3 to +6 Hegman's Guage fineness;
(f) filtering the mixture of step (e) to a particle size of +5 Hegman Guage to +8
Hegman's Gauge to obtain reusable paint/primer.
wherein the process is are carried out in the same machine or apparatus.
A still another embodiment of the present invention provides a process, wherein
in step (b) optionally milling is carried out prior to homogenization.
In still another embodiment of the present invention, wherein in step (d) of the
process chemical blending comprises of addition of surfactants, resins, pigments, solvents
and additives.
A further embodiment of the present invention provides resins that acts as a
drying agent by homogenizing with any quantity of water thereby eliminating the
requirement of a separate drying step in an oven or dryer.
Still in another embodiment of the present invention, the process can be carried
out in a machine or apparatus such as Pug Mill, Ribbon Blenders, Attetors or by High
Speed Dispersion Machines.
Yet in another embodiment of the present invention, the machine or apparatus is a
Pug Mill.
In a further embodiment of the present invention, the surfactant is anionic
surfactant.
Sill in another embodiment of the present invention, the surfactant is Alphox (9.5
Mole - Non-Toxic Type).
3 Yet in another embodiment of the present invention, the water used for washing is
demineralised water.
Still in another embodiment of the present invention after washing the water is
removed under gravity.
In still another embodiment of the present invention, the process may be used in
epoxy-amino/phenolic system (single pack - Stoving system), alkyd-amino system,
thermosetting acrylic systems, or thermoplastic-acrylic system.
Still another embodiment of the present invention provides a composition
comprising paint sludge and regeneration chemicals for use in industrial coating material
wherein the paint sludge is varied from 40-70%.
BRIEF DESCRIPTION OF THE FIGURES
Figure 1 shows flow chart of modified process - I
Figure 2 shows flow chart of modified process - I1
Figure 3 shows flow chart of modified process - 111
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an industrial coating material comprising of
processed paint sludge and process for obtaining such processed paint sludge.
The applicants of the present invention had obtained an earlier patent relating to
Indian Patent No. 247640 which relates to a process using paint sludge for making
reusable raw material for paints. However, the process of this patent requires transferring
the sludge to the mill after washing and thereafter treating the paint sludge into ball mill
or bead mill which is time and energy consuming and comprised of increased quantity of
paint sludge and thereby increased waste thereby resulting in more time and energy for
washing and recycling. The amount of paint sludge in this patent comprised of 60-80% of
i 3
i i -;
i
the total formulation and the waste obtained was 3-5%. In the present invention the
!
j inventors have developed the processing of paint sludge by varying the paint sludge from
40-70% and the waste obtained was 2-3%. Also, in the present invention time and energy
is reduced by processing the paint sludge in a single machine or apparatus without the
need to take out the processed sludge for separate washing.
The process of the present invention reduces the time required to carry out
the process by cutting down time consuming process steps by introducing the processing
in a machine or apparatus such as Pug Mill, Ribbon Blenders, Attetors or by High Speed
Dispersion Machines. The process of the present invention employs pug mill.
A pugmill is a continuous mill cum mixer by which homogeneous mixture can be
obtained in a shorter time. A typical pugmill consists of a horizontal boxlike vertical
chamber with top open for loadinglunloading of material to be processed. It consists of
two shafts with opposite directional paddles, and a drive assembly. The factors affecting
mixing and residence time are the number and size of paddles, paddle swing arc, overlap
of left and right swing arc, size of mixing chamber, length of pugmill floor, and material
being mixed.
The use of pug mill saves time since the process of chemical washing and transferring the
washed paint sludge from the washing container to the mill is not required when the
process is carried out in the pug mill.
Paint generally comprises of following materials:
1. Resin
2. PigmentsIExtenders
3. Solvents; and
4. Additives
All the ingredients are present in a homogeneous dispersed state. All have their
specific roles in paint properties. Over-sprayed paint material consists of all the
ingredients but very small percentage of solvents. When it is mixed in water and
flocculates, solvent content is reduced further and the paint when sprayed become small
droplets. The coagulation of small droplets results in mass formation i.e. paint sludge.
Several different types of sludge are generated in the paint industry. Some of the
paint systems where the process of the invention can be used are Epoxy-amino/phenolic
system (Single Pack - Stoving System), Alkyd-amino system, Thermosetting acrylic
systems, and Thermoplastic-acrylic system.
Depending on the type of sludge, the resins used can be any one or combination
of the following:
(a) amino-alkyd
(b) amino polyester or amino acrylic alkyd
(c) thermosetting acrylic
(d) acrylic and melamine mix (amino acrylic)
(e) modified epoxy
(f) epoxy and epoxyesters
(g) acrylated alkyd
(h) thermoplastic acrylic
(i) silicon or modified silicon based paint sludge
Cj) urea formaldehyde
The resins used in the present invention are Quick drying (QD) Resins, Melamine
Formaldehyde (MF) Resins, Epoxy Resins or combinations thereof or it may even be
polyester or silicon based resins.
Three different processes for conversion of sludge into reuseable paint is provided
in the present invention which is also illustrated by process flow diagrams (Figures 1 to
3). These processes can be carried out either in a Pug Mill, Ribbon Blenders, Attetors or
High Speed Dispersion Machines.
One of the process (Figure 1) comprises of collecting paint sludge; checking and
inspecting the paint sludge; subjecting paint sludge to homogenization followed by
washing with demineralized water; subjecting the washed sludge to coarse filtration;
8
subjecting the filtered sludge to chemical blending with regeneration chemicals with
continuous stirring; subjecting the blend to milling or grinding; filtering the milled or
grinded blend to obtain reusable paint, making modifications to the product thus obtained
as per requirement, testing the product followed by packaging and dispatch.
Another process (Figure 2) comprises of collecting the paint sludge; checking and
inspecting the paint sludge; initially subjecting the paint sludge to milling before
homogenizing the paint sludge followed by washing with demineralised water and
surfactant; subjecting the washed sludge to coarse filtration; subjecting the filtered sludge
to chemical blending by addition of regeneration chemicals with continuous stirring;
milling or grinding the blend; filtering the milled or grinded blend to obtain reusable
paint; additionally modifying the product as per final requirement followed by testing,
packaging and despatching.
In the third type (Figure 3) of process the paint sludge is collected, checked and
inspected which is then subjected to dispersion by high speed stirrer followed by washing
with surfactant and demineralised water; subjecting the washed sludge to chemical
blending by addition of regeneration chemicals with continuous stirring followed by
milling or grinding and filtering the milled or grinded blend to obtain reusable paint and
additionally modifying the product to meet final requirements, as per the need, followed
by testing, packing and dispatching the final product.
An important feature of the present invention is that the productivity increases by
the present process since in the earlier methods the washed paint sludge needed to be
transferred from the washing container to the conventional mills where the milling
process would take place, whereas the process of the present invention does away with
this step since the washing step as well as adding of regeneration chemicals and milling
are all carried out in the same pug mill itself and use of stirrer is not required since this
work is taken care of by the pug mill itself. Therefore, a lot of time and energy is saved
by the present invention by cutting down on time consuming process and steps.
Further, while carrying out water washing (DM Water Washing) of paint sludge
in pug mill some surfactant (9.5 Mole) is added in the pug mill itself along with washing
9
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I
y 136.
v,'
0 water so as to remove the greasy contaminations from the paint sludge and, the
this operation time and energy spend on chemical washing of paint sludge is saved since
chemical washing is not required, as addition of surfactants takes care of this step. The
properties of the paint sludge conversion product may remain unchanged and therefore,
its ultimate usage and performance remains unchanged.
Though industrial stirrer can still be used instead of pug mill, but in that case the
time required for transfer of in-process sludge from the stirrer vessels to mill will not get
saved, which can only be possible if the paint sludge is charged directly in the pug mill
and the paint sludge is taken out only when washed and becomes free of grease or oil.
The initial regenerative chemicals are added when primary milling of the sludge is over.
Contaminants are removed prior to treatment. The sludge obtained from a booth is
a semisolid mass containing paint residuals, water, oillgreases along with detackifire
(Booth Additive). Water, oil/grease and flocculent has detrimental effect on paint
properties and its reusability. These contaminants either have to be eliminated or
prevented from coming into process. Oillgrease contamination into the sludge should be
avoided during the sludge formation and collection process. Water also needs to be
removed from the sludge. In the present invention surfactants are used to remove such
contaminants.
During the conversion process, several pigments can be added to achieve the
desired color and consistency of paint.
It is an important feature of the invention that the resin used be a single resin or a
combination of resins.
The surfactant used in the present invention is Alphox (9.5 Mole Surfactant).
In another embodiment of the present invention there is provided special modified
resins which can tolerate and can get homogenized with any quantity of waterlmoisture
of up to 10% without any detrimental affect on the properties of the paint sludge for
converting it to primerlpaint produced by the recycling of this paint sludge. In the
composition the quantity of paint sludge has been varied from 60-80% to 40-70% of the
total formulation of the recycled
regeneration chemicals.
In the present invention an industrial coating material comprising processed paint
sludge is obtained by treating the paint sludge with regeneration chemicals wherein the
paint sludge is varied in the range of 40-70%.
In yet another embodiment regeneration chemicals comprising of surfactants in
the range of 0.05 to 0.17%, solvents in the range of 1 to 16%, resins in the range of 3 to
31%, pigments in the range of 0.5 to 12%, solvents in the range of 0.8 to 30% and
additives in the range of 0.1 to 0.6% depending on the total formulation is employed. ,
i
In still another embodiment of the present invention the paint sludge is selected
from the group consisting of amino alkyl based paint sludge, epoxy paint sludge, acrylic
based paint sludge, polyester melamine based paint sludge, aminopolyester paint based
sludge, thermosetting acrylic sludge, urea formaldehyde, silicon or modified silicon
based paint sludge and acrylated alkyl paint sludge or mixtures thereof.
In a further embodiment of the present invention, the resin is either a Quick
Drying alkyd (QD) Resin, Melamine Formaldehyde (MF) Resin, Epoxy Resin or a
combination thereof wherein the quick drying alkyed resin is based on coconut oil, soya
oil, linseed oil, CNS oil or rapeseed oil.
In a further embodiment of the present invention, the pigment is selected from the
group consisting of china clay, barytes, calcite, zinc oxide, zinc chromate, talcum, silica
powder (micropulverised), titanium dioxide, carbon black or any other conventional
pigments or conventional coloring agents.
In still another embodiment of the present invention, the solvents are selected
from the group consisting of methanol, xylene, toluene, or iso butanol.
In a further embodiment of the present invention, the additives are selected from
the group consisting of anti-setting agents, anti-corrosion additives, thickening agents,
dispersing agents, anti-oxidants, plasticizers, bonding agents, gloss improvers, drying
agents and any other conventional property enhancing additives.
Another embodiment of the present invention provides a process for the
preparation of a composition for conversion of paint sludge into reusable paint wherein
the process comprises of:
(a) collecting paint sludge;
(b) subjecting the paint sludge to homogenization or dispersion followed by
washing with demineralized water and addition of surfactant in a pug mill;
(c) subjecting the homogenized paint sludge obtained at the end of step (b) to
coarse filtration to remove particles larger than +I 00 mesh therefrom;
(d) subjecting the filtered sludge to chemical blending or regeneration chemicals
with continuous stirring in the pug mill;
(e) subjecting the mixture of step (d) to milling or grinding to obtain a particle
size of +3 to +6 Hegman's Guage fineness;
(f) filtering the mixture of step (e) to a particle size of +5 Hegman Guage to +8
Hegman's Gauge to obtain reusable paindprimer.
wherein the process is are carried out in the same machine or apparatus .
A still another embodiment of the present invention provides a process, wherein
in step (b) optionally milling is carried out prior to homogenization.
In still another embodiment of the present invention, wherein in step (d) of the
process chemical blending comprises of addition of surfactants, resins, pigments, solvents
and additives.
A further embodiment of the present invention provides resins that act as a drying
agent by homogenizing with any quantity of water thereby eliminating the requirement of
a separate drying step in an oven or dryer.
Still in another embodiment of the present invention, the process can be carried
out in Pug Mill, Ribbon Blenders, Attetors or by High Speed Dispersion Machines.
Yet in another embodiment of the present invention, the process is preferably
carried out in a Pug Mill.
In a further embodiment of the present invention, the surfactant is anionic
surfactant.
Still in another embodiment of the present invention, the surfactant is Alphox (9.5
Mole - Non-Toxic Type).
Yet in another embodiment of the present invention, the water used for washing is
demineralised water.
Still in another embodiment of the present invention after washing the water is
removed under gravity.
In still another embodiment of the present invention, the process may be used in
epoxy-aminolphenolic system (single pack - Stoving system), alkyd-amino system,
thermosetting acrylic systems, or thermoplastic-acrylic system.
Still another embodiment of the present invention provides a composition
comprising paint sludge and regeneration chemicals for use in industrial coating material
wherein the paint sludge is varied from 40-70%.
The invention is described with reference to the following examples and
flow diagrams. Some of the paint systems where the process of the invention can be used
are epoxy-aminolphenolic system (single pack - Stoving system), alkyd-amino system,
thermosetting acrylic systems, or thermoplastic-acrylic system. In all the following
examples, the process defined in any of the three process flow diagrams can be followed.
b
The following examples includes certain compositions already tri
c-. , ."$ s: 9 RXn i'
commercial level with the new process is shown below by ~ a ~ e-.q ~ l e s ~ ~ j
a t ;'
EXAMPLES
EXAMPLE 1:
S. No. Product Percentage by weight
1. Paint sludge 27.0 to 57.0
2. Alphox (Surfactant) (9.5 Mole) 0.054 to 0.066
3. QD Resin (A Quick Drying Alkyed 6.5 to 8.8
Resin based on Coconut Oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
4. Soya Lecithin (Additive) 0.1 to 0.1
5. Benton Jelly (Thickening Agent) 0.9 to 1.2
6. Baryte (Pigment) 3.0 to 3.8
7. Talcum (Pigment) 3.0 to 3.8
8. Zinc Phosphate (Pigment) 0.5 to 1.6
9. Zinc Chromate (Pigment) 0.9 to 1.2
10. Epoxy Resin 0.9 to 1.2
11. Melamine Formaldehyde Resin 4.3 to 5.3
12. Methanol (Solvent) 0.8 to 1 .O
-- -
13. Xylene (Solvent) 12.6 to 15.5
14. Toluene (Solvent) 2.2 to 7.1
15. IS0 Butanol (Solvent) 1.0 to 1.2
16. Black Strainer for ACUB Primer (Milled 11.0 to 18.4
Carbon Black with 3% Resin with which
the Primer is to be made)
EXAMPLE 2
S. No. Product Percentage by weight
1. Paint Sludge 25.0 to 54.2
2. Alphox (Surfactant) (9.5 Mole) 0.14 to 0.17
3. Benton Jelly (Thickening Agent) 1.5 to 1.8
4. Soya Lecithin (Additive) 0.4 to 0.5
5. QD Resin (A Quick Drying Alkyed 12.0 to 15.1
Resin based on Coconut Oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
6. Black Stainner for casting sealer DA Grey 10.4 to 12.7
(Milled Carbon Black with 3% Resin with
which the Primer is to be made)
7. Zinc Chromate (Pigment) 1.1 to 3.6
8. Zinc Phosphate (Pigment) 2.1 to 2.6
9. Micron Talcum (Pigment) 3.5 to 4.4
10. Micron Baryte- 1240 (Pigment) 7.1 to 8.7
11. Xylene (Solvent) 10.9 to 1.4
12. IS0 Butanol (Solvent) 2.3 to 2.9
13. Lead Octane (Dryerlbonding agents) 0.7 to 0.9
14. Cobalt Octate (Dryerhonding agents) 0.3 to 0.5
15. Mn. Octate (Dryerlbonding agents) 0.2 to 0.3
16. Zinc Octate (Dryerbonding agents) 0.3 to 0.5
EXAMPLE 3
S. No. Product Percentage by weight
1. Paint Sludge 22.1 to 49.3
2. Alphox (Surfactant) (9.5 Mole) 0.14 to 0.17
3. QD Resin (A Quick Drying Alkyed 3.0 to 3.6
Resin based on Coconut Oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
4. Xylene (Solvent) 18.4 to 22.5
5. Soya Lecithin (Additive) 0.3 to 0.4
6. Benton Jelly (Thickening Agent) 1.3 to 1.6
7. Zinc Chromate (Pigment) 0.9 to 3.4
8. Zinc Phosphate (Pigment) 2.8 to 3.5
9. Micron Baryte- 1240 (Pigment) 6.6 to 8.1
Micron Talcum (Pigment) 3.3 to 4.1 1
11. Black Stainner for AD Semi Glossy Black 2 1.1 to 36.9
(Milled Carbon Black with 3% Resin with
which the Primer is to be made)
12. IS0 Butanol (Solvent) 5.3 to 6.5
/ 13. Lead Octate (Dryerlbonding agents) 0.7 to 0.8 1
/ 14. Zinc Octate (Dryerlbonding agents) 0.3 to 0.4 1
/ 15. Mn. Octate (Dryerlbonding agents) 0.2 to 0.2 1
1 16. Cobalt Octate (Dryerlbonding agents) 0.3 to 0.4 1
EXAMPLE 4
S. No. Product Percentage by weight
1. Paint Sludge 32.0 to 50.4
2. Alphox (Surfactant) (9.5 Mole) 0.07 to 0.09
3. QD Resin (A Quick Drying Alkyed 6.8 to 30.5
Resin based on Coconut Oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
4. Soya Lecithin (Additive) 0.1 to 0.1
5. Benton Jelly (Thickening Agent) 1.1 to 1.4
6. Micron Baryte (Pigment) 2.0 to 3 .O
7. Micron Talcum (Pigment) 1.1 to 1.4
8. Zinc Phosphate (Pigment) 0.2 to 1.4
9. Xylene (Solvent) 21.0 to 25.9
10. Utox (Commercial grade of Anodes 1.5 to 1.9
Titanium Oxide)
11. Epoxy Resin 1.1 to 1.4
12. Araldite GY-250 IN 1.1 to 1.4
13. Cobalt Octate (Dryerlbonding agents) 0.2 to 0.2
14. Mn. Octate (Dryerlbonding agents) 0.2 to 0.2
15. Zinc Octate (Dryerlbonding agents) 0.2 to 0.3
16. Zirconium Octate (Dryerlbonding agents) 0.4 to 0.5
17. Methanol (Solvent) 2.0 to 9.1
EXAMPLE 5
S. No. Product Percentage by weight
1. Paint Sludge 20.0 to 37.5
2. Toluene (Solvent) 9.1 to 11.1
3. Zinc Phosphate (Pigment) 1.1 to 1.3
4. Zinc Chrome (Pigment) 1.1 to 1.3
5. Talcum (Pigment) 3.5 to 4.3
6. Baryte (Pigment) 9.1 to 11.1
7. Carbon Black 0.4 to 0.4
8. QD Resin (A Quick Drying Alkyed 13.2 to 25.2
Resin based on Coconut Oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
9. Soya (Additive) 0.4 to 0.4
10. Jelly (Thickening Agent) 2.8 to 3.4
11. Lead Octate (Dryerlbonding agents) 0.7 to 0.8
12. Cobalt Octate (Dryerlbonding agents) 0.4 to 0.4
13. Mn. Octate (Dryerlbonding agents) 0.2 to 0.3
14. Zinc Octate (Dryerlbonding agents) 0.4 to 0.4
15. Xylene (Solvent) 10.5 to 12.9
16. Alphox (Surfactant) (9.5 Mole) 0.14 to 0.17
17. Black Stainer (Milled Carbon Black 6.3 to 9.9
with 3 % Resin with which the
Primer is to be made)
EXAMPLE 6
S. No. Product Percentage by weight
1. Paint Sludge 20.7 to 36.4
2. Toluene (Solvent) 12.9 to 15.8
3. Zinc Phosphate (Pigment) 1.0 to 1.2
4. Zinc Chrome (Pigment) 0.5 to 1.7
5. Talcum (Pigment) 3.3 to 4.1
6. Baryte (Pigment) 8.8 to 10.7
7. Carbon Black 0.7 to 0.9
8. QD Resin (A Quick Drying Alkyed 11.7 to 25.4
Resin based on Coconut Oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
9. Soya (Additive) 0.3 to 0.4
10. Jelly (Thickening Agent) 2.7 to 3.3
11. Lead Octate (Dryerlbonding agents) 0.4 to 1.1
12. Cobalt Octate (Dryerhonding agents) 0.3 to 0.4
13. Mn. Octate (Dryerlbonding agents) 0.2 to 0.3
14. Zinc Octate (Dryerlbonding agents) 0.3 to 0.4
15. Xylene (Solvent) 10.8 to 13.1
16. Alphox (Surfactant) (9.5 Mole) 0.07 to 0.08
17. IS0 Butanol 3.1 to 3.7
18. Black Stainer (Milled Carbon Black 1.3 to 1.6
with 3% Resin with which the Primer
is to be made)
EXAMPLE 7
S. No. Product Percentage by weight
1. Paint Sludge 27.7 to 47.3
2. Toluene (Solvent) 15.1 to 29.5
3. Zinc Phosphate (Pigment) 0.9 to 1.2
4. Zinc Chrome (Pigment) 0.9 to 1.2
5. Talcum (Pigment) 1.9 to 2.3
6. Baryte (Pigment) 2.8 to 3.4
7. Carbon Black 1.2 to 3.7
8. QD Resin (A Quick Drying Alkyed Resin 15.9 to 19.5
based on Coconut Oil, Soya Oil, Linseed
Oil, CNS Oil or Rapeseed Oil)
9. Soya (Additive) 0.5 to 0.6
1 10. Jelly (Thickening Agent) 1.9 to 2.3 1
Lead Octate (Dryerlbonding agents) 0.9 to 1.2 1
I 12. Cobalt Octate (Dryerhondig agents) 0.5 to 0.6 1
1 13. Mn. Octate (Dryerlbonding agents) 0.3 to 0.4 1
1 14. Zinc Octate (Dryerlbonding agents) 0.5 to 0.6 1
1 15. Xylene (Solvent) 4.9 to 10.5 1
16. Alphox (Surfactant 9.5 Mole) 0.09 to 0.1 1
EXAMPLE 8
S. No. Product Percentage by weight
1. Paint Sludge 20.6 to 34.1
2. Toluene (Solvent) 19.0 to 23.2
3. Zinc Phosphate (Pigment) 1.0 to 1.2
4. Zinc Chrome (Pigment) 1.0 to 1.2
5. Talcum (Pigment) 3.2 to 4.0
6. Baryte (Pigment) 8.4 to 10.3
7. Carbon Black 0.7 to 0.9
8. QD Resin (A Quick Drying Alkyed 12.0 to 23.5
Resin based on coconut oil, Soya Oil,
Linseed Oil, CNS Oil or Rapeseed Oil)
9. Soya (Additive) 0.3 to 0.4
10. Jelly (Thickening Agent) 2.6 to 3.2
11. Lead Octate (Dryerlbonding agents) 0.6 to 0.8
12. Cobalt Octate (Dryerlbonding agents) 0.3 to 0.4
13. Mn. Octate (Dryerlbonding agents) 0.2 to 0.2
14. Zinc Octate (Dryerlbonding agents) 0.3 to 0.4
15. Xylene (Solvent) 8.6 to 14.9
16. Black Stainer (Milled Carbon Black 1.1 to 1.4
with 3% Resin with which the Primer
is to be made)
17. Alphox (Surfactant 9.5 Mole) 0.06 to 0.08
The present invention is described with reference to the above examples, which
merely illustrate and demonstrate the invention. These examples should not be construed
to limit the scope of the invention in any way.

We Claim:
I. An industrial coating material comprising a processed paint sludge obtained by
treating the paint sludge with regeneration chemicals wherein the paint sludge is varied in
the range of 40-70%.
2. The industrial coating material as claimed in claim 1 , wherein, the regeneration
chemicals comprises of surfactants in the range of 0.05 to 0.17%, solvents in the range of
1 to 16%, resins in the range of 3 to 3 I%, pigments in the range of 0.5 to 12%, solvents in
the range of 0.8 to 30% and additives in the range of 0.1 to 0.6% depending on the total
formulation.
3. The industrial coating material as claimed in claim 1, the paint sludge is selected
from the group consisting of amino alkyl based paint sludge, epoxy paint sludge, acrylic
based paint sludge, polyester melamine based paint sludge, aminopolyester paint based
sludge, thermosetting acrylic sludge, urea formaldehyde, silicon or modified silicon
based paint sludge and acrylated alkyl paint sludge or mixtures thereof.
4. The industrial coating material as claimed in claim 2, wherein the resin is either a
Quick Drying alkyd (QD) Resin, Melamine Formaldehyde (MF) Resin, Epoxy Resin or a
combination thereof wherein the quick drying alkyed resin is based on coconut oil, soya
oil, linseed oil, CNS oil or rapeseed oil.
5. The industrial coating material as claimed in claim 2, wherein the pigment is
selected from the group consisting of china clay, barytes, calcite, zinc oxide, zinc
chromate, talcum, silica powder (micropulverised), titanium dioxide, carbon black or any
other conventional pigments or conventional coloring agents.
6. The industrial coating material as claimed in claim 2, wherein the solvents are
selected from the group consisting of methanol, xylene, toluene, or iso butanol.
I
I
I e 7. The industrial coating material as clahed in claim 2, wherein the addi
selected from the group consisting of anti-setting agents, anti-corrosion additives,
thickening agents, dispersing agents, anti-oxidants, plasticizers, bonding agents, gloss
improvers, drying agents and any other conventional property enhancing additives.
8. A process for conversion of paint sludge into reusable paint or primer for
industrial coating material wherein the process comprises of:
(a) collecting paint sludge;
(b) subjecting the paint sludge to homogenization or dispersion followed by
washing with demineralized water and addition of surfactant in a pug mill;
(c) subjecting the homogenized paint sludge obtained at the end of step (b) to
coarse filtration to remove particles larger than +I00 mesh therefrom;
(d) subjecting the filtered sludge to chemical blending or regeneration chemicals
with continuous stirring in the pug mill;
(e) subjecting the mixture of step (d) to milling or grinding to obtain a particle
size of +3 to +6 Hegman's Guage fineness;
(f) filtering the mixture of step (e) to a particle size of +5 Hegman Guage to +8
Hegman's Gauge to obtain reusable paintlprimer.
wherein the process is carried out in a single machine or apparatus thereby resulting in
faster processing.
9. The process as claimed in claim 8, wherein in step (b) optionally milling is carried
out prior to homogenization.
10. The process as claimed in claim 8, wherein in step (d) chemical blending
comprises of addition of surfactants, resins, pigments, solvents and additives.
11. The process as claimed in claim 10, wherein the resins acts as a drying agent by
homogenizing with any quantity of water thereby eliminating the requirement of a
separate drying step in an oven or dryer.
-
12. The process as claimed in claim 8, wherein, the-process is carried out in any of
machine or apparatus such as Pug Mill, Ribbon Blenders, Attetors or by High Speed
Dispersion Machines.
13. The process as claimed in any of the preceding claims, wherein the machine or
apparatus is a Pug Mill.
14. The process as claimed in any of the preceding claims, wherein the surfactant is
anionic surfactant.
15. The process as claimed in any of the preceding claims, wherein the surfactant is
Alphox (9.5 Mole - Non-Toxic Type).
16. The process as claimed in claims 8, wherein, the water used for washing is
demineralised water.
17. The process as claimed in any of the preceding claims, wherein after washing the
water is removed under gravity.
18. The process as claimed in any of the preceding claims, wherein the process may
be used in epoxy-aminolphenolic system (single pack - Stoving system), alkyd-amino
system, thermosetting acrylic systems, or thermoplastic-acrylic system.
19. A composition comprising paint sludge and regeneration chemicals for use in
industrial coating material wherein the paint sludge is varied from 40-70%.