FORM 2
THE PATENT ACT, 1970,
(39 OF 1970)
&
THE PATENTS RULE, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10; RULE 13)
"A SYSTEM FOR SEPARATING METALLIC AND NON-METALLIC CONTENT OF PAINT SLUDGE AND DEWATERING THEREOF"
MAHINDRA & MAHINDRA LIMITED A COMPANY REGISTERED UNDER THE PROVISIONS OF COMPANIES ACT, 1956 HAVING ADDRESS AT R & D CENTER, AUTOMOTIVE SECTOR, 89, M.I.D.C, SATPUR, NASHIK - 422 007, MAHARASHTRA, INDIA.
THE FOLLOWING SPECIFICATION DESCRIBES THE NATURE OF THE INVENTION AND MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF INVENTION:-
The invention relates to a system for separating metallic and non-metallic content of paint sludge and dewatering the said sludge. More particularly the system for separating metallic and non-metallic content of hazardous paint sludge safely and dewater thereof.
BACK GROUND OF INVENTION:-
The most serious problems in industry that make use of the paint process is the generation of waste known as paint sludge.
The painting by spraying, generate waste due to over spray or the paint not reaching the target. This over spray washed with the help of circulating/running water gets collected in a sludge pit. This mixture of water with over sprayed paint is called 'paint sludge'.
The paint- related wastewaters can contain organic solvents, heavy metals and other toxic materials used in paint formulation and equipment cleaning.
OBJECT OF 1NVENTION:-
It is object of invention to provide a system to handle hazardous paint sludge safely.
It is also object of invention to provide a system to separate metallic and non-metallic content of paint sludge.
It is also object of invention to remove water from the separated metallic and non-metallic content for reducing weight for handling.
STATEMENT OF INVENTION:-
Accordingly invention provides a system for separating metallic and non-metallic content of paint sludge and dewatering thereof comprises a pair De-sludger mechanism for Non-metallic& Metallic booth having mechanical scrapper blades,

for seperating out paint sludge , attached to sprockets & chain, driven by the electrical geared unit; a differntial type duct with pair of hoppers at one end, aligned to receive sludge from the said scrapper for metallic and non mettalic sludge having the provision for easy attach & de-attach of paint Sludge bags at out let at other end, fitted vertically with saidone end top between the said mettalic and non- mettallic booths; a limit swich providedat at each of common sludge collection hopper for stopping for 3 sec to remove the water; a pneumatic pressing mechanism with pressure regulated ram provided to remove the remaining water content present in paint sludge Gunny bag .
BRIEF DESCRIPTION OF DRAWINGS:
Invention is described with reference to the figures of accompanying drawing
wherein;
Figure 1 discloses the newly developed set up for dewatering the paint sludge as
per the present invention;
Figure 2 shows the set up developed for separating the metallic and non-metallic content of the paint sludge in accordance with the present invention;
Figure 3 shows the exploded view the separating duct for the metallic and non-metallic content of the paint sludge.
DESCRIPTION OF THE INVENTION:-
Conventionally the paint sludge in the paint shop is collected in metallic container that increases weight due to presence of water therein.
Referring to Figure 1, a setup for dewatering the paint sludge is provided. It reduces the water content in Paint sludge by use of press mechanism and sludge container of required porosity walls thereof. This helps in reducing the overall weight of the paint sludge.

Referring to Figure 2, the Non-Metallic content of the paint sludge is separately collected and then the same is used as a raw material for making of fresh Black Primer paint for underbody applications in the automotive industry.
Paint sludge of the automotive paint shop is hazardous waste and it has to be disposed off by special disposal processes defined as per the statutory norms. The metallic container was being used in the conventional method to collect the paint sludge along with water is totally eliminated due to introduction of new set up developed as shown in Figure 1 for the collection of paint sludge. These specially designed sludge containers with desired porosity walls remove the water content due to its porous texture.
In the conventional method of sludge collection, both Non-Metallic and Metallic content of the paint sludge is collected in mixed form. As per the new set up developed therefore, as shown in Figure 2, the Non-Metallic and Metallic content of the paint sludge are separated in the process and collected separately. This is achieved as the collection ducts were provided and the mechanism therefore was provided in the system as shown in figure 2. Thus, non-metallic content of the paint sludge separated is used as a raw material for making of the fresh Black Primer paint for underbody applications for the automotive bodies.
As shown in above fig no 1,
It is pneumatic pressing mechanism, used to remove remaining water content present in paint sludge Gunny bag The air pressure required to press gunny bag is 2 bars. The pressure has been controlled for avoiding the tearing of sludge collecting bag by fitting FRL at the inlet air pipe. FRL (Filter Regulator and Lubrication) unit has been put up in the series in between ram and the inlet pipe of air. This regulates and lubricates the air flow and thereby reduces the pressure at the desired point.
When air pressure is ON, Ram goes downward & presses paint sludge bag. Due to this pressure application water comes out from bag. In this way remain water content removed from paint sludge & weight of sludge reduced.

Bag having specification of porous agricultural waste Material sack (Gunny bag) with porosity 1 to 2 mm. When the water mixed sludge comes in the sludge collecting bag, it is in the lump form. When the ram is activated to remove the water, there are likely chances that the lump of sludge may disintegrate and come out of the pores of the sludge collecting bag if the pores are of bigger size and therefore the most optimized size of the pores is 1 to 2 mm.
Its unique feature is only water drained out from paint sludge& paint sludge remains in bag.
As shown in fig no.2 ,it is complete Ecological Skimmer Pump Arrangement (ESKA )system of paint sludge collection.
The system equipped with separate De-sludger mechanism for Non-metallic& Metallic booth having mechanical scrapper blades driven by the electrical geared unit of 0.25 Kw Motors of 'Bauer' make with the help of sprockets & chain. The paint particles (sludge) are separated out by these mechanical scrapper's. It moves with paint sludge & stops at common sludge collection hopper for 3 sec with the help of limit switches to remove the water.
We have fitted a unique diffemtial type duct of Special SS material having the provision of holding Sludge bags for separate collection of both Metallic & Non-metallic paint sludge into separate porous agricultural waste material sack (Gunny bag) with porosity 1 to 2 mm. In this the water content in both paint sludge bags drained directly due to gravity. The duct is integrated one for metallic and non-metallic contents and there is a common wall that seperates the duct for two different purposes. For free flowing of the sludge lumps, the most optimized angle of the duct outlet is 25 to 35 degrees. The said ducts are provided with hooks for fitting the sludge collecting bags.
When paint sludge floats in hopper along with water from paint booth, the scrapper moves & shift this paint sludge into the Duct in both Metalic & IMon-metalic sides in the duct provided .After putting the sludge in bags water is

drained out .So weight is reduced & sludge collected separately. The scrapper is optimized by providing the flexible cover on its lower edge so as to caary the solid material leaving behind the water therein.
As shown in fig.no. 3, it is differntial type duct of Special Stainless steel material having the provision for easy attach & de-attach of paint Sludge bags .It is fabricated for the separation & collection of Metallic & Non-Metallic paint sludge into separate porous sludge collecting bag (made from agricultural waste material) having the porosity 1 to 2 mm.
When this type of Duct is attched then,both metallic & Non-metallic paint sludge collected in separate bags.I.
The benefits derived out of this invention are (a) Reduction in Paint Sludge weight by 34% is achieved with newly dewatering set up and the porous containers used therein for the sludge collection; (b) This directly impacts on Sludge disposal cost reduction by almost 50% as compared to the conventional method; (c) Manual handling of sludge collection drums is eliminated and the sludge handling process become very easy; (d) Cleanliness of work place improved drastically.
Following table shows the economic significance achieved by using the system as per the present invention-

Paint Sludge Weight Before De-Watering Process
Month Paint sludge generated in Kg
Apr-13 17538
May-13 20820
Jun-13 39470
Jul-13 14110
Aug-13 14580
Sep-13 18170

Paint Sludge W< Watering
Month sight After De-Process
Paint sludge generated in Kg
Apr-14 15680
May-14 10290
Jun-14 28051
Jul-14 19090
Aug-14 9420
Sep-14 20260

Oct-13
24850
Nov-13 26020
Dec-13 36530
Jan-14 16340
Feb-14 16570
Mar-14 17860
Total
Paint
Sludge
Weight
in KG 262858
Rate of
Paint
Sludge
Disposal 18 Rs per Kg
Total Cost
Required for
Disposal 4731444

Oct-14 18360
Nov-14 14100
Dec-14 13090
Jan-15 19014
Feb-15 20064
Mar-15 16140
Total Paint Sludge Weight in KG 203559
Rate of Paint Sludge Disposal 18 Rs per Kg
Total Cost Required for Disposal 3664062

Saving in Paint
Sludge Weight for
Disposal 59299
Rate of Disposal per KG (Rs.) 18
Total Saving 1067382

10.67 Lacs per Year.

WE CLAIM:-
1. A system for separating metallic and non-metallic content of paint sludge and dewatering thereof comprises a pair De-sludger mechanism for Non-metallic& Metallic booth having mechanical scrapper blades, for seperating out paint sludge , attached to sprockets & chain, driven by the electrical geared unit; a differntial type duct with pair of hoppers at one end, aligned to receive sludge from the said scrapper for metallic and non mettalic sludge having the provision for easy attach & de-attach of paint Sludge bags at out let at other end, fitted vertically with saidone end top between the said mettalic and non- mettallic booths; a limit swich providedat at each of common sludge collection hopper for stopping for 3 sec to remove the water; a pneumatic pressing mechanism with pressure regulated ram provided to remove the remaining water content present in paint sludge Gunny bag.
2. The system as claimed in claim 1 wherein the said pneumatic pressing mechanism is required to press gunny bag with air pressure of 2 bars.
3. The system as claimed in claims 1 and 2 wherein the said pneumatic pressing mechanism provided with a pressure controller by fitting for avoiding the tearing of sludge collecting bag by fitting Filter Regulator and Lubrication unit put up in series in between ram and the inlet air pipe.
4. The system as claimed in claims 1 to 3 wherein the said gunny bag is of porous agricultural waste material sack (Gunny bag) with porosity 1 to 2 mm to enable flow out of water with gravity.
5. The system asclaimedin claimsl to 4 wherein the said differential duct made of special steel.