Extraction systems - For clean and safe work areas

Basics of extraction technology

What is an extraction system?

When working with materials that produce waste substances, extraction systems help to remove and/or separate them. Waste materials can be produced, for example, when spraying adhesives. This can result in overspray, i.e. a material mist that does not reach the workpiece. Extraction systems capture this material mist and can help to reduce exposure to potentially harmful substances in the workplace.

Operating and testing extraction systems

Before commissioning an extraction system, an explosion safety test must be carried out (technical test & order test by qualified persons).
Annually a functional test
Every 3 or 6 years a technical or technical + organizational test must be carried out by a competent person.

We can offer the tests in each case.

Standards, laws and information

For the safe operation and the avoidance of health risks there are the following standards and regulations:

Machinery Directive 2006/42/EC
EN 16985:2019 Paint booths for organic coating materials - Safety requirement.
DGUV 209-046 Painting rooms and equipment for liquid coating materials; structural facilities, fire and explosion protection, operation; as of August 2016

The extraction systems supplied by WALTHER PILOT are designed in accordance with the relevant laws, regulations, standards and guidelines.

Extraction systems with dry separation

In dry separation, the overspray is bound and then filtered. This is separated from the air with the aid of filter mats. The filter mats are multi-layered to ensure high absorption capacity and a long service life for the filters.

Advantages

Different design of separator filters possible
Low investment costs (cheaper than wet separators)
Easy handling
Applicable from small to large overspray quantities
ATEX design standard (zone 2)
Simpler and generally less expensive disposal
Well suited for adhesives
Low energy consumption
No regulations according to 42. BlmSchV - "Legionella regulation"

Disadvantages

Wear parts (follow-up costs filter)
Fire risk with self-igniting paint systems
Possibly higher downtimes for filter changes
Changing suction conditions due to dirty filters

With dry separation, operating and disposal costs can be reduced depending on the application and operating conditions. Depending on the coating material used and the applicable local disposal regulations, used filter mats can be classified as “residual waste” and disposed of accordingly (making disposal relatively inexpensive).

Unlike wet scrubbing, dry separation does not require process water. This eliminates a common cause of bacterial and mold growth. In addition, noise levels can be significantly reduced. The effort required for water changes and cleaning water-carrying system components is also reduced. The risk of corrosion on the cabin structure is likewise reduced.

Extraction systems with wet separation

The operating principle of wet separators is to bring the particles dispersed in the raw gas stream into contact with a scrubbing liquid in order to bind them therein and then to separate the resulting particle-liquid mixture from the air stream.

Wet separators are particularly suitable for applications involving sticky or highly flammable paints and aerosols.

For wet separation to be effective, it is necessary to create as large a phase interface as possible as a contact surface between the scrubbing liquid and the gas to be cleaned.