IMT’s Spraying and Coating Systems Protect and Remediate Sensitive Surfaces in Many Industries ~ technoboxes

East-West-Report - Industrial Engineering

IMT's spraying systems are used e.g. in the wind turbine sector. IMT Spray Systems GmbH, the German expert in spraying and coating systems, continues to make news with 2- and 3-component systems that give a variety of industries the tools to immunize a variety of sensitive surfaces against premature wear-and-tear and the ability to help remediate surfaces, especially concrete, that have already been damaged by the inevitable march of time.

Our article takes a closer look at four members of IMT’s extended OPTI MIX family: the OPTI MIX 2K-HD, the OPTI MIX 3K-HD, as well as the SPACHTEL MIX 2K-ND and the KLEBE MIX 3K-ND.

OPTI MIX 2K-HD

In many ways, IMT’s love affair with 2- and 3-component spraying and coating systems began with the company’s introduction several years ago of the OPTI MIX 2K-HD, a 2-component mixing machine for epoxy resins, polyurethane and poly-urea systems that supports high pressure, low pressure and casting processes, as well as all modern mixing processes, including static and dynamic systems and the counter-injection principle. Equipped with pulsation-free, multi-piston axial pumps, one to deliver the polyol A-component and one to deliver the isocyanate B-component, the OPTI MIX 2K-HD makes it possible to reliably process unfilled and low-viscosity materials in industries and applications as diverse as wind turbines, autos, coal mining, and tube and tank manufacture.

The A- and B- material components are gently stirred and heated in two tanks that utilize an ingenious mix of technologies to control the temperature of the components and then deliver them to a spray gun for final application to the target surface. The pumps, which sport an output capacity ranging from 1.0 to 7.5 liters /minute as a function of the installed pump and drive options and available mixing ratios between 1:1- and 10:1, are attached on the intake side to nitrogen-charged downdraft heaters. The heaters, each of which has a separate heating and control system that syncs up with the unit’s master SPS control unit, consist of three sections: a storage reservoir, a damper register and a collection basin.

In this design, both the A- and B-component flow along similar delivery paths. The material passes from the storage reservoir and into the damper register, where a mix of water and anti-freeze flows around several pipe bundles and heats the component. The process heats only the exact amount of material required. The materials then feed to the pumps and subsequently to the hose package via a volume flow meter and pressure sensor. A sophisticated control system monitors and corrects the frequency-controlled electric pump motors for any RMP deviations or wear-and-tear that might cause fluctuations in the transport volume.

The data required to control all of these processes are acquired by the volume flow meters and processed by the SPS control system. The system compares the dosage of both components with respect to one another and the overall volume flow with the reference setting. Using this frequency regulator, both volume streams are transported according to the preset mixing relationship with a maximum deviation of ± 2%. Using the keyboard, display and corresponding menu system, a variety of mixing relationships for all common materials can be easily entered into the integrated SPS control unit. Pressure sensors measure the operating pressures, which are compared with the default values in the SPS. The unit shuts down automatically in case of overpressure.

The hose package mentioned above is yet another example of the IMT's spraying and coating systems are used to immunize orprotect many types of sesitve surfaces from premature wear-and-tear engineering detail that has the OPTI MIX 2K-HD and all other IMT spraying and coating systems standing head-and-shoulders above the competition. The hose package consists of two separate heating hoses for the A- and B- components. These hoses consist of an inner hose made of PTFE and a surrounding jacket made of a 2-layer, stainless steel wire mesh. These hoses are rated for operating pressures up to 425 bar. The A- and B-hoses are designated by the colors blue and red and have different connecting threads, excluding a mix-up of the components.

Both material hoses are heated separately and have their own temperature control system. In each case, the stainless steel jacket serves as the heating resistor. Temperatures are captured by temperature sensors and processed in the unit's SPS system by means of temperature regulators. This precise control guarantees maximum temperature deviations at the spray gun of ±2%. The heating hoses are equipped with flexible, silicon-based insulation.

The OPTI MIX 2K HD Coating Unit comes with a heated or unheated hose package in standard lengths of 10, 25, and 50 meters with special lengths available on request and with a 2-component static mixing pistol as standard equipment. Static mixers in a variety of types for processing epoxy and PU are also available. These ensure homogenous mixing of both components. For special applications, e.g., poly-urea applications, spray pistols with counter-injection mixing heads are also available.

Never one to rest on its laurels, IMT Spray Systems has not only continued to improve and optimize the underlying technology that was first introduced with the OPTI MIX 2K-HD, it has also successfully applied that technology to other mixing machines that define the extended OPTI MIX family.

OPTI MIX 3K-HD

One of the best examples is the OPTI MIX 3K-HD, a 3-component mixing machine for epoxy resins and polyurethane systems. Offering the same support as the OPTI MIX 2K-HD for high pressure, low pressure and casting processes, as well as all modern mixing processes, the 3K-HD takes center stage with output capacities ranging from approximately 3 to 15 liters/minute and the ability for users to specify variable mixing ratios, e.g., a ratio of Component A with 100% to Component B with 30%. Component B can be further specified as B1 and B2, e.g., 75% to 25% or 100% to 0% (2K). Based on these recipes, five mixing ratios can be stored and directly selected by users

As is the case with all IMT spray and coating systems, the material The OPTI MIX 3K-HD in operation. components are separately and gently circulated and heated, in this case in three heated stainless steel tanks with fill volumes of 70 liters and automatic fill level sensors and replenishment systems. The components are delivered to the spray pistol at process temperatures via a hose package that is also heated. Other technical highlights include a pressure monitoring system with safety shutdown and an easy to use SPS control system that constantly monitors and adjusts all machine functions, mixing ratios and operating temperatures. These data can be displayed, recalled, edited or newly input via the unit’s display.

SPACHTEL MIX 2K-ND

Rounding out our look at IMT’s spraying and coating systems are the SPACHTEL MIX 2K-ND, a 2-component mixing machine for epoxy resin, polyurethane and poly-urea systems, and the KLEBE MIX 3K-ND, a 3-component mixing machine for high viscosity filled and unfilled resins.

With the SPACHTEL MIX 2K-ND, 2-component elastomers can be IMT's spraying and coating systems are used to immunize orprotect many types of sesitve surfaces from premature wear-and-tear processed using low pressure and casting processes. All modern mixing processes including, for example, static and dynamic mixers, are supported. Discharge rates of 1.0 to 7.5 l/min with mixing ratios between 10:1 and 1:10 can be achieved depending on the installed drive and pump options. Other mix ratios and discharge rates can also be realized. Supply containers for the materials are made of stainless steel and fill levels are electronically monitored.

KLEBE MIX 3K-ND

With the KLEBE MIX 3K-ND, high viscosity filled (e.g., fiberglass-filled) and unfilled resins can be processed using high-pressure and low-pressure processes. All modern mixing processes including, for example, static and dynamic mixers, are supported. Discharge rates are specified in l/m. The mixing ratio is also variable, e.g., Component A with 100% to Component B with 30%. Component B can be further specified as B1 and B2, e.g., 75% to 25% or 100% to 0% (2K). Based on these recipes, five mixing ratios can be stored and directly selected using the step switch. Once processing is finished, the mixing/dosing unit can be cleaned.

In both the SPACHTEL MIX and the KLEBE MIX, all machine functions are monitored via an easy to use SPS-equipped control system and the mixing ratios and operating temperatures are monitored constantly. Using a touch panel, these data can be displayed, recalled, edited or newly input via the unit’s display.

As fascinating as the engineering and hardware behind these systems may be, so too is the range of applications for which these spraying and coating systems are used. Broadly speaking, the applications fall into two wide-ranging categories: immunization and remediation.

IMT’s spraying and coating systems are used to immunize, or protect, IMT's spraying and coating systems are used to immunize orprotect many types of sesitve surfaces from premature wear-and-tear many types of sensitive surfaces from premature wear-and-tear. Our photos illustrate just a few examples from different industries, including the wind turbine sector, where coatings mixed and applied using IMT systems protect the sensitive surfaces of turbine rotors that are exposed to what are often harsh seaside conditions. Other applications that call for the type of surface protection possible with IMT spray and coating systems hail from the automotive industry, where sensitive surfaces are sealed using 2K- and 3K- systems, from the coal mining industry, where coatings are applied to excavator rollers as protection against wear-and-tear, and the tube and tank industries, where coatings provide optimal protection for the interior and exterior surfaces of pipes and metal storage containers.

Other application areas for IMT’s spray and coating systems fall into the category of “sanieren”, or remediation. Here, coatings are used to remediate concrete surfaces that belong to railway lines, sewage systems, seaside wave breakers, and sewage and wastewater treatment plants. Our photo block either shows IMT systems in action in several of these applications, or the results of remediation carried out with OPTI MIX or other systems manufactured and available from IMT Spray Systems GmbH.

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