Ch emi cal Pr ocess I ndust ri es

CH-211

E n g r . Ka mr a n A l a m
DEPARTMENT OF CHEMICAL ENGINEERING
FACULTY OF MATERIAL & CHEMICAL ENGINEERING
11/24/2019GHULAM ISHAQ KHAN INSTITUTE OF ENGINEERING SCIENCES & TECHNOLOGY 1
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INTRODUCTION

o The final finishing of all surfaces such as walls, ceilings,

woodwork, metalwork, etc is necessary to make them
look good and also for their protection from moisture
and corrosion etc.
o So according to the nature of the surface and the finishing
required, the surface should be coated with different types
of paints.

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INTRODUCTION
Any Liquid that after application to a
Substrate in thin Layer ,converts to a
Solid Film

“mixture of Pigments, Binder,

and Solvents imparting desired
colour and protection”

P i g m e n t s : gives the paint color, B i n d e r : sticks the S o l v e n t s : to make the

make is opaque and occasionally paint to the surface paint spreadable
to prevent corrosion 11/24/2019
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W H Y D O W E N E E D PA I N T S ?

Art work protect metals from corrosion reflective coating water insulation for
roofs & ceilings

thermal insulation to reduce

the energy consumption of Fire Resistant Coating for generating electricity from heat energy.
cooling appliances. 11/24/2019
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PAINT CLASSIFICATION

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TOP 5 PAINT PRODUCERS

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W ORLD WIDE PAINT PRODUCTION

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BASIC PAINT CONSTITUENTS
Paint Ingredients
o Every paint is a mixture of microscopic color, p i g m e n t
p a r t i c l e s , which provide the paint mixed in a
liquid p a i n t v e h i c l e that holds the pigment in
suspension, allows it to be applied with a brush, then
dries to bind it to the support (paper, board or canvas).
o The v e h i c l e also contains other substances that
reduce manufacturing costs, adjust the visual
appearance and handling attributes of the paint, and
increase its shelf life.
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 Backbone Composition
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o Each paint manufacturer develops a b a c k b o n e c o m p o s i t i o n (basic recipe of pigment

& vehicle ingredients) that is fundamentally designed to keep manufacturing costs under
control & to get the best possible handling attributes
o The backbone composition usually includes most or all of the following ingredients

 vehicle or medium consisting of:

Binder, plasticizer, humectant, extender or filler,
m a n u f a c t u r i n g a d d i t i v e s and w a t e r
 one or more p i g m e n t s
 Br i g h t e n e r (transparent or "white" crystals) that lighten the
value and increase the chroma of the dried paint dispersed in
Vehicle
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Chemical Inorganic Compounds With Appealing/Useful Color

1. PIGMENTS
Attributes And That Do Not Dissolve In Water.

Various pigments used for making paints are

 White: White lead, titanium dioxide, zinc oxide.
 Red: Red lead, iron oxides, etc.
 Blue: Ultramarine, cobalt blues, iron blues etc.
 Black:
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Carbon black, lamp black, furnace black etc
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2. Extenders/ Fillers
improve consistency, levelling
and setting of the paint 3. Driers
Acts as catalyst & promotes oxidation
Decrease the cost of paint
process which accelerates drying of the film
Increase weathering power They dissolve in the hot oil and the drying
of the film
time is much reduced
e.g. Talc, china clay, gypsum, silica,
Too rapid drying is not desirable because
barite, glass flakes, asbestos etc.
of some unwanted effects, e.g, wrinkling.

e.g. Initially PbO was used as a drier, but the

11/24/2019 modern driers are Co, Mn, Zn, etc
 Backbone Composition
7. Plasticizers
Provide elasticity to the film and thus
prevent cracking of the paint.
Chemically, plasticizers are mostly esters
e.g.
Triphenyl phosphate, castor oil etc
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5 . T h i n n e rs
dissolve film forming material and to thin
concentrated paints for better handling
Also used to suspend pigments
Solvent such as, spirit, toluene and
e.g.,
turpentine maintains the fluidity of the
freshly applied film for reasonable period
of time.
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6 . A n t i - s ki n n i n g a ge n t

An anti-skinning agent is any corrosion

coating maintenance measure taken to 8 . Re s i n s
prevent the formation of insoluble skins
on a coating's surface due to Resins are film forming
polymerization or oxidation reactions
materials required for water
base paints & contain no oils.
Certain anti-skinning agents are also e.g.
added to the paint in order to prevent Varnishes etc
gelling and skinning of the finished
product before application of the paint
by brushing, spraying or dipping

e.g. 11/24/2019
Polyhydroxyphenols
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9 . B i n d e rs

act to fix the

paint on the 10.Extenders
coated surface
Extenders are added to 11. Oher Compounds
and provide
the paint mix in order
tough and glossy Water based paints also
to prevent the
film on the surface require dispersing agents
cracking of the film
being painted (e.g. casein), antifoam agent
when dry.
(e.g. pine oil) & preservative
e.g.,
Clay, talc, etc. (e.g. chlorophenol).

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 Paint Manufacturing

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PA I N T M A N U FAC T U R I N G


Mixing of mill
 base with other

Thinning and
Required amount
 paint ingredients
of ingredient along 

Tinting
or tinting agents 
with pigments and
vehicles are mixed
in mixer. 
Thinning and
(Sigma mixer)
tinting in

agitated tanks
dispersion is done by breaking down
bigger aggregates and agglomerates
to smaller
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PA I N T M A N U FAC T U R I N G
o Sigma Mixers: Disadvantages:
Advantages  mixer works at a fixed speed.
 Ideal for mixing, kneading of highly viscous  Power consumption is high

mass, sticky & dough like products

 creates a minimum dead space during
mixing.
 Used for liquid-solid mixing and solid- solid
mixing, the wet granulation process in the
manufacture of tablets, pill masses.
 It has close tolerances between the blades and
the sidewalls as well as bottom of the mixer shell.
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PA I N T M A N U FAC T U R I N G

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T I N T I N G, S H A D I N G & TO N N I N G
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PA I N T M A N U FAC T U R I N G
o FEEDING, WEIGHING, ASSEMBLING AND MIXING
o Required amount of ingredient along with pigments and vehicles are mixed in mixer which is
usually high speed disperser (e.g., sigma mixer).

o Grinding and Mixing

o The basic operation in the manufacture of paint is the dispersion of pigment particles
(often mixed with extenders) in a paint vehicle or medium to produce uniform, stable system.
o The process of pigment dispersion essentially consists of wetting, dispersion and stabilization of
pigments and extenders in vehicle.
o The dispersion involves breaking down bigger aggregates and agglomerates to
smaller units in mills (usually ball/pebble), wetting of these units and particles by
the paint medium and stabilization of the resulting dispersion.
o The choice of pigment and vehicle are dominant factors in selecting the equipment to be used
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PA I N T M A N U FAC T U R I N G
o After grinding, the mill base is mixed with other paint ingredients, i.e. vehicle and other
additives and if necessary with tinting agents in mixer.
Thinning and Tinting:
o it is then thinned and tinted with agitated tanks, that may hold batches for thousands of liters.
From centrifuging up to Storage:
o Centrifuges, screen, or pressure filters are used to remove non-dispersed pigments.
o The straining of paint is done to remove contaminants and it generally utilize metal or
synthetic fiber gauge (screen).
o The paint mixture is then poured into cans or drums, labeled, packed and moved to storage,
each step being completely automatic.

Tests carried out for finished paint: degree of dispersion (i.e., fineness of grind), viscosity etc.
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PA I N T M A N U FAC T U R I N G
S E T TI NG OF PA I NT
o When the paint is applied on the surface of the metal or wood, the oil present in it
forms a protective film of dried oil.
o The film is formed through oxidation in presence of air and polymerization of the
unsaturated constituents of drying oil.
o The drier present in the paint accelerates the drying of the protective film through
oxidation and polymerization and thus acts as a catalyst for these reactions.
o Pigments strengthen the film and protect it by reflecting the destructive ultraviolet light,
while extenders increase the covering power and weathering of pigments and thus
improve the consistency, levelling and setting.
The cracking aspects are reduced by adding some oils as plasticizers.
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PA I N T M A N U FAC T U R I N G
RE QUI RE MENTS OF A GOOD PA I NT
 Pigment should be opaque to ensure good covering power.
 Should be chemically inert to secure stability and hence long life.
 Should have a good colour and high hiding power.
 Should be weather resistant.
 Should have good wash-ability and metal anti corrosive property.
 Its consistency should be suitable to appreciation by the types of
application such as brushing or roller coating.
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PAINT FAILURE
The main reasons of paint failure after application on surface are the applicator and improper
treatment of surface.
Dilution
 This usually occurs when the dilution of the paint is not done as per manufacturers
recommendation.
 There can be a case of over dilution and under dilution, as well as dilution with the
incorrect diluent.

C O N TA M I N AT I O N
 Foreign contaminants added without the manufacturers consent which results in various film
defects.

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PAINT FAILURE
Weak to support paint attract
Blast Cleaning/
coating on surface
moisture &
Mechanical Cleaning
salt
Being porous

Interferes in adhesion
between surface & Degreasing
Coating

Paint adheres well to dust

Result
Detachment of dust along Compressed air / Vacuum
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PAINT FAILURE
Osmotic Adhesion Fresh Water
Failure &
Blistering Cleaning
Corrosion

• Blast Cleaning,
adhesion/ Unevenness of
• Mechanical
cohesion the Painted
Cleaning,
Compatibility Surface
• Paint Removal

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PAINT APPLICATION DEFECTS

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PAINT APPLICATION DEFECTS
• progressive powdering of paint film from the surface
• paint weathers and the binder is slowly degraded by sunshine/moisture or
destructive oxidation of the oil after drying, releasing the binder's hold on

CHALKING the pigment.

• All paints chalk to some degree, it is a normal, desirable way for the paints to wear
away and provide a good surface for future repainting.

• Refusal of some portions of the surface to be painted is called cissing

• caused by painting over contaminated surfaces such as wax, oil or polish. The
CISSING paint cannot adhere to the surface and draws away leaving unpainted areas.

• Allow the surface to dry and then rub down using 'wet and dry' abrasive paper and a solution of
warm water and detergent. Once rinsed and dried the area can be repainted.
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PAINT APPLICATION DEFECTS
• Formation of bubbles like shapes due to poor adhesion of paint to the
surface.
• Due to water vapor trapped between the paint films or Painting in direct sunlight
BLISTERING
on a hot surface trapping solvent vapor as the paint dries too quickly.
• Scrape away blistered paint, ventilation, paint in non-direct sunlight and non-
humid conditions.

• Discolouration of paint film due to pigment seeping to the surface from

undercoats or gum from knots in timber.
• strip off the old paint. If this is impractical, seal the surface with anti Knotting
BLEEDING
agents or Aluminium Wood Primer.
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PAINT APPLICATION DEFECTS
• Formation of a waterfall – like appearance on the surface
• due to , too much paint being applied in one coat or thinning
the paint too much.

SAGGING • sand and reapply a new coat of paint.

• Formation of soap patches

• Due to Chemical action of alkalis in the presence
of moisture
• using Alkali Resisting Wall Primer, strip, wash, allow to dry
SOAPNIFICATION
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PAINT APPLICATION DEFECTS
• Hairline cracking, will eventually flake off as the cracks become more
evident and begin spreading.
• due to the absence of plasticizers, poor surface preparation or
Checking/Flaking applying a paint that is too thin.

• If the center portion remains attached to the surface and the portion
around the center peels off, then paint is alligatoring.
• applying a topcoat to a glossy surface and it cannot bond

ALLIGATORING properly, insufficient dry time, multiple coats of an oil

based paint that have aged.
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PAINT APPLICATION DEFECTS
E F F L O R E S C E N C E • Formation of a series of open blisters in a paint film due to soluble
salts rising to the surface from brick, plaster and cement
objects.
• requires the removal of the moisture source.

• Appearance of a darker/denser color or higher sheen where two

layers overlap during paint application.
• when wet and dry layers of paint overlap.
• Failure to maintain a "w e t e d g e " when painting

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PAINT APPLICATION
o Paint application is mostly done by hand brushes and rollers.
o Spray painting are gaining favor over other methods because of the ease and
rapidity of spread, thus saving labor, though wasting a little material.

o A wide variety of atomizers for spray paintings are available, including internal and
external mixings.

o Spray guns are operated frequently at pressure of 275 to 414 kPa.

hand brushes
11/24/2019 atomizer Spray guns
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PAINT TYPES (based of their applications)
A. Rust Inhibiting Paints & Primers:
• formulated with anticorrosive pigments to prevent or reduce the corrosion of metal surfaces.
B. Fire Retardant Paints:
Formulated with silicone & polyvinyl chloride to reduce the flame spread of combustible material
C. Heat Resistant Paints:
• Formulated with silicone resins to withstand high temperatures.
D. In tumescent Coatings:
• These when exposed to the heat of a fire, swell to form a thick insulating layer of inert foam that
retards flame spread and combustion.
E. Distempers:
• durable and economical water based paints. The major constituents of distemper include
colouring
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PAINT TYPES (based of their applications)
E. Emulsion Paint:
• These are the superior quality of paint formed by mixing oil/water and an emulsifying
agent to prevent the combination separating. They have much better ease of application,
are washable and have a greater overall decorative appeal.
F. Cement Paints:
• It is a special paint coatings made for masonry and cement-based materials, including
concrete, mortar (and brick), concrete block and stucco. Not only it adds to the aesthetics

of the wall but also provides a waterproofing coating.

G. Enamel Paints:
• Enamels are hard, washable and usually glossy paints. They can be oil based or alkyd based
and come in several sheens. They find application not only on metal surfaces but also on
interior
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