WHAT EXACTLY IS A GAS CATALYTIC/IR OVEN?
For curing any paint or powder coating one needs to heat the paint to a specific temperature and retain it for a certain period as recommended by the paint/powder supplier. It is assumed most of the ovens used worldwide will use convection heat transfer with airflow in the oven to heat the parts first which in turn will heat the paint/ powder. This means higher the thickness of the part longer the time it takes in the oven to cure the paint/powder. Consequently higher fuel consumption, high powder consumption, longer length of the oven etc. Normally powder/paint suppliers specify 10 minutes retention time at 180 degrees centigrade to cure powder and 25 minutes at 140-180 degrees to cure paint.
However if we use radiation heat transfer technique we will be able to heat paint/powder directly without heating the metal. However conventional electric infra red heaters produces intense short wave length which is highly sensitive when used to cure paint/powder. Further life of these electric heaters are limited which means replacement costs. Instead radiation heat can be created by oxidizing the gas
(LPG or Natural Gas) using a catalyst .The gas flow can be regulated using a digital program which can be varied or stopped zone wise. Combining little airflow with radiation can even cure paint/powder on complex shape parts. Typically these ovens cure powder in 3 to 4 minutes (total time) & 4 to 5 minutes to cure liquid paints on flat parts saving huge amount of fuel and power.
5 Advantages of using a gas catalytic oven in powder coating plants and painting lines/shops.
1. LOWER ENERGY CONSUMPTION
GAS CATALYTIC OVENS consume way less fuel (around 40 % – 60 %) THAN CONVECTION OVEN. The reason is in conventional ovens the complete component is heated so it consumes more energy and in gas catalytic covens only the paint/powder is heated without heating the whole component, hence gas catalytic ovens are energy efficient.
2. CURES METAL PARTS MUCH FASTER
In convention ovens the component is heated from room temperature to 200 degrees centigrade and it takes 10-12 min to cure depending on the size and thickness of the component. Further it has to be in the oven for a minimum period of time to ensure proper curing, due to this the length of the oven required will be a minimum of 24 meters.
3. MINIMUM MAINTENANCE COSTS
Gas catalytic ovens do not use burners and air circulation blowers hence bringing down maintenance costs drastically.
4.FLASH OFF ZONE NOT REQUIRED
Since gas catalytic ovens heat only the paint and not the whole surface, the time required to cool the component will come down.
5. LOW RUNNING COSTS
Gas catalytic ovens take up less space and consumes low energy hence bringing down running costs.
Prism gas catalytic/IR ovens has been installed successfully and are running worldwide. This gas catalytic oven can be used to cure products like pressure cookers, rail coaches/wagons, hydraulic cylinders, bus bodies, shock absorbers, electric panels, fan components and many more.