Design and performance evaluation of a paint particle dispersion reduction device for airless spraying

Abstract

Airless spray painting, widely adopted for its efficiency and cost-effectiveness, generates a significant amount of airborne paint particles that contribute to air pollution and pose health risks to workers and nearby residents. In this study, a paint particle dispersion reduction device (PPDRD) utilizing an axial cyclone separator and a high efficiency particulate air (HEPA) filter was designed and evaluated to minimize the dispersion of paint particles during airless spray applications. The cyclone separator captured larger paint particles through centrifugal force, while the HEPA filter effectively removed smaller particles that escaped the cyclone separator. Computational fluid dynamics (CFD) simulations were conducted to optimize key design parameters, including the number and height of guide vanes and suction flow rate. Lab-scale and field experiments demonstrated that the PPDRD significantly reduced airborne paint particles, with respirable particles (4 μm or smaller) decreasing by 50–80 % depending on particle size, while maintaining coating quality. These findings indicate that the PPDRD effectively mitigates the inhalation risks associated with hazardous paint aerosols, providing a practical solution for improving workplace safety and environmental compliance. This technology is expected to be widely applicable in exterior building painting, shipbuilding, and the automotive industry.