Integrated Design and Performance Validation of an Advanced VOC and Paint Mist Recovery System for Shipbuilding Robotic Spraying

Volatile organic compounds (VOCs, dominated by xylene, toluene, and benzene) and paint mist emissions from ship painting represent a major environmental and health concern, posing a critical bottleneck to the green transformation of the shipbuilding industry. To tackle this challenge, this study presents an integrated recovery system designed specifically for ship automatic-spraying robots. Guided by the synergistic principle of “air-curtain containment, multi-stage adsorption, and negative-pressure recovery,” the system features a modular design that ensures full compatibility with the robots’ spraying trajectory without operational interference. Core adsorption materials, namely glass fiber filter cotton and honeycomb activated carbon fiber, were selected to suit the high-humidity and high-pollutant-concentration environment typical of ship painting. An appropriately matched axial flow fan maintains stable negative pressure throughout the system. Furthermore, the design integrates an air curtain isolation subsystem and an automated control subsystem, enabling coordinated operation and real-time adjustment. Using ANSYS Fluent, geometric and flow field simulation models were established to analyze airflow distribution and pollutant adsorption behavior, which led to the optimization of key structural and material parameters. Field experiments conducted in shipyard environments demonstrated the system’s superior performance: it achieved a VOC removal efficiency of 88.4% and a paint mist capture efficiency of 85.7% under optimal working conditions, with a maximum simulated paint mist capture efficiency of 86.2%. The system maintained stable performance under complex vertical and overhead spraying conditions, with an efficiency attenuation of less than 1.5%, and its outlet emissions fully complied with the mandatory limits specified in the Emission Standard of Air Pollutants for the Shipbuilding Industry (GB 30981.2-2025). The relative error between experimental data and simulation results is less than 2%, confirming the reliability and practicality of the proposed system. This research provides an efficient and adaptable pollution control solution for green shipbuilding and offers valuable technical insights for the sustainable upgrading of automated painting processes in heavy industries.