Multi-stage, atex compliant turn-key systems for dust filtration – VOC abatement

How we made it and what we used: two important challanges to solve big customer’s needs in chemicals, adhesives and cosmetics production

Case 1 | Adhesives and home-care chemicals production…special needs!

The customer presented in this case-history is a global company and a world leader in adhesives, cosmetic, detergents and home-care products.

During the assessment-step related to a new production plant construction, the customer contacts Tecnosida® requiring project evaluation and design for two abatement systems deeply customized on production process needs.


Chemical intermediates and raw materials (such as epoxy and silicone resins) are extensively used in the production lines; these substances contain variable amounts of calcium carbonate, carbon black and crosslinking resins.

Given the explosive nature of the compounds, the system Tecnosida puts forward shall comply with ATEX norms.

After a technical site inspection, Tecnosida® designed a complete solution that guarantees:

  • an adequate air suction, in order to protect internal users and workers in production facilities;
  • a sealed piping network to convey gaseous substances and vapors, with flexible drop lines and shutters for local collection points exclusion;
  • a multistage filtration and depuration system with:

The complete system was designed to meet specifical binding requirements of italian health and environment legislation.

Do you want to learn more about: “Multi-stage, atex compliant turn-key systems for dust filtration – VOC abatement“?

Step 1 – Collection and air ventilation

Tecnosida® designs a suction and ventilation line composed of 20 collection points able to capture all pollutants directly at the source. The whole lsystem was projected and balanced with regards to the possibility, given to each user/point, to open/close the local suction point due to non-continuous activities developed.

According to specific dimensions, quality and profile of each operative area, suction armshoods and fittings were selected and applied to ensure best efficency and efficacy.

All the system, and each one of the components, has been designed in accordance with the  ATEX directive 94/9/CE-99/92/CE DPR126/98 and completed with an equipotential connection of metal mass for grounding.

Articulated arms for air extraction

Step 2 – Air Filtration

Multi-stage air filtration system

Due to the mixed nature of main pollutants to be treated, two air treatment lines have been designed and manufactured,  was given installation to a multi-stage abatement systems.


An ATEX II 3 D certified cyclone system, made of carbon steel for dusty compounds pre-separation was designed and installed. This stage is used to pre-separate dust up to a certain granulometry and was completed with rotary valve for discharge.

Dust collector

Dustdown® self-cleaning bag filter was installed to remove fine dust and particulate matter (PM). This filter was equipped with anti-explosion safety panels and designed to comply with ATEX standard;

Activated Carbon Filter

Finally, a Chemsorb® active carbon purifier for adsorption of fumes and chemical vapors (VOC) present in the flow was designed and installed. This purifier was equipped with safety panels and is ATEX II 3 GD compliant too.

Step 3 : Commissioning and Testing

The turnkey system delivery included electrical panel, connection of utilities and pressure inverters / stabilizers for ventilation management.

Our specialized technicians have carried out final testing and calibration of all managed parameters of the plant.

Tecnosida®  plant was realized in compliance with Lombardy BAT- Best Available Technologies (D.MF.01, AC.RI.01 and D.MM.01) and was able to reduce pollutants emissions in compliance with all limits established by national and local legislation.

Do you want to learn more about: “Multi-stage, atex compliant turn-key systems for dust filtration – VOC abatement“?

Case 2 | Chemical specialities and intermediates production

The customer presented in this case history is a global company that operates in the chemical sector developing, producing and marketing chemical specialties and intermediate products. For this reasons production processes considered here are dedicated to create multiple compounds, including anionic and cationic surfactants, polyurethanes, adhesives, sealants and chemicals specialities for textile industry.

For its typical production processes, the chemical plant where the solution described below was adopted shows a non-stop (24h) operation system and is characterized by complex connection points, many mixing areas, vat and piece washing equipments and component/raw materials loading units.

ATEX Symbol

With such a different and distributed range of process, sub-process and operations, the first step taken into account was an internal assessment to define which specific needs were relevant as far air pollution control was concerned.  The output of this analysis indicated that there was a clear necessity to:

  • to capture and break down powders, both from mineral and polymeric matrix
  • to treat solvent vapors (VOC) containing traces of isocyanates also.

The two groups of pollutants listed above, besides, were mixed toghether and is mixture of dust and solvents, in relation to its chemical-physical characteristics, could be flammable and even explosive. This elements indicated that all filtration and abatement system should be designed and manufactured in accordance with the ATEX European directive.

Turnkey multi-stage system

Following a careful on-site technical inspection, Tecnosida® proposes the construction of a turnkey system  for dedusting, conveying and VOC treatment.

Pollutants collection

The collection step was performed through suction arms and hoods specially sized according to the geometry of the production machines and the specific suction needs. In this application the components are all ATEX certified in order to be used in a potentially explosive atmosphere

Ventilation system

Air conveyoring was performed through the installation of specifically designed pipes used to bring air and pollutants from the sourcing area to the abatement system;

Two-stage abatement system

  • In the first stage is performed dust filtration. This process is carried out through a Dustdown® bag filter which is particularly suitable to remove fine and ultrafine dust and particulate. The filter was designed and equipped to be ATEX compliant and included specific components such as anti-explosion safety panels.
  • In the second stage three parallel activated carbon filters Chemsorb®  were deisgned to allow a challanging break down phase for vapors and VOCs deriving from solvents use. These purifiers were realized in vertical version and in compliance with ATEX directive.
Dust collector with three active carbon filters

The plant was built in compliance with Italian (Lombardy) BAT Best Available Technologies (D.MF.01 and AC.RI.01) and was able to reduce the emissions of pollutants well below manadatory legal limits, thus solving the customer’s problems.