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.
- 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.
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.
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.
Step 2 – Air Filtration
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.
Step 3 : Commissioning and Testing
The turnkey system delivery included electrical panel, connection of utilities and pressure inverters / stabilizers for ventilation management.
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.
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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.
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:
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.
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.
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.