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Ideal Solution for VOCs Capture & DOP Recovery
The origins of modern industrial electrostatic exhaust purification equipment and electrostatic precipitation technology can be traced back to traditional electrostatic precipitators, widely used for dust control in heavy industries like power plants, steel mills, and construction materials production. With technological advancements, electrostatic precipitators are evolving toward larger-scale designs and wider electrode spacing. Traditional designs typically have electrode gaps under 300 millimeters, whereas wide-spacing technology increases the gap to 400 millimeters or more.
When PVC resin is combined with solvents like D70 or D80 or plasticizers such as DOP, it creates a flexible or semi-rigid material that can be molded using processes like dipping, extrusion, injection molding, or calendering. However, these solvents can release volatile organic compounds (VOCs), which pose health and environmental risks if not managed properly. Effective VOC capture is essential to reduce emissions, protect workers, and safeguard the surrounding environment.
Flexible PVC products, which use a high plasticizer content, include items such as PVC gloves, artificial leather, inflatable toys, hoses, cable insulation, and films. In contrast, formulations with lower plasticizer levels or solvent-based processing yield semi-rigid and rigid products like adhesives, protective coatings, shoe soles, foam products, sheets, boards, and toys, with solvent-cast PVC also serving as a base for inks, paints, and dipping compounds.
VOCs' Thread to Human Health and Environment
VOCs (Volatile Organic Compounds) are harmful to both human health and the environment. Short-term exposure can cause headaches, dizziness, eye irritation, and respiratory problems, while long-term exposure increases the risk of serious health issues like liver damage, cancer, and neurological disorders. Environmentally, VOCs contribute to the formation of ground-level ozone, which is a key component of smog, damaging plant life and reducing air quality. Some VOCs also act as potent greenhouse gases, exacerbating climate change by trapping heat in the atmosphere.
VOCs Recovery Greatly Hedges Production Cost
The economic value of solvents in chemical production costs is significant, as they are often key components in manufacturing processes. Recovering and reusing solvents, via technologies like VOC recovery systems, can significantly reduce costs. Recycling solvents reduces the need for fresh supplies, cuts disposal expenses, and can even generate additional revenue from reprocessed materials. Here's a brief overview of their role:
Solvents, such as D70, D80, or DOP, are typically a large part of raw material costs. They are used for dissolving, mixing, or carrying other substances, and are often required in high volumes for processes like coating, cleaning, or product formulation.
Solvents can enhance production efficiency by improving flow, reducing viscosity, and preventing blockages in production lines. They help optimize the use of materials and reduce waste, potentially lowering overall production costs.
Solvent disposal and managing VOC emissions come with regulatory costs. Efficient solvent usage and recovery can reduce waste disposal costs and ensure compliance with environmental regulations, minimizing fines and operational disruptions.
Don't Let RTO Burns Your Money
If VOCs can be recycled, then using an RTO to burn them away is like burning money. While RTOs are effective at destroying VOCs, they don't capture or reuse the valuable chemicals. Instead, they incinerate them, wasting the potential for recovery and reuse. In contrast, VOC recovery methods like carbon absorption allow for the recycling and reuse of VOCs, turning waste into a resource and offering long-term economic and environmental benefits.
Kleanland VOC Capture System
Kleanland developed a VOC recovery system in 2018 that quickly gained over 90% market share in plastic glove factories. This system effectively recycles VOCs—turning waste into reusable chemicals—and often delivers a 100% payback within a year, especially as PVC glove production surged during the pandemic. It is particularly adept at recycling viscosity reducers and DOP.
Kleanland VOC Recovery dominate 90% Projects with PVC glove manufacturers
How Kleanland VOC Capture System Work?
Smoke Collection and Cooling
During the glove manufacturing process, exhaust gases containing hot steam and oil fumes are collected by a smoke collection system. These gases are directed through ducts to a cooling unit, where circulating water lowers their temperature to below 30°C. As a result, pollutants condense into larger particles, making them easier to remove.
Electrostatic Purification
After cooling, the exhaust gases enter an electrostatic oil smoke removal system. High-voltage electrostatics charge the oil smoke particles, causing them to adhere to the anode plates of the device. The collected particles then flow down to the bottom of the system and are discharged safely through a pressurized pipe.
Exhaust Gas Discharge
The purified air is transported by an induced draft fan through ducts and is finally released into the atmosphere through a chimney, ensuring that only clean air is discharged.
Fire Safety Features
The system is equipped with an automatic fire safety mechanism. If a fire hazard or temperature anomaly is detected, the fire protection system is instantly triggered. The safety measures include:
What Industries May Apply this System to Save Production Cost?
Coatings and Paints
Contain organic solvents such as benzene, toluene, and xylene, which release VOCs during spraying or drying.
Solvent-based coatings, paints, varnishes, thinners.
Building coatings, automotive painting, furniture surface treatment.
Printing and Inks
Solvents in the ink (such as ethyl acetate, acetone) evaporate during printing and drying.
Packaging printing, publication printing, label production.
Adhesives and Sealants
Contain volatile components like formaldehyde and ethyl acetate, which release VOCs during curing.
Industrial adhesives, construction sealants, shoe adhesives.
Plastics and Rubber Products
Plasticizers and foaming agents (such as benzene compounds) decompose or volatilize at high temperatures during processing.
Plastic injection parts, rubber tires, foam materials.
Furniture and Wood Products
Adhesives (urea-formaldehyde resin) and surface coatings release formaldehyde and benzene compounds.
Engineered wood, wooden furniture, composite flooring.
Textiles and Dyeing
High-temperature treatment in stenter machines releases formaldehyde, organic silicon, and other VOCs.
Dyed fabrics, coated textiles, exhaust from fabric finishing processes.
Petrochemical Products
Refining, storage, transportation, and usage processes lead to volatilization.
Gasoline, diesel, lubricants, solvents (such as xylene, styrene).
Electronics Manufacturing
VOCs evaporate from cleaning agents (isopropanol), solder flux, and photoresists.
Circuit boards, semiconductor packaging, display screens.
Automotive Manufacturing
Solvent-based coatings in paint shops and adhesives in interiors release benzene, toluene, and other VOCs.
Automotive coatings, interior materials, adhesives.
Pharmaceuticals and Cosmetics
Ethanol, acetone, and other solvents used in production volatilize during packaging.
Drug synthesis, perfumes, nail polish.