Stenter Emission Purification and Heat Exchange Recycling Energy-Saving Solution
This an emission control solution for fabric stenter machine at textile production line in textile plant. The textile stenter machine uses gas to heat and set the cloth. Its high temperature waste gas is toxic and contaminating. Kleanland electrostatic precipitators are specially tailored for stenter machine waste gas purification and heat recycling resuage.
Kleanland Stenter Machine Air & Heat Handling System
Garment Finished Treatment Procedures
The textile dyeing and finishing process typically includes four main steps:
These steps can vary depending on the type of product.
A stenter machine plays a crucial role in the finishing stage of textile production. When fabrics are heat-set, the process involves high temperatures, which produce large amounts of hot gases inside the machine's oven. These gases often carry harmful pollutants, including organic oils, dyes, chemical additives, lubricants, and tiny fibers. The emissions, which contain oil, smoke, and dust, can seriously harm both human health and the environment.
Fabric Stenter Machine Usage and Its Pollution Source
Heat-setting is a critical step in textile production where fabric is stretched under controlled tension and heated to a precise temperature. During this process, substances such as weaving oils and dyeing auxiliaries are applied to enhance the fabric’s performance. After maintaining the fabric at high temperature for a set period, it is rapidly cooled. This cooling solidifies the changes made to the fabric's microscopic structure, removes internal stress in the fibers, and gives the material a stable, durable shape that resists deformation.
A textile stenter machine is commonly used for this process, and it plays a dual role: shaping the fabric and emitting exhaust gases. These emissions contain a mix of pollutants, including oily residues, chemical additives, and microscopic particles. Understanding and optimizing the stenter machine's operation not only improves fabric quality but also minimizes environmental impact. A simplified flow diagram of the stenter machine’s operation and waste gas emissions is provided below for reference.
The stenter machine operates at high temperatures, typically between 180°C and 220°C, to heat-set fabrics. During this process, the fabric releases a mix of water, solvents, and oily residues due to evaporation caused by the heat. These residues often include complex chemical compounds like synthetic fiber oils, softeners, antistatic agents, and emulsifiers (such as phosphate esters, fatty acid esters, sulfate esters, and polyethers). Additionally, lubricants and finishing agents applied during fabric treatment (e.g., for water repellency or fire resistance) further add to the chemical complexity of the emissions.
The released pollutants include aldehydes, ketones, hydrocarbons, fatty acids, alcohols, esters, lactones, heterocyclic compounds, and aromatic substances. These compounds are expelled along with hot exhaust air through the machine's chimney.
The exhaust gases from the stenter machine contain fine oil mist particles with concentrations ranging from 50 to 200 mg/Nm³ and particle sizes between 0.01 to 1.0 μm. These gases are also quite hot, with temperatures around 120°C to 150°C. The unique challenges of stenter exhaust emissions lie in their combination of high temperature, high humidity, and high pollutant concentration.
Given their chemical makeup and physical properties, managing and treating these emissions is critical to reducing environmental and health impacts. Advances in filtration and gas treatment technologies are essential to address these challenges effectively.
Textile Stenter Waste Emission Control Work Flow
Based on the characteristics of the exhaust gas, this process is designed to include the following components:
Smoke collection system (fan, ducts) → Cooling system → Primary purification system (electrostatic adsorption) → Extraction and discharge system (terminal fan, ducts, chimney).
A flow diagram of the treatment process is shown below.
Explanation for the Textile Cloth Stenter Air Cleaning Solution
Collection and Cooling:
The hot, moisture-filled exhaust gases from the stenter machine, containing oily fumes, are captured by a smoke collection system. These gases are then transported through pipelines to a cooling unit, where circulating water lowers their temperature to below 40°C. This cooling causes pollutants to condense into larger oil mist particles, making them easier to remove.
Electrostatic Purification:
The cooled exhaust is directed into an electrostatic precipitator. In this system, high-voltage electrostatic fields charge the oil mist particles, which are then attracted to and collected on the device’s anode plates. The collected oil flows to the bottom of the unit and is safely drained away. Additionally, ozone generated within the electrostatic unit neutralizes some odors, further improving air quality.
Exhaust Discharge:
After purification, the cleaned exhaust gases are expelled through a fan system and released into the atmosphere via a chimney, ensuring compliance with environmental standards.
Fire Safety System:
To ensure safety, the purification system is equipped with an advanced fire protection mechanism. If a fire is detected by sensors or the thermal detection system, the fire safety system activates immediately. It:
Cuts power to the electrostatic equipment.
Rapidly closes fire dampers at both ends of the unit to prevent fire spread and block airflow.
Opens motorized valves to release firefighting water into the unit, extinguishing the fire.
Triggers audible and visual alarms to alert operators.
This process ensures both environmental compliance and operational safety, providing a robust solution for managing stenter machine exhaust emissions.
Kleanland Offers 2 Air Cleaning Solutions for Stenter Machines
For textile printing and dyeing exhaust emissions, we recommend two solutions: one focused on high performance and the other on cost-effectiveness, tailored to meet the diverse operational needs of users.
High Performance Solution from Kleanland Stenter Emission Control
This solution is specifically designed for handling challenging textile dyeing and printing exhaust gases that are rich in lint, moisture, and paraffin residues. It features an integrated system with the following components:
High-Performance Washing and Cooling Unit:
This unit effectively cools the exhaust gases, pre-treats pollutants, adds humidity for better processing, and prevents fire risks.
Dual-Drive Central Purification Equipment:
This innovative purifier uses a multi-stage independent power supply for its electrostatic fields. If one stage malfunctions or loses power, the system continues running uninterrupted. The purifier automatically adjusts the current based on the pollution level, ensuring efficient operation and energy savings. It is designed with a horizontal structure and a wide-gap electrostatic field, making it highly resistant to lint, water, and paraffin contamination. This design simplifies cleaning and maintenance, reducing downtime.
Specialized Water Tank:
The system includes an advanced oil-water separation tank with multiple filtration layers and cooling capabilities. This ensures that oils and other contaminants are efficiently separated and managed.
This combination of high-performance components makes the solution ideal for managing complex exhaust conditions, providing a balance of efficiency, durability, and ease of maintenance, while also reducing operational costs.
High Cost-effective Solution from Kleanland Stenter Air Purification
This solution integrates a high-performance washing and cooling unit, honeycomb purification equipment, and a fan, offering a streamlined yet effective approach to exhaust gas treatment.
High-Performance Washing and Cooling Unit:
The cooling unit is the same advanced model used in the high-performance solution. It effectively reduces the temperature of the exhaust gases, pre-treats pollutants, and provides fire safety features.
Honeycomb Purification Equipment:
Designed with a horizontal layout, this unit is easy to clean and maintain, reducing operational downtime.
Its honeycomb purification module features small cylindrical electrostatic fields powered by a multi-source, multi-stage system. This innovative design ensures that maintenance can be performed without halting the system, enabling continuous operation and uninterrupted production.
This solution is ideal for businesses seeking reliable, low-maintenance exhaust treatment systems that minimize downtime and maximize productivity. It combines efficiency with ease of operation, making it a practical choice for handling textile dyeing and printing emissions.
Suggested Electrostatic Precipitator Air Handling Units Relating to Stenter Air Filtration
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Device Details
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Tubular Hive Industrial ESP Device
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