Thermal recovery integrated in a heat generator from the converting sector

The intervention proposed for the customer is focused on the abatement of pollutant emissions. The high concentration of these pollutants in outgoing fumes from production however, together with the need for heating diathermic oil that the machine works with, allowed us to combine business with pleasure, namely to fully exploit the combustion of the pollutants themselves to bolster operation of the production machine.

Advantages of the technology

  • High purification efficiency (98-99.5%)
  • Reduced auxiliary fuel consumption, often only necessary for start-up
  • Reduced production of secondary pollutants (CO, NOx)
  • Maximum reduction or elimination of fuel consumption of the heat generator
  • Automatic operation, with easy diagnostics

Intervention and proposal

The removal of the VOC present in the emissions resulting from printed/lacquered/coupled flexible film drying processes through thermal oxidation consists in raising the temperature of the emissions (in accordance with the correct resistance and turbulence time parameters) so as to achieve the following combustion reaction:

VOC + O2 + En. Activation —> CO2 + H2O + heat

The oxidation reaction allows us to further raise the temperature, proportional to the concentration of incoming pollutants and to their heat value.

This energy supply can be exploited not only to replace the activation energy necessary for the occurrence of the reaction, but also to heat the fluids necessary to guarantee the drying processes of the printed/lacquered/coupled materials.

The regenerative solution consists in recovering the energy of the purified gases leaving the combustion chamber, by using the ceramic masses appropriately crossed by the gases to be treated. This also guarantees the maximum heat recovery efficiency.

The excess heat in the combustion chamber is sent to a heat generator incorporated in the plant. The latter is capable of generating the heat necessary to heat the thermal fluids used in the drying process not only by a specific burner, but also by using the hot fumes specifically drawn from the thermal oxidizer.