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Industrial Volatile Organic Compounds Control

VOCs treatment project at a well-known shipbuilding paint base

Paint production releases organic waste gas with large concentration fluctuations and complex components ( VOCs ). How to balance emission standards, energy saving and emission reduction, and workshop environment improvement? A well-known shipbuilding paint production base applied MEGAUNITY's new generation of waste gas collection technology and combined purification system to further improve energy efficiency and workshop environmental quality. The system has been operating stably and has achieved significant results. Let's reveal how it achieves workshop environment renewal and a double reduction in comprehensive operating costs 。

Project Background: Facing Three Core Challenges

The base continuously produces process waste gas and environmental exhaust during production. Its components are complex (containing ethyl acetate, xylene, acrylic acid, and more than ten other organic solvents), and its emission characteristics are significantly different, making governance face three difficulties:

1、 Insufficient source capture efficiency : The original workshop exhaust system has limited capacity, and the peak concentration of waste gas repeatedly exceeds the safety threshold during high-intensity operations such as material loading and tank cleaning.

2、 Fluctuating load impacts system stability : Multiple production lines and asynchronous processes lead to continuous fluctuations in waste gas volume and concentration, easily causing system instability or unexpected shutdowns.

3、 Persistent odor pollution affects the working environment ： Solvent volatilization and process residues form low-concentration, high-odor threshold mixed odors, which have a long-term impact on employee health and production comfort.

Overcoming Pain Points: Three-Level Technology Combination Breaks the Deadlock

To accurately grasp the characteristics of waste gas, the MEGAUNITY technical team spent tens of days in-depth investigation at the customer's production site and conducted systematic basic data surveys; strictly in accordance with the actual operating needs of the workshop, they conducted multi-dimensional and high-density waste gas sampling and analysis at different time periods for different floor operating areas, exhaust ports of existing dust removal equipment, and dust-free process waste gas emission points. Based on this, it is customized " Classification governance, combined purification ” strategy:

1、 Equipment modification, collection upgrade

Using MEGAUNITY's latest generation of waste gas collection technology, the factory's existing production equipment is directly modified for equipment installation to improve the VOC capture efficiency of operations such as material loading, dispersion, and packaging, reducing dust escape and material loss.

2 、Renovation and upgrading, revitalizing assets

Targeted modifications are made to the existing waste gas treatment equipment to allow it to continue to process waste gas from newly planned specific areas, effectively controlling investment costs.

3 、Zeolites rotary wheel + RCO system, subduing large-volume, low-concentration waste gas

Applicable objects: Large-volume, low-concentration environmental exhaust and dust-free dispersed waste gas

The zeolite rotary wheel efficiently adsorbs VOCs in large-volume, low-concentration waste gas, concentrating and desorbing it into small-volume, high-concentration waste gas. RCO system, under the action of a catalyst, only needs 400℃ or so of a lower temperature to completely decompose high-concentration waste gas into CO₂ and H₂O . Its high 99% purification efficiency and 95% heat recovery efficiency balances purification effect and ultra-low energy consumption (significantly more energy-efficient than high-temperature RTO ).

4 、High-efficiency dust removal +RCO system, directly targeting high-concentration dusty waste gas

Applicable objects: Dusty, high-concentration process waste gas

Waste gas first passes through a high-efficiency dust removal and filtration device to remove dust, protecting subsequent equipment, and then directly enters RCO the system for catalytic oxidation purification, with a highly efficient process.

5 、Intelligent safety, stable escort

Constant pressure balance: The system automatically adjusts the pressure of each branch line, reducing transportation energy consumption;
Intelligent monitoring: Real-time monitoring of key parameters such as concentration and temperature, automatically optimizing operation to ensure stable compliance;
Multiple protections: Equipped with emergency discharge, flame arresters, explosion vents, and other multi-level safety interlocks and emergency measures to ensure system safety.

Significant Results: Stable and Reliable

Accurate and efficient: The most suitable process is adopted for waste gas of different origins and characteristics, resulting in high processing efficiency;
Economic optimization: Renovation and upgrading save investment; zeolite rotary wheels significantly reduce energy consumption for large-volume processing; RCO High heat recovery efficiency reduces operating costs; combined processes maximize equipment utilization and avoid waste;
Stable and reliable: The scientifically designed concentration range and balance mechanism effectively cope with fluctuations, ensuring continuous and stable emission compliance and eliminating the risk of unplanned shutdowns caused by excessively high concentrations;
Environmental improvement: Significantly improves the air quality inside the workshop, ensuring personnel health.

This system is a complex system for the paint industry VOCs Waste gas treatment provides a highly efficient and economical technical model, achieving a win-win situation in terms of environmental and economic benefits. MEGAUNITY, with its rich industry experience, has provided services to well-known paint companies such as Nippon Paint, AkzoNobel, and Nippon Paint. VOCs The equipment has been running stably for a long time, and has been highly recognized by customers.