In the production process of lithium batteries, organic solvents such as NMP and electrolytes are used. If the organic gases generated by their volatilization are discharged into the atmosphere without treatment, they will cause significant harm to the environment and human health. A company in Hebei requires an efficient and stable VOCs treatment system to meet environmental protection requirements and production safety needs. MEGAUNITY customized a solution based on the characteristics of the project's exhaust gas, achieving ultra-low emissions of tail gas and significantly reducing operating costs through optimized design, providing an excellent model for exhaust gas treatment in the lithium battery industry.
Source and Characteristics of Exhaust Gas
The exhaust gas in this project mainly originates from the volatilization of organic solvents used in processes such as raw material stirring, injection machine operation, and vacuum pump operation during lithium battery production.
1. Significant concentration differences:
The concentration and airflow of organic exhaust gases volatilized from different processes vary greatly. This project divides the exhaust gas into low concentration, medium concentration, and high concentration exhaust gas systems based on the characteristics of the exhaust gas.
2. Complex and special composition:
Contains organic solvents such as NMP, ethyl methyl carbonate (EMC), dimethyl carbonate (DEC), and corrosive acidic gases such as hydrogen fluoride (HF);
Contains organosilicon compounds (such as trimethylfluorosilane), which form silicon dioxide after high-temperature oxidation and easily clog equipment;
3. High safety requirements:
The exhaust gas concentration fluctuates greatly, requiring comprehensive safety control measures;
Special exhaust gas components easily corrode equipment, requiring targeted anti-corrosion design.
MEGAUNITY Customized Solution
In response to the complexity and safety requirements of the project exhaust gas, MEGAUNITY adopts a "classified treatment + multiple protections" approach, designing differentiated processes for the three systems and ensuring stable operation through full-process safety control.
1. Subsystem Process Design
1. Low Concentration System:
Process route: Alkali washing tower + dual-stage activated carbon adsorption process
The alkali washing tower removes acidic gases (such as HF) to protect subsequent equipment;
Dual-stage activated carbon adsorption ensures deep purification of low concentration exhaust gas without affecting continuous production.
2. Medium Concentration System:
Process route: Alkali washing tower + activated carbon adsorption-desorption process
The alkali washing tower removes acidic gases (such as HF), the demister and dry filter intercept particles and sticky droplets to protect subsequent equipment; activated carbon is used for adsorption-desorption cyclic regeneration, saving operating costs.
3. High Concentration System:
Process route: Pretreatment + RTO process
The pretreatment filter uses MEGAUNITY's latest generation of inclined bag filter technology to efficiently remove oil mist and particles, preventing clogging of the RTO regenerator;
The RTO device achieves a purification efficiency of ≥99% and a thermal efficiency of 95%, reducing energy consumption while achieving milligram-level emissions.
2. Core Technology Highlights
1. Anti-clogging design:
The RTO uses layered regenerators and a combination of multiple pore sizes to delay silicon dioxide clogging of ceramic regenerators;
2. Full-process safety control:
Concentration control: LEL online monitoring is set at the RTO inlet to keep exhaust gas concentration within a safe range;
Flashback prevention and pressure relief: a flame arrester is installed at the front end, and the equipment is equipped with a rupture disc to ensure rapid pressure relief in case of abnormal pressure;
Low-temperature protection: based on local climate conditions, the equipment uses rock wool insulation and electric heating valves to prevent freezing and clogging in winter.
3. Intelligent Operation and Maintenance Guarantee:
Equipped with PLC + touch screen control system, supporting remote monitoring (MEGAUNITY private cloud platform), real-time tracking of temperature, pressure, and other parameters;
Functions such as automatic dosing and liquid level control reduce manual intervention, ensuring stable system operation.
3. Project Results and Value
1. Emission indicators far exceed national standards:
The treated tail gas has a non-methane total hydrocarbon concentration ≤20mg/m³ (internal control standard), particulate matter ≤20mg/m³, and acidic gases (such as HF) ≤4mg/m³, far below the requirements of the "Battery Industry Pollutant Emission Standard" (GB30484-2013).
2. Significantly reduce operating costs:
The RTO thermal efficiency reaches 95%, and heat self-sustainment can be achieved at appropriate concentrations;
System treatment is divided according to exhaust gas concentration to reduce energy waste, saving about 20% of annual operation and maintenance costs compared to traditional processes.
3. Ensure production continuity:
The system is equipped with backup treatment equipment. When the main equipment is under maintenance, exhaust gas is temporarily treated by the backup equipment, which does not affect workshop production and effectively ensures production continuity.
The lithium battery industry's exhaust gas components are complex and pose high safety risks. Treatment solutions need to balance purification efficiency, equipment protection, and energy consumption control. MEGAUNITY, leveraging customized design, mature anti-clogging technology, and full-process safety management, provides a stable and reliable VOCs treatment solution for this project, meeting environmental protection requirements while reducing costs and increasing efficiency for enterprises, supporting the construction of zero-carbon industrial parks.
If you need customized solutions for specific working conditions, please contact the MEGAUNITY team. We will provide you with full-cycle services from design to operation and maintenance, jointly promoting green development in the industry.
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E-mail： marketing@megaunity.com
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