Cases by Purificon GmbH.
Exhaust air aftertreatment and exhaust air technology. Optimization of exhaust air systems and redesign of extraction systems.
New planning for exhaust air treatment in a gigafactory for Li-ion batteries
Air volume in m3/h
Industry: AUTOMOTIVE
Solution
Central multi-stage exhaust air post-treatment for the separation of hydrogen fluoride using gas scrubbers and activated carbon adsorbers for VOC separation. Additional decentralized dry filters, some equipped with constructive explosion protection, are used to separate laser fumes and dust in the final production steps.
Subsequent measurements of emissions such as dust, gases and VOCs carried out by us allowed us to validate the original design.
In Germany and Europe, battery cell factories were only in the planning and development stages at the start of this project.
There was no precise knowledge of the process emissions, which is necessary for the precise design of the intake air aftertreatment.
Following the mechanical assembly of the cells, the cells are filled with electrolyte and the cell chemistry is conditioned (formation and ageing). Among other things, this produces various gaseous and vaporous process emissions, which are to be fed into a targeted and suitably designed exhaust air after-treatment system in order to permanently comply with the emission limits required by the BImschG and TA Luft.
A solid design basis and air volume balance was developed through comprehensive research and analysis of the scientific literature as well as the collection of available process and manufacturer information. PURIFICON GmbH supported the project for more than three years, enabling the design to be continuously refined and successfully commissioned.
Optimization of an exhaust air system with gas scrubber and biofilter in rapeseed oil production
Air volume in m3/h
Industry: FOOD
Solution
Development of a comprehensive action plan for the optimization of the system, including decoupling the fans via draught interrupters, local adaptation of the piping, use of heat recovery systems for cooling the exhaust air, etc.
The naturally grown exhaust air system with a total of five integrated radial fans and around 30 extraction points did not deliver the desired extraction performance in some places. The reasons for this were not clear at first glance. The exhaust air temperature after the gas scrubber was still too high for it to enter the biofilter.
Extensive measurements in the duct system with recording of all parameters to create holistic air volume and energy/heat balances. Verification of the data obtained with the assumed original design.
Suction of highly hygroscopic metal salts
Air volume in m3/h
Industry: CHEMICALS
Solution
Production and installation of the specially designed collection element. Installation of a dry separator with an appropriate filter surface and tight shut-off flaps to prevent clogging during standstill.
An existing extraction system with a dry filter had been expanded over the years and did not have sufficient capacity to comply with the workplace limit values for harmful fine dust. In addition, there were repeated difficulties due to caking of the hygroscopic dust deposits.
Analysis of dust formation in the production process using video recordings and the dust emission velocities derived from them. CAD design of a suitable capture element and CFD-based test of functionality in the flow simulation with consideration of fine dust transport (“discrete particle model”). Redesign of the filter system with design for hygroscopic dusts.
Optimization of indoor air parameters in a materials testing laboratory
Air volume in m3/h
Industry: PLASTIC MANUFACTURING
Solution
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The precise and homogeneous setting of the room air parameters temperature and humidity is essential for reproducible and reliable quality testing of the polymer materials produced. In this case, there were regular deviations from the target values in the room - despite the adequate performance of the installed system technology.
Comprehensive spatially and temporally resolved measurements of the indoor air parameters temperature, humidity and flow allow a comprehensive understanding of the problem. Together with IR thermal imaging, they form the data basis for creating a digital twin. Flow simulations (CFD analysis with ANSYS Fluent) were then used to simulate the actual situation and subsequently test optimization measures.
Air volume in m3/h
Industry: AVIATION
Solution
Partially redundant exhaust air post-treatment with activated carbon adsorbers for VOC separation. 3D BIM model as the basis for preparing the offer and further planning phases. Design of the ventilation and air conditioning systems with cooling load calculation. Chimney height calculation in accordance with TA Luft 5.5 and VDI 3781 Sheet 4.
An über 80 Absaugstellen mit Testständen, Zerlege- und Waschplätzen gelangten VOC-haltige Abluftströme in das Raumluftsystem. Nach Identifikation von potenziell krebserzeugenden Stoffen in den verdampfenden Treibstoffresten sollte die Absaugung signifikant verbessert werden. Aus Gründen des Umweltschutzes sollte ferner ein eigenes Abluftnachbehandlungssystem konzipiert werden, um die VOC-Emission in die Atmosphäre nach Stand der Technik zu minimieren.
Umfangreiche Bestandsaufnahme der vorhandenen Maschinen und Absaugstellen inkl. Emissions- und Luftmengenmessungen, Neukonzeption (Auslegung der Erfassung an den einzelnen Stellen, Luftmengenbilanz, Auslegung der Abluftnachbehandlung) und Entwurfsplanung mit 3D-BIM-Rohrleitungs- und Aufstellplanung als Vorbereitung der Marktanfrage durch unseren Kunden.
System evaluation for the separation of VOCs during spark erosion
Air volume in m3/h
Industry: METAL PROCESSING
Solution
The evaluations of the measurements carried out and the derived parameters of separation efficiency and loadability showed that the activated carbon was only able to selectively remove part of the mixture of substances from the exhaust air flow. Specific suggestions for optimization with regard to contact time, bulk height, etc. help to optimize the adsorber and tailor it to the process.
Die korrekte Funktion eines neu installierten Aktivkohleadsorber war unklar – insbesondere hinsichtlich der Abscheideleistung der durch Verdampfen und der Pyrolyse des Dielektrikums entstehenden VOC-Emission.
Durch lufttechnische und FID-Messungen der VOC-Emission im Reingas und Rohgas des Adsorbers konnten verlässliche Daten über die Funktion des Adsorbers abgeleitet werden. Ein Bericht in Gutachtenform wurde als Grundlage für weiterführende Maßnahmen erstellt.