How to Solve the Four Major Challenges in VOCs Treatment for Rubber Factories?
2025-02-20
Key Topics Covered in This Article:
What are the main sources of VOCs emissions in the chemical industry?
What are the primary characteristics of VOCs exhaust gas in this case study, including pollutant types and concentrations?
What were the key challenges in this project, and what solutions were implemented to address them?
1. Case Study Overview
This case study focuses on a VOCs treatment project for a butyl rubber factory located in the Yangtze River Delta region. The factory’s downstream industries include:
Tire manufacturing
Medical rubber stoppers
Shock absorbers and sealing components
Food-related applications such as chewing gum
As one of the leading butyl rubber manufacturers in China, the company has a significant market share and is one of the few enterprises capable of producing both chlorinated butyl rubber and food-grade butyl rubber.
2. Project Parameters and Pollutants
Based on an in-depth analysis of on-site conditions and operational data, the following parameters were identified: 3. VOCs Emission Sources in Rubber Manufacturing
VOCs emissions in chemical production are closely tied to raw material characteristics, process conditions, and operational methods. The following are common VOCs emission sources:
4. Key VOCs Characteristics in This Case
Complex Composition: VOCs emissions contain a mix of organic compounds (e.g., hydrocarbons) and inorganic pollutants (e.g., HCl, particulates).
High Toxicity: Hazardous substances such as benzene, halogenated hydrocarbons, and sulfur compounds pose risks to health and the environment.
Fluctuating Concentrations: VOCs concentrations vary significantly due to process complexities. 5. Addressing the Four Key Challenges in VOCs Treatment
Issue: VOCs concentration fluctuates nearly threefold, making it difficult to meet the strict local emission standard (≤30 mg/m³).
Solution: The AuSSE 5-Tower RTO achieves a 99.5% destruction efficiency, ensuring that emission concentrations remain ≤30 mg/m³ at all times.
Challenge 2: Large Variations in Exhaust Gas Volume
Issue: The factory’s multiple production lines generate VOCs emissions ranging from 15,000–100,000 m³/h, while the conventional RTO system has a minimum operational range of 30,000 m³/h, leading to high energy consumption.
Solution: The AuSSE 5-Tower RTO operates efficiently across 12,500–100,000 m³/h, significantly improving adaptability to fluctuating air volumes and reducing operational costs.
Challenge 3: Fluctuations in RTO Outlet Concentrations During Valve Switching
Issue: Conventional RTO systems experience VOCs concentration surges during valve switching.
Solution: A buffer tower (C Tower) stabilizes emissions, while synchronized AB and DE towers ensure consistent residence time, maintaining steady treatment efficiency.
Challenge 4: Complexity and Reliability of Multi-Valve Systems
Issue: Previous RTO systems required 15 valves, increasing operational complexity and failure risks. If any valve malfunctioned, the entire system had to be shut down.
Solution: The AuSSE 5-Tower RTO features only 4 valves, with independent ABC and CDE tower operation. In case of a valve failure, the system retains over 60% treatment capacity, significantly enhancing reliability.
6. Single-Valve RTO: A Game-Changer for Chemical Industry VOCs Treatment
The Single-Valve RTO technology not only simplifies equipment structure but also enhances treatment efficiency and operational stability. Key benefits include:
12.5%–120% scalable airflow capacity, accommodating large air volume fluctuations.
5+ years guaranteed valve performance, ensuring long-term system stability.
Innovative five-tower design, minimizing valve count while maintaining independent operation, allowing continuous functionality even during faults.
Before vs. After Equipment Installation: Key Improvements
The implementation of the AuSSE 5-Tower RTO has delivered significant benefits,
including:
Reduced emission concentrations
Lower natural gas consumption
Decreased annual downtime
Optimized operating costs
By leveraging 40 years of SSE's RTO technology expertise from the U.S., AuSSE has developed a simplified yet highly efficient RTO system with advanced safety features.
Our commitment is to provide cost-effective and environmentally sustainable solutions that balance operational efficiency and compliance for the chemical industry.
