Regenerative Thermal Oxidizer (RTO) for Coating Industry

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Overall Solution for VOCs Waste Gas Treatment in the Film Coating Industry

RT solutions for coating industry

Treatment Target

  • Organized emission <50 mg (non-methane total hydrocarbons);
  • Energy saving, only use natural gas to start the furnace!
  • Unorganized within the factory: non-methane total hydrocarbons <10mg/m3;
  • After treatment, chimney emission indicators: nitrogen oxides <50mg/m3;
RTO solutions for coating industry

Collection of VOCS Exhaust Gas in Film Coating Plant

  • Oven cross ventilation

The low-concentration exhaust gas from the rear oven is sent to the fresh air inlet of the front oven as fresh air, and is generally not passed into the first 2-3 high-concentration ovens. This method can reduce the exhaust volume of the coating machine.

RTO solutions Coating machine wind reduction
  • Coating head/glue room connected to oven in series

The low-concentration exhaust gas from the coating head/glue preparation room is sent into the fresh air inlet of the oven by a fan and used as fresh air for the oven (generally not passed into the high-concentration ovens in the first two sections). This method can reduce the exhaust volume of the coating head and glue preparation room, and avoid the low-concentration exhaust gas from entering the RTO to dilute the total concentration.

RTO solutions for coating industry
  • Low-concentration exhaust gas large circulation form wind reduction – suitable for hot air heat recovery

RTO solutions for coating industry

Waste Heat Recovery Methods & Selection

  • Steam waste heat recovery

Waste heat recovery coating industry
Waste heat recovery coating industry
  • Heat transfer oil waste heat recovery

Waste heat recovery coating industry
Waste heat recovery coating industry
  • With standby electric heating and waste heat recovery

Waste heat recovery coating industry
Waste heat recovery coating industry

Emissions of Exhaust Gas from Thin Film Coating VOCS

RTO solutions for coating industry

For example, a coating machine has 8 ovens, the total exhaust volume of the ovens is 10,000 m3/h, and the average temperature of the ovens is 140°C (the average temperature of the high and low temperature zones of the 8 ovens). Then the energy consumption of the oven of a coating machine is

Reference Exhaust Gas Volume of Coating Machine

 

Coating product classificationOven lengthReference exhaust air volumeExhaust air temperature
Advertising consumables24 m~40m9000m³/h~ 10000m³/h60℃~80℃
Anodized aluminum (transfer paper)12 m~24m8000m³/h~ 10000m³/h60℃~70℃
Reflective film, reflective material24 m~72m7000m³/h~ 10000m³/h70℃~80℃
Solar backplane film20 m~32m8000m³/h~ 10000m³/h70℃~80℃
Aluminum-plastic film24 m~32m9000m³/h~ 12000m³/h70℃~80℃
Tape16 m~28m10000m³/h~ 12000m³/60℃~80℃
Release film20 m~36m9000m³/h~ 10000m³/h60℃~100℃
Protective film24 m~36m9000m³/h~ 10000m³/h70℃~80℃
Lithium battery separatorabout 28mabout 35000m³/h40℃~60℃
Photosensitive filmabout 60mabout 50000m³/h70℃~80℃

RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry
RTO solutions for coating industry

Properties of Common Solvents for Thin Film Coating

SubstanceMolecular formulaMolecular weightLower explosion limit (%)Density Kg/LHeating value Kcal/kgSafe concentration
(25%LEL)
Ethyl acetate EACC4H8O2882.2895610121.6 g/m³
TolueneC6H5CH3921.28701013812.3 g/m³
ButanoneCH3COCH2H5721.7810809813.6 g/m³
Propyl acetateC5H10O21022888677022.7 g/m³
XyleneC8H101061.28701029514.2 g/m³
MethanolCH3OH326792568821.4 g/m³
AcetoneCH3COCH3582.5785736316.2 g/m³
CyclohexaneC6H12841.19471001210.3 g/m³
CyclohexanoneC6H10O981.1950858412.0 g/m³
EthanolC2H6O463.3790709816.9 g/m³
IsopropanolC3H8O602786790213.4 g/m³
120# solvent oilMixture of n-heptane, isoheptane, cycloheptane, etc.1.1766106958.8 g/m³

Safe Concentration of VOCS Exhaust Gas

The concentration of organic gases in the air is usually expressed in g/m3. Taking ethyl acetate as an example

RTO solutions for coating industry

Classic Cases in Coating Industry

Shanghai Kaixinsen

The main products are: diffusion film, prism film, micro-transparent film, solar film and other functional films.
The project is divided into two phases, the first phase is 40,000 air volume RTO, and the second phase is 50,000 air volume RTO.

Phase I 40,000 air volume system flow chartRTO case in coating industry

RTO case in coating industry

Production lineProduct width (mm)Production line speed (m/min)Oven
T2T31520135节
W31520205节
W41520205节

 

  • Total exhaust gas volume: 40000m³/h
  • Main components of exhaust gas: butanone, toluene
  • Concentration of exhaust gas: 1800~3000mg/m³
  • Residual heat utilization: thermal oil

Phase II 50,000 air volume system flow chartRTO case in coating industryRTO case in coating industry

Production lineProduct width (mm)Production line speed (m/min)Oven
T41520135节
T51520135节
W515201312节
W615201312节
  • Total exhaust gas volume: 50000m³/h
  • Main components of exhaust gas: butanone, toluene
  • Concentration of exhaust gas: 1800~3500mg/m³
  • Residual heat utilization: thermal oil

Guangdong Xinrui New Material Technology Co., Ltd.

The main products are: transfer paper, transfer film, anodized aluminum, polyester film, window film, protective film, etc.RTO case in coating industry

  • RTO case in coating industry RTO case in coating industry
  • Total exhaust gas volume: Phase I: 30,000 m³/h 1 unit
  • Phase II: 20,000 m³/h 1 unit
  • Phase III: 70,000 m³/h RTO+180,000 m³/h rotor 1 unit
  • Main components of exhaust gas: toluene, ethyl acetate
  • Exhaust gas concentration: 2,000~5,400 mg/m³
  • Waste heat utilization: hot air

Enjie Zhuhai New Material Technology Co., Ltd.

Main products: Wet-process lithium battery separato

RTO case in coating industry

Production equipment exhaust situation
Wet-process lithium battery separator coating line (Japan line)

RTO case in coating industry

  • Total exhaust gas volume: 80000m³/h 3 units
  • Main components of exhaust gas: acetone, etc.
  • Concentration of exhaust gas: 3500~7000mg/m³
  • Residual heat utilization: steam
  • Project features:
    · Front-end LEL real-time concentration detection to ensure safety
    · Pipeline fire dampers to ensure safety
    · System maintains self-operation
    · Emissions meet standards

Jiangxi Ruijie New Material Technology Co., Ltd.

Main products: Lithium battery aluminum plastic film

RTO case in coating industry

Production equipment exhaust situationRTO case in coating industryLithium battery aluminum plastic film coating line (Japanese line)

  • Total exhaust gas volume: 65000Nm³/h 2 units
  • Main components of exhaust gas: ethyl acetate, butanone, methylcyclohexane, toluene, isopropanol.
  • Exhaust gas concentration: 3500~7000mg/m³
  • Waste heat utilization: hot air

Project features:
· Front-end LEL real-time concentration detection to ensure safety
· Pipeline fire dampers to ensure safety
· Gas collection boxes for unified collection
· Emissions that meet standards

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