Products: Industry Applications

Paint Manufacturing

Installation

Description: VOC emission control for multiple processes within a paint manufacturing facility to meet upcoming MACT standards.

Start-up: September 21, 2001 (replaced prototype system that had been in place since December 2000)

Operating Temperature: 70° - 90°F (21.1 - 32.2°C)

Continuous Operation: at 80° ± 5-8°F (29.5 ± 2-3°C) and R.H. of >98% achieved within 24 hrs.

Air Flow: 5000 cfm, increased to 9500 cfm

Sampling and Initial Operational Results

• Evaluation of inlet and outlet VOC concentration w/hand held FID & PID; Tedlar bag samples to GC analysis for verification
• Total VOC concentrations measured >5,000 ppm (from hand held instrumentation) with concentrations of >250 ppm of Toluene from laboratory samples
• VOC removal efficiency varied between 68 to 86%

Conclusions from Initial Installation

• Original prototype biofilter design undersized by >30% for actual VOC concentrations. System designed for average concentrations of 1,200 ppm total VOC’s, with maximum loadings of 2,000ppm
• Original dual tower design difficult to control
• Wicking at the edges of the beds, decreased uniform watering

Solutions

• BRI, at request of customer, upgraded biofilter with a properly sized (8’ x 10’ x 24’) system to handle increased airflow (10,000cfm) and actual VOC loadings (3,000ppm averages, with 12,000ppm peaks)
• Improved air distribution & humidification systems
• Recycling sump water for media watering (partial or complete reuse)
• Increased bed depth & surface area with new media design
• Enhanced data collection: pH, conductivity, available Nitrogen, total salts

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