Solution CLEACOM

Established 24/7 technology for the separation of dust and fume during compounding processes Fume extraction at an extruder Reduced consumption of resources with dry separation. Wet separation with water circulation. Durable functionality with proven components. CLEACOM Engineered System Solutions 2 Keller Lufttechnik has considerable experience with the treatment of dust, fume, gaseous and adhesive aerosols released during compounding and ex- trusion processes. Utilizing established technology, emissions are extracted properly at the source and separated in centralized or decentralized systems. Fillers, fibers, additives, pigments and liquids (curing agents and lubricants) do affect emissions in a variety of ways. Since dusts can be flammable or explosive, Keller offers comprehensive advice and performs appropriate analy- ses. Efficient and reliable 24/7 separation of emissions All-in-one solution for maximum efficiency during compounding and extrusion processes. Keller Lufttechnik analyses specific processes and delivers turn-key all-in-one solutions Extensive demands are placed upon all components to ensure maximum productivity during the refinement and packaging of plastics employing plas- tics granulation. Besides process technology, a major consideration is the collection of dust and fumes and controlling the air quality inside the workplace. 3 ... with proficiency and expertise Aerosols and fumes are released dur- ing extrusion processes. They are captured with collection hoods, rinsed with water and fed to a wet scrubber. The wet scrubber utilizes water as fil- tration medium – with the advantage of a maximum operating safety despite adhesive emissions.Dusts from the treatment section (mix- ing, weighing, feeding) are added to a dry separator. Pollution and surface dust is extracted manually with an- other vacuum creating dry system. As a general rule, other designs and con- figurations are possible, upon request. Three extraction systems combined can fulfill all the extraction require- ments The modular design of Keller com- ponents provides a variety of solu- tions. Compact single systems can be equipped with the same high-efficiency technology as systems with several compounding lines. Harmful substances such as sedimented sludge can often be collected. (See page 11) Keller systems are suitable for initial start-up, renovations, or retrofitting of existing systems. Perfect for start-up, renovation or retrofitting Example: The delivery and supply of raw materi- als is managed differently, depending on demand and physical location. The prototype illustrated in this brochure assumes supplying with Big Bags or sacks. The dosing stage is located above the extruders and the raw materials are dispensed above the dosing stage. 4 Reliable separation of emissions and fumes at the extruder The degassing of volatile components occurs in the degassing zone at the extruder head, during fabrication of plastic compounds such as molten polymer, vinyl acetate, POM, PC, and ABS, thereby removing fumes, airborne particulate, and adhesive aerosols. Without suitable extraction methods, these emissions would otherwise be directly discharged into the environ- ment. This is the primary reason for taking into consideration the presence of hazardous agents and the air quality standards within the workplace. Degassing during extrusion processes Fumes from degassing at the extruder head and at the preliminary degassi\ ng step can be collected by extraction hoods and directed to the separation Requirements for the air quality at workplaces and the reduction of air - borne pollutants are described in VDI guideline 2262-3. Workplace limit values are outlined in the Technical Rules for Hazard Sub- stances (TRGS 900) of the Federal Insti- tute for Occupational Safety and Health. Air decontamination is the basis for specific requirements Airborne pollutants must be extracted reliably Airborne emissions from extruders must be reliably extracted. A key pre- requisite for optimal fume collection is installing the correct extraction hood. Since extruder installations are cus- tomer-specific, Keller offers a wide range of movable or stationary extrac- tion hoods. Additional exhaust air extraction during vacuum degassing Connection of the fume extraction to the vacuum degassing station Collection hood Pre-spraying Return pipe Folding collection hood (option) for an easy cleaning and preliminary spraying Movable collection hood Extraction through hinged support arms 5 Pre-spraying for wet separation There exists a risk of deposit build-up from adhesive aerosols. System dam- age or breakdown could be the end result with the potential of igniting fires inside the ductwork. Adhesive aerosols have a tendency to accumulate in the dirty air ducts … Airborne substances are flushed out with water … but atomizing with water at the collection point alters this effectively Pre-spraying occurs behind the collec- tion hoods (condensation and pre-sep- aration stages) which are connected to the central water supply. The prelimi- nary spraying creates a dense and fine water droplet curtain which saturates the air moisture and cools down the extracted fumes. This adiabatic cooling leads to conden- sation of gaseous components such as high flashpoint solvents following the preliminary spraying in the extraction pipes. Pictured above: Water hoses for the preliminary spraying lie in the channels on the extraction pipes. Each spraying point is operated separately from the water treatment station. Airborne substances are flushed out the dirty air duct and collected in a container together with excess water from the preliminary spraying. Water from the preliminary spraying is discharged by a separate channel for additional water treatment. The majority of the extracted airborne substances flow into the wet separator with the water droplets The dirty air ducts are free of deposit build-up to a great extent, which main- tains consistent preliminary separation efficiency for longer periods of time. The technology of the VDN-TA wet separator is based on the Venturi principle 6 Separation of water combined with air and emissions VDN-TA wet separator VDN-TA wet separator consists of a combination of various components and functions. It offers a dual stage separation system with preliminary spraying and main spraying. Main spraying The separated air is accelerated by the Venturi nozzle. A water curtain is formed directly behind the nozzle which moistens the solid and liquid aerosols. Separation of water droplets and air The water/air mixture which radi- ally flows into the droplet separator is separated by the cyclone principle. The water which is combined with airborne particulate flows out into a water treatment tank. Fan Radial fans are used for wet separation processes. 7 Water treatment for recycling Because of the intensive use of water, the spraying system is based on a water circuit. Solely the volume of water from wetting the suction air and the sludge discharge has to be refilled. The chemi- cal consistence of the extrusion emis- sion can require an additive feeding to the water circuit. Water circuit Central water treatment The contaminated water is discharged into the water treatment tank via the pipe connection. Additional waste water is pumped into the same tank. Sludge is formed from sediments and surface contaminants. Adequately treated water in this circu- lating system can be re-used for spray- ing purposes.The water which is cleaned sufficiently by this separation in the water circuit can be reused for the spraying. A skimmer is used for lightweight fluids such as oil for surface separation. Water treatment ... with integrated de-sludger The de-sludger is adapted to the specific flow conditions of waste water, circu- lating system water and replacement water. 8 Extraction of dusts from the treatment De-dusting bulk mate- rial upon refilling storage containersThe compounding system is re-supplied with bulk material stored in Big Bags. Airborne particulate created inside a dust-proof system while re-supplying bulk material is separated and ex- tracted. Some supplies can be replenished though a flap. This also activates the extraction system. Treatment platform with raw material added by Big Bags or sacks in the im\ age above, below is the dosing stage. Dust separation with collection hoods at the weighing scales above hoppe\ rs. Dust separation with collection hoods at the extruder’s feed throats Separation of dusts from displacement air Dust clouds may rise when pour - ing bulk materials onto the weighing scales. Special collection hoods sepa- rate dispersed residual dust at the end of the supply piping. The material is conveyed through pipe- lines into the extruder. At the terminal end, replacement air and residual dust are extracted by optimized collection hoods. Closed extraction to separate the bulk material during the feeding of raw material (Big Bags or sacks) 9 … dry extraction and separation VARIO dry separators in various sizes are used for the extraction of dry dusts. Y-filters efficiently separate dust par- ticles. With the use of efficient filters, the clean air can be re-directed into the manufacturing area. The filter cleaning is effected by com- pressed air pulses during operation. VARIO dry separator VARIO dry separator in standard design VARIO dry separator (ATEX compliant) equipped with explosion pressure surge resistant housing design and suitable discharge lock. Additional flameless pressure relief is provided by a Q-Box or by a ProFlap back pressure flap. An explosive environment can be cre- ated depending on the character and composition of the dusts. For additional information please visit our homepage www.exschutz.net Caution! Dust explosion risk If explosion protection measures ac- cording to ATEX 95/137 are required, relevant regulations are mandatory. Q-Box The VARIO dry separator is equipped with a Q-Box for interior flameless pressure relief. Burst panels can be installed on an exterior wall for indoor installations, or on the exterior of the VARIO housing for outdoor installa- tions. ProFlap back pressure flap A ProFlap back pressure flap provides effective additional explosion protec- tion. The dirty air duct is closed auto- matically in the event of an explosion shock wave. Discharge lock As another measure for explosion pro- tection, VARIO disposes of a flame and pressure proof discharge unit. Constructive explo- sion protection according to ATEX guidelines 10 For manual dust extraction Central vacuum suction unitIn addition to the previously described extraction systems, it would be wise to utilize a highly efficient centralized system even for surface cleaning. Keller Lufttechnik offers a variety of vacuum suction systems. The vacuum suction system consists of: R?#H Suction nozzles R?#H Channels with quick-connect couplings R?#H Piping R?#H Dedusting unit with round filter and collection tank R?#H V acuum unit (adequate) The dust attains the filter material as dust-air mixture with relatively fine particles through a pre-separation for coarse dirt particles. Dust is further filtered from the air flow and collected in containers or discharged by appro- priate discharge systems. Several multiple stage fans, side chan- nel blowers or rotary blowers are used to create a vacuum. Many dusts are combustible and explo- sive. For information please see page 9. Detailed information about ATEX, fire and explosion protection can be found on our homepage www.exschutz.net Components Separation of dirt and dust Vacuum creation Fire or explosion risk? Vacuum suction system for operation with external vacuum pump Suction hose with changeable suction nozzles. Several suction stations can be used simultaneously. 11 Each solution can be customized Wet and dry separation system, all components on the same level System installation on three levels Dry separation for dosing platform and extruderWet separation extruder Water discharge (preliminary spraying) Waste water recirculation Dust extraction from treatment Discharge pipe for central vacuum system CLEACOM Your benefit from our experience © Keller Lufttechnik - all rights reserved. Subject to modifications.\ 06/2014 Wet scrubber with water treatment tank Dry separatorCentral vacuum suction system Collection of gases and aerosols at the extruder CLEACOM project consultation We are pleased to offer you a consulta- tion without obligation by recommending individualized solutions for retrofitting, renovation or installing new systems. Do not hesitate to contact us in the explo- ration period of your project. We are especially qualified to provide you with specific information on fire and explosion protection. Please visit our new homepage www.exschutz.net