How to reduce waste gas emissions during the production of hot melt wires

How to reduce waste gas emissions during the production of hot melt wires

Current status of waste gas emissions during the production of hot melt wires
In the production of hot melt wires, waste gas mainly comes from the heating, melting, extrusion and other links of raw materials. These waste gases are complex in composition and usually contain a variety of volatile organic compounds (VOCs), such as diols, dibasic acids, amines, etc., as well as possible additives and diluents. If they are directly discharged without treatment, they will cause many harms to the environment and human health, such as air pollution, respiratory diseases, and damage to the surrounding ecosystem.
With the continuous improvement of global environmental awareness and increasingly stringent environmental regulations, hot melt wire manufacturers are facing an urgent need to reduce waste gas emissions.

Methods to reduce waste gas emissions from the source
Optimizing raw material selection: Selecting high-quality, low-volatile raw materials is the basis for reducing waste gas generation. For example, some polymer materials that have been specially treated or modified will significantly reduce the release of volatile organic compounds during the production process. In addition, it is also possible to consider using renewable or degradable environmentally friendly raw materials to reduce potential harm to the environment from the source.
Improve production process: Use advanced production process and equipment to improve the airtightness and automation of the production process, which can effectively reduce the leakage and escape of waste gas. For example, adopt new extruders and reactors, optimize heating methods and temperature control, so that raw materials can be melted and reacted at a lower temperature, thereby reducing the volatilization of organic matter caused by high temperature. At the same time, reasonable production layout and pipeline design can also help reduce the retention and diffusion of waste gas in the production process.
Improve equipment efficiency: Regular maintenance and maintenance of production equipment to ensure that it is in good operating condition can not only improve production efficiency, but also reduce the risk of waste gas leakage caused by equipment failure or aging. For example, timely replacement of worn seals, cleaning of scale and blockages in pipelines, ensuring the airtightness and ventilation of equipment, so that waste gas can be smoothly collected and treated.

Waste gas collection and treatment technology
Effective waste gas collection system: A well-designed and efficient waste gas collection system is one of the key links in reducing waste gas emissions. According to the distribution and characteristics of the waste gas sources in the production process of hot melt wire, appropriate gas collection hoods, ventilation ducts and other equipment are used to collect the waste gas as much as possible to avoid direct discharge into the workshop and the atmosphere. For example, for equipment such as extruders and reactors, a closed gas collection hood can be set up to suck the waste gas into the pipeline through negative pressure, and then transport it to the waste gas treatment equipment.
Activated carbon adsorption method: Activated carbon adsorption method is one of the most widely used waste gas treatment technologies at present, especially suitable for treating large air volume and low concentration of organic waste gas. The principle is to use the porous structure and strong adsorption of activated carbon to adsorb organic matter in the waste gas on the surface of activated carbon, so as to achieve the purpose of purifying the waste gas. After the activated carbon adsorption is saturated, it can be desorbed and regenerated by hot air or other means, and the desorbed organic matter can be recycled or further processed. However, the activated carbon adsorption method also has some limitations, such as the limited service life of activated carbon, the need for regular replacement, and poor treatment effect on high-concentration waste gas.
Combustion method: Combustion method includes direct combustion, thermal combustion and catalytic combustion, which are suitable for treating medium and high concentration organic waste gas. Direct combustion method is to use waste gas as fuel, completely burn it at high temperature, and decompose organic matter into carbon dioxide and water; thermal combustion method needs to use other fuels or combustion-supporting gases to oxidize and decompose organic matter in waste gas at high temperature; catalytic combustion method is to make organic matter in waste gas undergo oxidation reaction at a lower temperature under the action of catalyst, and convert it into harmless carbon dioxide and water. The treatment efficiency of combustion method is high, but the equipment investment and operation cost are high, and the operating conditions are strict.
UV photolysis purification method: UV photolysis purification method uses high-energy ultraviolet light beams to decompose organic molecules in waste gas and convert them into harmless substances such as low molecular weight compounds, carbon dioxide and water. This method has the advantages of simple equipment, easy operation, low operating cost, strong adaptability, and can treat organic waste gas with various components. However, UV photolysis purification method has high requirements for waste gas pretreatment, such as the waste gas cannot contain too much dust and water vapor, otherwise it will affect the photolysis effect.
Biological deodorization method: Biological deodorization method uses the metabolism of microorganisms to convert the odor components in the waste gas into simple inorganic substances, such as carbon dioxide, water, etc. This method has the advantages of environmental protection, energy saving, no secondary pollution, and low operating costs. However, the treatment efficiency of biological deodorization is relatively low, the area occupied is large, and there are certain requirements for the composition and concentration of the waste gas. It is usually suitable for the treatment of low-concentration, biodegradable organic waste gas.
Combined process: In order to overcome the shortcomings of a single waste gas treatment technology and improve the treatment effect, more and more companies have begun to use combined processes to treat waste gas in the production process of hot melt wire. For example, the waste gas is first adsorbed by activated carbon and then catalytically burned, or UV photolysis purification is combined with biological deodorization. Through the complementary advantages of multiple technologies, the deep purification of waste gas can be achieved to ensure that the waste gas meets the emission standards.

Key points of daily management and maintenance
Strengthen equipment inspection: Arrange special personnel to regularly inspect the exhaust gas collection and treatment equipment, and check whether the equipment’s operating status and parameters are normal, such as the air volume and pressure of the fan, the inlet and outlet concentration difference of the activated carbon adsorber, the temperature and flame of the combustion equipment, etc. Timely discover and solve problems that arise during the operation of the equipment to ensure the stable operation of the equipment.
Regular maintenance: Develop a detailed equipment maintenance plan and regularly clean, maintain and repair the equipment. For example, clean the dust and dirt in the gas hood and ventilation duct, replace the activated carbon in the activated carbon adsorber, and inspect and repair the burner, catalyst and other components of the combustion equipment. Regular maintenance can extend the service life of the equipment and improve the operating efficiency and treatment effect of the equipment.
Monitoring and recording: Install exhaust gas online monitoring equipment to monitor the exhaust gas emission concentration, flow rate and other parameters in real time to ensure that the exhaust gas emissions meet environmental protection standards. At the same time, record and analyze the monitoring data to timely understand the operating status and treatment effect of the equipment, and provide a basis for the adjustment and optimization of the equipment. Once it is found that the exhaust gas emissions exceed the standard, timely measures should be taken to rectify and avoid pollution to the environment.
Employee training and management: Strengthen the environmental awareness and operation skills training of production employees, make them familiar with the correct operation methods and precautions of waste gas collection and treatment equipment, strictly abide by the operating procedures, and avoid equipment failure or excessive waste gas emissions due to improper human operation. At the same time, encourage employees to actively participate in environmental protection management, and reward employees who put forward rationalization suggestions and discover equipment hidden dangers.

Case analysis and experience sharing
Case 1: A hot melt wire production enterprise adopts a combined process of “waste gas collection + activated carbon adsorption + catalytic combustion” to treat waste gas in the production process. First, the waste gas is collected through the gas collection hood and ventilation duct, and then enters the activated carbon adsorber. The organic matter in the waste gas is adsorbed by the activated carbon, and the purified gas meets the emission standards. When the activated carbon adsorption is saturated, the activated carbon is regenerated by the catalytic combustion device, and the high-concentration organic waste gas desorbed is catalytically burned. By adopting this combined process, the company not only effectively reduces waste gas emissions and reduces environmental pollution, but also reduces waste gas treatment costs, and improves the company’s economic and environmental benefits.
Case 2: Another hot melt wire production plant adopts the “UV photolysis purification + biological deodorization” treatment process. The waste gas first passes through the UV photolysis equipment, using high-energy ultraviolet light beams to decompose the organic molecules in the waste gas into low-molecular compounds, and then enters the biological deodorization equipment, through the metabolism of microorganisms to further degrade the organic matter, and finally achieve the standard emission of waste gas. By optimizing process parameters and strengthening equipment management, the company has made the treatment system run stably, the treatment effect is good, and the waste gas emission concentration is far below the local environmental protection standard limit, which has established a good environmental image for the company.

Future development trends and prospects
Technological innovation and optimization: With the continuous advancement of science and technology, waste gas treatment technology in the production process of hot melt wires will continue to innovate and improve. For example, the research and development and application of new and efficient adsorption materials, catalysts, biological strains, etc. will further improve the efficiency of waste gas treatment and reduce treatment costs. At the same time, intelligent control technology will also be widely used in waste gas treatment equipment to realize the automatic operation, remote monitoring and fault diagnosis of equipment, and improve the operation reliability and management level of equipment.
Source control and green production: In the future, hot melt wire manufacturers will pay more attention to source control and green production, starting from raw material selection, production process design and other aspects to reduce the amount of waste gas generated as much as possible. For example, develop and apply low VOCs raw materials and solvent-free production processes, promote the use of environmentally friendly additives and auxiliaries, etc., to achieve green and sustainable development of the production process.
Strengthening policies, regulations and supervision: In order to effectively control waste gas emissions and protect the environment and human health, governments of various countries will continue to strengthen the supervision of industrial waste gas emissions and formulate more stringent standards and regulations. Hot melt wire manufacturers need to pay close attention to changes in relevant policies and regulations, take proactive measures to reduce waste gas emissions, and ensure that enterprises produce legally and in compliance with regulations. At the same time, enterprises should also strengthen communication and cooperation with government departments and environmental protection agencies, strive for policy support and financial assistance, and jointly promote waste gas treatment.

In short, reducing waste gas emissions during the production of hot melt wires is an inevitable requirement for enterprises to achieve sustainable development. By taking measures such as source control, optimizing production processes, adopting efficient waste gas treatment technologies, and strengthening daily management, hot melt wire manufacturers can improve their competitiveness and economic benefits while meeting environmental protection requirements, and make positive contributions to protecting the environment and human health.