Focus on Intelligent Control of Rubber Factory VOCs Waste Gas Treatment Overall Process

“With the implementation of new Environmental Protection Law and Air Pollution Prevention and Control Action Plan, environmental protection has become a national strategic decision, and the governance of VOCs during the ‘13th Five-Year Plan’ period is a top priority.” Wei Yu, general manager of Beijing New Universal Environmental and Engineering Technology Co., Ltd. (NEWU EET), said in an interview with the reporter of this journal recently that in the tire industry, due to the extensive development in early stage, there are a lot of historical environmental debts. At present, environmental protection has become a “bottleneck” for the development and even survival of many enterprises. The main pollutants in the tire industry include waste water, waste gas, solid (hazardous) waste, noise, etc. Raw materials such as crude rubber are prone to generate a large amount of harmful gases during high-temperature plastication and processing of rubber mixing, calendering, vulcanization, etc. Therefore, the VOCs waste gas problem in the tire industry is most serious.

Wei Yu said that the national standard of Emission Standard of Pollutants for Rubber Products Industry(GB27632-2011) was officially implemented at the end of 2012, and the requirements for relevant emission indicators have been greatly improved. In particular, the national environmental protection supervision has been strengthened in the past two years. Common people are paying more and more attention to environmental protection issues, and complaints about factory smells are increasing. Local emission standards have been stricter and stricter in recent years. What’s more, the State Council has issued the Opinions on Comprehensively Strengthening Ecological and Environmental Protection and Lawfully Promoting Triumph in the Uphill Battle for Prevention and Control of Pollution. Therefore, tire enterprises are increasingly demanding environmentally friendly transformation and VOCs waste gas treatment. For this reason, NEWU EET has undertaken many waste gas treatment projects for tire factories.

Wei Yu introduced that NEWU EET is a national high-tech enterprise integrating R&D, design, manufacturing, engineering procurement construction and environmental protection services. It was established in 2007 and is a wholly-owned subsidiary of New Universal Science and Technology (stock code: 300472). In 2013, it began to fully participate in the environmental protection and governance work of the tire industry. The company has considerable talent advantages and technical strength in the field of atmospheric controlling and water treatment. Its business scope mainly includes waste gas treatment in rubber, petrochemical, spray paint, pharmaceutical and other industries; air pollution control in power station boilers, industrial furnaces and other fields; industrial waste water and urban sewage treatment.

The reporter learned that in the past two years, NEWU EET has launched a series of products with completely independent intellectual property rights aiming at characteristics of tire factory waste gas: efficient purification all-in-one machine (EPA), composite catalytic oxidation all-in-one machine (COA), composite photocatalytic oxidation equipment (ELC), injection low-temperature plasma equipment (INP), etc. These technologies are respectively applied to different industries, different production sections and different emission requirements, and have been very effective. For example, EPA technology is very suitable for treating organic waste gas with low concentration, small air quantity and strict emission requirements; COA technology is suitable for treating organic waste gas with complex gas composition and large air quantity; ELC and INP technologies are more suitable for treating organic waste gas with simple composition, low concentration and relatively low emission requirements. Wei Yu expressed that there is no best processing technology, only the most suitable processing technology.

He also told the reporter that with the continuous improvement of environmental standards in various regions and the popularization of VOCs online monitoring systems, the original environmental protection technology has become more and more limited, and the tire industry urgently needs an efficient and thorough waste gas treatment technology. To this end, the company continues to summarize and innovate in environmental protection technology. In 2017, it took the lead in using waste gas deep processing technology of rubber factory with complete independent intellectual property rights in large-scale tire enterprises such as Zhongce Chaoyang Rubber Company and Pirelli Tyre Co., Ltd. The problem of high-oil, water-containing and high-dust organic waste gas in rubber mixing section is effectively solved. After treatment, the waste gas indicators are far lower than the national and local emission standards, thus truly achieving “ultra-low emissions” and being highly evaluated by users.

In particular, the RTO project of Zhongce Chaoyang Company, which is undertaken by NEWU EET, adopts powder spraying pretreatment device + cylinder concentrating device + rotating RTO pyrolysis device. Through independent innovation, with scientific process design, stable operation, excellent project quality and ultra-low emission indicators, it is highly appreciated by users and local environmental protection departments. The relevant government departments and people from various industries often visit and inspect the site, which has become a highlight of local environmental protection. On September 15, 2018, the China Petroleum and Chemical Industry Federation organized an expert appraisal meeting towards the “Rubber Factory VOCs Waste Gas Ultra-Low Emission Treatment Process and Key Technical Equipment” project of NEWU EET. The appraisal experts all agreed that this VOCs waste gas treatment technology has “filled in the domestic blank and reached the international advanced level.”

It is known that this governance technology also has significant advantages in economy. After implementing and transforming the project (RTO) in Zhongce Chaoyang Company, it saves about RMB 500,000 Yuan of operating cost per year compared with the operation energy consumption before transforming (spray), and the emission indicators are far lower than before transforming. The stink of rubber that has been distributed over the factory for many years has basically disappeared. The resident complaint rate has dropped by 74.5% year-on-year. In addition, the technology is based on the rubber factory RTO waste gas treatment intelligent control system of cloud platform, and has created a management system of informationized management, automated control, intelligent point inspection, and equipment life-cycle monitoring.

Wei Yu said that the company currently has good environmental performance in all major segmentations of rubber industry, including Zhongce, Hankook, Kumho, Wanli, AEOLUS, Linglong, Nexen, Pirelli and other companies in the tire industry; Dinglian, ASIMCO, Xingyu and other companies in the product industry; Sanlux, Jinlilong and other companies in the rubber belt industry; and Stair and other companies in the rubber chemicals industry. After professional third-party testing after treatment, these projects all meet national, industrial and local emission standards, and are recognized by users and local environmental protection departments.

Wei Yu said that “the class of company depends on the class of technology”. In future, NEWU EET will continue increasing technological innovation & investment, continuously introduce high-end technical talents, increase R&D equipment, build R&D platforms, introduce devel-opment software, actively respond to the call of national “smart manufacturing”, and further develop the intelligent control and remote diagnosis service system for rubber factory waste gas treatment based on “cloud platform” and “big data analysis”, to realize real-time monitoring and intelligent control of the whole process of rubber factory organic waste gas treatment, contributing to the upgrading of environmental protection in the rubber industry.  

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