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Individuals, small companies and large companies are all committed to reducing their carbon footprint. Therefore, the use of lithium ion batteries (LIB) is becoming more and more common.
Personally, the use of battery packs in solar homes and all-electric car battery packs has been expanding rapidly.
However, the manufacture of such battery packs generates many air pollutants, which need to be treated before being released into the atmosphere.
A major LIB supplier faced a unique set of challenges in its central production facility.
Three identical abatement systems are required, each of which needs to process more than 35,000 scfm of exhaust air, which is larger than the typical size of an electrically heated air pollution control system. The system needs to consider the following factors:
The manufacturing process of a complete LIB involves many different operations and processes, which produce a series of hazardous air pollutants (HAP) and volatile organic compounds (VOC) at different temperatures.
N-methylpyrrolidone (NMP) is used to manufacture battery electrodes. This is a solvent, but the manufacturer can recycle and reuse it without having to deal with it in the pollution control process.
The supplier has more module production lines and multiple electrophoretic paint production lines with curing ovens, and solvent recovery processes cannot be selected in these production lines. This leads to the complexity of providing compliance solutions.
Image source: Anguil Environmental System
The unique situation of LIB suppliers presents the challenge of creating a compliant solution that can capture and process 70,000 scfm of exhaust air while maintaining the following restrictions:
Anguil is one of the few industrial air pollution control solution providers that can provide a full range of catalytic and thermal oxidation technologies, including emission concentrators. Anguil's extensive technology enables the company to evaluate each option and assess its relevance to strict project goals.
The first step is to decide to route each ambient process air source to the zeolite concentrator wheel. The concentrator wheel uses a zeolite substrate to adsorb the HAP and VOC in the process gas onto the surface of the rotating wheel.
Approximately 10% of the original flow volume of the heated flow is used to desorb contaminants from the concentrator wheel. This highly concentrated stream significantly reduces the size of any downstream oxidizer integrated with the concentrator wheel, thereby reducing capital and ongoing operating costs.
Next, Anguil's engineers decided to use a regenerative catalytic oxidizer (RCO) with electric heating elements to treat the thermal process flow from the curing furnace and the concentrated gas flow from the concentrator wheel. This combination is often called RCTO.
The use of a catalyst in a thermal oxidizer means that emissions can be destroyed at much lower temperatures; (600-800°F, 315-427°C) instead of the normal range (1400-1500°F, 760-816°C) ).
The lower operating temperature also allows the use of smaller and more reliable electric heating elements in terms of physical size and kW rating.
RCO uses ceramic blocks as the heat transfer medium, which can achieve 97% combustion heat recovery (TER). This combination of lower operating temperature and 97% TER means that RCO is the best solution to keep utility consumption to a minimum while ensuring a low-maintenance operating system.
As mentioned earlier, each oxidation system (three in total) and concentrator wheel will be placed on the third floor of the building. This must be done while the building is being constructed, on an existing mezzanine, allowing 15 feet of overhead clearance.
By taking this into consideration during the design process, Anguil ensured that each piece can be raised to the third floor by an external elevator and can pass through narrow overhead doors.
In addition, each of the three units are installed in series and connected by common inlet and outlet manifolds, thereby reducing installation costs.
After the installation is complete, the startup technicians from Anguil completed the final debugging process. The technicians carried out operator training, including classroom training and "glide" training. Test data shows that each of the three systems achieves an overall emission removal rate of more than 90% and a TER of 97%.
Image source: Anguil Environmental System
After listening to customer needs and operational constraints, Anguil was able to provide an oxidation system that can process up to 70,000 scfm of VOC-rich air without the use of fossil fuels, and all of these are in line with specific footprint and Size requirements.
The use of the zeolite concentrator wheel on the ambient temperature source reduces the size of the downstream oxidizer required and the associated utility requirements.
The use of electric heating RCO eliminates the need for fossil fuel burners, which has always been another customer requirement. Compared to thermal oxidizers, the catalyst allows the oxidizer to operate at a greatly reduced temperature.
This in turn minimizes the size of the electric heating element. Since RCO provides 97% of the TER, this not only further reduces the utility requirements, but also reduces the size of the heating element.
Since the heat source from the curing oven is sent directly to the RCO inlet, there is no negative impact on the operation or efficiency of the concentrator wheel.
Three identical systems capable of handling 35,000 scfm means that customers can handle up to 70,000 scfm of VOC air while maintaining the specified n 1 arrangement.
By designing each system to minimize footprint and height to the maximum allowable parameters, suppliers can save valuable floor space in the facility. The effectiveness and efficiency of the system exceeded the design specifications set by the supplier.
Image source: Anguil Environmental System
This information is derived from materials provided by Anguil Environmental Systems and has been reviewed and adapted.
For more information on this source, please visit Anguil Environmental Systems.
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Anguil Environmental System. (2021, April 15). Lithium-ion battery (LIB): a fossil-fuel-free solution. AZoCleantech. Retrieved from https://www.azocleantech.com/article.aspx?ArticleID=1205 on November 22, 2021.
Anguil Environmental System. "Lithium-ion battery (LIB): a solution without fossil fuels". AZoCleantech. November 22, 2021. <https://www.azocleantech.com/article.aspx?ArticleID=1205>.
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Anguil Environmental System. 2021. Lithium-ion battery (LIB): a fossil fuel-free solution. AZoCleantech, viewed November 22, 2021, https://www.azocleantech.com/article.aspx?ArticleID=1205.
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