Advancing VOC Emission Control in Aerospace, and Aviation industries
Best Practices and Environmental Considerations
Emission Control Technologies Guidelines
Key takeaways
- Where VOCs come from: PCB conformal coating, underfill/edge bonding, and component cleaning & curing lines in Aerospace, and Aviation manufacturing.
- Three core technologies: SRU™ solvent recovery (up to 99% solvent recovery efficiency), RTO™ thermal oxidation (Destruction Removal Efficiency exceeding 99%), and RBC™ rotary bed concentration for dilute, high-volume streams.
- SRU vs. RTO: SRU recovers and reuses solvent (lower OPEX, decarbonization); RTO destroys VOCs into CO2 and water (best for streams with no recovery value).
- For complex flows: DEC.HSU™ hybridizes adsorption, concentration and oxidation in one process.
- Regulatory drivers: EU Industrial Emissions Directive (IED) / BAT-BREF and the US Clean Air Act (CAA) set the applicable stack emission limits.
The Aerospace, and Aviation industries generates substantial Volatile Organic Compound (VOC) emissions from solvent-based coating, painting, and electrode manufacturing processes. Regulatory compliance, environmental responsibility, and operational economics demand a proven, application-specific solution.
Protecting mission-critical electronics with conformal coatings is non-negotiable in the Aerospace, and Aviation industries. However, the application and curing of these specialized coatings release high concentrations of Volatile Organic Compounds (VOCs) that demand rigorous, dedicated air pollution control.
We provide independent, turnkey VOC extraction and abatement systems engineered specifically for the stringent safety, compliance, and operational demands of conformal coating lines.
Volatile Organic Compounds (VOCs) are a major source of air pollution, contributing to smog, and ground-level ozone formation. VOC emissions also show harmful effects on human health, causing respiratory problems and other health effects.
Typical pollutants and compounds found in Aerospace, and Aviation industries include:
- esters and glycol ether acetates such as 2-methoxy-1-methylethyl acetate;
- ketones such as 2,6-dimethylheptan-4-one;
- alcohols and glycol ethers such as butanol, 2-(2-butoxyethoxy) ethanol, and 1-phenoxypropan-2-ol;
- aromatics such as light aromatic solvent naphtha (petroleum);
- aldehydes and amides such as 4-morpholinecarbaldehyde;
- amino alcohols such as 2-amino-2-methylpropanol;
- inorganics / aqueous such as demineralised water.
Air Pollution Control systems like SRU™ • Solvent Recovery Units, RTO™ • Regenerative Thermal Oxidizers eventually coupled with up-stream and/or down-stream RBC™ • Rotary Bed Concentrators are designed and tuned to handle the specific solvent profiles of each Aerospace, and Aviation application. The technical requirements for VOC abatement vary depending on the specific end product and the chemical composition used. DEC tailors every APC system to meet the unique needs of the Customer.
Advanced VOC Emission Control for Aerospace, and Aviation Applications
The Aerospace, and Aviation manufacturing industries face significant environmental challenges due to the high volume of VOCs released during manufacturing operations. DEC provides industry-leading advanced APC systems. These technologies ensure that the Customer remains compliant with strict global emission standards while optimizing operational efficiency.
There are three main VOC emission control technologies that can be used in Aerospace, and Aviation industries, to comply with environmental regulations. The best-performing technologies include:
SRU™ • solvent recovery units
SRU, Solvent Recovery Unit (also known as SRP, Solvent Recovery Plant) is a gas phase VOC adsorption system, based on activated carbon, complete of onsite desorption technology, typically employed as VOC Emission Control, allowing to respect VOC emission limits with a typical efficiency up to 99%, while recovering the solvents for direct reuse, at a fraction of their purchase cost, generating a very interesting ROI (a sustainable technology and a true path to decarbonization). They can cover from small to large SLA (solvent-laden air) volumes and deal with a wide variety of VOCs, including water-miscible, non-water-miscible solvents.
RTO™ • Regenerative Thermal Oxidizers
RTO, Regenerative Thermal Oxidation works by burning VOCs at high temperatures in a closed combustion chamber: through the oxidation reaction VOCs are converted to GHG (green house gases, CO2, NOX, CO, and H2O). The heat generated during the combustion process is then captured and used to preheat incoming air (SLA, solvent-laden air), which in turn reduces fuel consumption and enhances energy efficiency compared to traditional thermal oxidation methods. The multi-tower design of RTO allows for continuous operation and a Destruction Removal Efficiency (DRE) exceeding 99%.
RBC™ • Rotary Bed Concentrators
RBC, Rotary Bed Concentration works by utilizing a rotating honeycomb wheel impregnated with adsorbents; typically hydrophobic zeolites; to continuously concentrate VOCs from high-volume, low-concentration exhaust air. As the contaminated air passes through the rotating bed, the VOCs are captured on the adsorbent material while the cleaned air is discharged to the stack. A smaller, heated stream of air then passes through a separate desorption sector of the wheel; this process releases the concentrated VOCs into a much smaller air volume, which is subsequently re-directed to an SRU for recovery or an RTO for destruction.
- Rotor Concentrator, upstream version: aimed at reducing fugitive emissions, optimizing capture at the source.
- Rotor Concentrator, downstream version: dedicated to reducing emissions at the stack, ensuring compliance with the most restrictive emission limits.
For more complex flows, the DEC.HSU™ • Hybrid Sorption Unit process combines above processes and technologies to maximize abatement efficiency, offering a hybrid solution that perfectly meets the requirements of the Customers.
SRU™ vs. RTO™ vs. RBC™: quick comparison
| Technology | Operating principle | Typical efficiency | Best fit |
|---|---|---|---|
| SRU™ (solvent recovery) | Activated carbon adsorption with on-site desorption and solvent recovery | Up to 99% solvent recovery | Reusable / high-value solvents, ROI and decarbonization focus |
| RTO™ (thermal oxidation) | High-temperature combustion of VOCs into CO2 and water with heat recovery | DRE exceeding 99% | Mixed or non-recoverable solvents, continuous high-volume streams |
| RBC™ (rotary concentration) | Rotating zeolite wheel concentrates dilute VOCs into a smaller air stream | Concentrates flow ahead of SRU/RTO | High-volume, low-concentration exhaust; upstream fugitive capture or downstream stack compliance |
Additional ancillary systems further protect the core APC equipment: XSU™ • Wet & Dry Scrubber Units remove particulate matter and acidic gases upstream of the main treatment system, while AFU™ • Adsorbent Filtering Units act as guard beds and concentration buffers, shielding the downstream processes from contaminants and smoothing out VOC load fluctuations.
Environmental Regulations - VOC emission control
VOC emission control is mandatory in several countries, with specific limits at the stack of every industry. Below we will cover the main codes for the Aerospace, and Aviation sector.
The Industrial Emissions Directive (IED) is a European Union directive that sets limits on VOC emissions from industrial processes. The IED includes a Best Available Techniques (BAT) Reference Document (BREF) for the Aerospace, and Aviation sector, which outlines the best practices for controlling VOCs.
The US Clean Air Act (CAA) is a federal law that regulates air pollution in the United States. The CAA includes a number of provisions that address VOC emissions.
Specialized Solutions for Specific Aerospace, and Aviation Applications
- PCB Conformal Coating: automated and selective coating lines applying high-performance, solvent-based protective layers to mission-critical printed circuit boards;
- Underfill and Edge Bonding: precise application of epoxy resins to stabilize sensitive electronic components against extreme aerospace vibration and mechanical shock;
- Component Cleaning and Curing: multi-stage extraction covering high-precision fluid cleaning stations, buffer zones, and high-temperature curing ovens.
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FAQs • Frequently Asked Questions
✈️ VOC Emission Control for Aerospace, and Aviation ✈️
What are the main sources of VOC emissions in Aerospace, and Aviation industries?
VOC emissions mainly originate from solvent-based conformal coatings, painting operations, and electronic component manufacturing, including PCB conformal coating lines, underfill and edge bonding processes, and component cleaning and curing stations.
Why is conformal coating a major VOC concern in aerospace electronics manufacturing?
Conformal coatings protect mission-critical printed circuit boards, but their application and curing release high concentrations of VOCs such as esters, ketones, glycol ethers, and aromatics, requiring dedicated air pollution control on automated and selective coating lines.
What VOC emission control technologies are used in Aerospace, and Aviation industries?
The three best-performing technologies are DEC.SRU™ Solvent Recovery Units, DEC.RTO™ Regenerative Thermal Oxidizers, and DEC.RBC™ Rotary Bed Concentrators, each tuned to the specific solvent profile of the application.
What is the difference between SRU and RTO for aerospace applications?
SRU systems use activated carbon adsorption to capture and recover solvents for reuse, achieving up to 99% recovery efficiency, while RTO systems destroy VOCs through high-temperature oxidation into CO2 and water, with a Destruction Removal Efficiency exceeding 99%.
What role do Rotary Bed Concentrators (RBC) play in aerospace VOC control?
RBC systems use a rotating zeolite-impregnated wheel to concentrate VOCs from high-volume, low-concentration exhaust air into a smaller stream, which is then routed to an SRU for recovery or an RTO for destruction; they can be deployed upstream to reduce fugitive emissions or downstream to meet stack limits.
What is the DEC.HSU™ Hybrid Sorption Unit?
DEC.HSU™ combines adsorption, concentration, and oxidation technologies into a single hybrid process, maximizing abatement efficiency for complex or variable VOC flows typical of aerospace manufacturing.
What ancillary systems support VOC control in aerospace applications?
DEC.XSU™ Wet & Dry Scrubber Units remove particulate matter and acidic gases upstream of the main treatment system, while DEC.AFU™ Adsorbent Filtering Units act as guard beds that shield downstream equipment from contaminants and smooth out VOC load fluctuations.
Which specialized aerospace and aviation applications require dedicated VOC extraction?
Key applications include PCB conformal coating lines, underfill and edge bonding for electronic component stabilization, and multi-stage component cleaning and curing operations covering fluid cleaning stations and high-temperature curing ovens.
Which regulations apply to VOC emissions in the Aerospace, and Aviation sector?
Key frameworks include the EU Industrial Emissions Directive (IED) with its Best Available Techniques (BAT) Reference Document, and the US Clean Air Act (CAA), both of which set specific stack emission limits for the sector.
How are VOC control systems tailored to each aerospace application?
Because VOC abatement requirements vary with the end product and chemical composition used, DEC engineers each APC system around the specific solvent profile, air volume, and compliance target of the Customer's process.
