Advancing VOC Emission Control in Expandable Polystyrene (EPS) industries

Best Practices and Environmental Considerations

Expandable Polystyrene (EPS): the techniques

Expanded polystyrene (EPS) is a lightweight foam product used for insulation, packaging, and various other applications. The manufacturing process involves heating polystyrene beads impregnated with a blowing agent. The heat causes this blowing agent to vaporize, expanding the beads and forming the characteristic foam structure.

The release of VOCs occurs during several stages of production, including:

pre-expansion;

curing/aging of pre-puffed beads;

molding into final shapes;

storage of the finished product.

EPS production relies on n-pentane (C₅H₁₂) as the blowing agent, which is a key source of Volatile Organic Compound (VOC) emissions. These emissions are a major environmental and health concern due to their role in forming ground-level ozone (smog) and their potential health effects. To mitigate these impacts, manufacturers must employ various Emission Control Technologies.

Expandable Polystyrene (EPS): VOC Emission Control Technologies

The most common and effective technologies for controlling VOC emissions from EPS facilities fall into two main categories: Solvent Recovery or Thermal Oxidation.

expandable polystyrene, pentane, VOC emission control, solvent recovery, thermal oxidizer, VOC emission control, air pollution control, emission reduction, activated carbon adsorption, XTO, thermal oxidation, RTO, regenerative thermal oxidizer, CTO, catalytic oxidation, solvent compatibility, efficiency, return of investment, ROI, cost, budget, EU, Solvent Emission Directive, SED, BAT, BREF, US, Clean Air Act, CAA, environmental impact, compliance, greenwashing, abatement, energy efficiency, reduction, minimization, mitigation, prevention, treatment, testing, filtration, CAPEX, OPEX, renovation, smoke, recommendations, guidelines, cost estimation, abatement options, emission reduction potential, emission control characteristics, challenging, SRU, VOC recovery equipment, solvent recycling, VOC capture, solvent reclamation, solvent purification, VOC treatment, solvent regeneration, distillation, solvent distillation, VOC recovery process, activated carbon, adsorbent, ethyl acetate, nitrogen, N2, LEL monitoring, engineering, supply, turnkey, sustainable, innovation, decarbonization, chemical recycling, recycling, sustainability solutions, sustainability, reclaiming, carbon offset, circular economy, climate change, climate policy, climate action, environmental challenges, sustainable development, sustainability roadmap, récupération des solvants, récupération des COV, Unité de Récupération des Solvants, URS, recuperación de disolventes, recuperación de solventes, lösemittelrückgewinnung, lösemitteln aus abluftströmen, abluft rückgewinnung anlage, ARA, full electric solvent recovery, e-SRU, eSRU, VOC recovery, solvent recovery equipment, solvent recycling, VOC capture, solvent reclamation, solvent purification, solvent regeneration, dehydration, distillation, distillation plant, adsorption systems, adsorption, absorption, molecular sieves, thermal oxidizers, regenerative thermal oxidizer, catalytic oxidizer, direct thermal oxidizer, DTO, flameless thermal oxidizer, full electric regenerative thermal oxidizer, e-RTO, eRTO, oxidizer, rotary bed concentrator, RBC, rotor concentrator, activated carbon steam regeneration, activated carbon nitrogen regeneration, activated carbon steam desorption, activated carbon nitrogen desorption, nitrogen generator, N2G, solvent recovery for flexible packaging, solvent recovery for converting, Ultra Low emission, ULE, Ultra Low VOC emission, Best Available Technique, BAT reference documents, Industrial Emissions Directive, IED, Maximum Achievable Control Technology, MACT, Best Demonstrated Technology, BDT, Cleain Air Act, CAA, industry regulations, low carbon emissions, green deal, carbon reduction, low carbon, carbon neutrality, net-zero emissions, greenhouse gas mitigation, carbon footprint, carbon capture and storage, CCS, Green House Gas, GHG, scope 1, scope 2, scope 3, CO2, Triple Bottom Line, TBL, Environmental Social Corporate Governance, ESG, Smart Modular System, SMS, Custom Built System, CBS, DEC, Dynamic Environmental Corporation, DEC IMPIANTI, DEC HOLDING, DEC SERVICE, DEC ENGINEERING, DEC AUTOMATION, DEC LAB, DEC ANALYTICS, DEC Group

The choice of VOC emission control technology is determined by several factors, including regulatory requirements, the quantity, type, and concentration of VOCs emitted, energy consumption, footprint, overall cost-effectiveness, and the environmental model (circular or linear).

Solvent Recovery Unit (DEC.SRU™): adsorption is a recovery technique that captures VOC molecules on the surface of a solid material, typically activated carbon. In this process, the exhaust air is passed through a bed of activated carbon, which has a vast internal surface area. The pentane molecules adhere to the porous surface of the carbon. Once the carbon bed becomes saturated, it must be regenerated to release the adsorbed VOCs. This is often done by passing steam (SRU_RSV™ process) or hot inert gas - Nitrogen (SRU_RSG™ process) through the bed, which desorbs the pentane. The desorbed pentane is then cooled and recovered as a liquid, which can be reused or sold. This method is particularly effective for streams with a consistent concentration of a single VOC like pentane. SRUs capture VOCs from the exhaust air, allowing for the recovery and direct reuse of the solvents, which not only reduces emissions but also offers economic benefits by minimizing raw material costs.

solvent recovery for Expandable Polystyrene (EPS) industry, SRU, SRS, SRP, VOC emission control, solvent recovery, VOC recovery, VOC abatement, VOC emission control technology, VOC abatement systems, air pollution control, solvent recovery systems, environmental compliance, VOC recovery system, Solvent Recovery Unit, VOC recovery equipment, solvent recovery equipment, solvent recycling, VOC capture, solvent reclamation, solvent purification, VOC treatment, solvent regeneration, distillation, solvent distillation, VOC recovery process, activated carbon, adsorbent, pentane, nitrogen, N2, LEL monitoring, engineering, supply, turnkey, sustainable, innovation, decarbonization, energy efficiency, chemical recycling, recycling, sustainability solutions, sustainability, reclaiming, carbon offset, circular economy, climate change, climate policy, climate action, environmental challenges, sustainable development, sustainability roadmap, DEC, Dynamic Environmental Corporation, DEC IMPIANTI, DEC HOLDING, DEC SERVICE, DEC ENGINEERING, DEC AUTOMATION, DEC LAB, DEC ANALYTICS, DEC Group

Regenerative Thermal Oxidizer (DEC.RTO™): RTOs are a highly efficient and popular choice for EPS facilities. They work by passing the VOC-laden air through a series of ceramic beds. As the air passes through a pre-heated bed, the pentane heats up. It then enters a combustion chamber where it's destroyed at temperatures of approximately 815°C (1,500°F). The hot, clean air then passes through a second ceramic bed, which absorbs the heat before the air is exhausted. This process is reversed periodically, allowing for heat recovery efficiencies of up to 99%. The high heat recovery minimizes the need for auxiliary fuel, especially given the high heat value of pentane. Any thermal oxidation processes will contribute to increasing your GHG (green house gasses) emissions and your fuel consumptions.

Regenerative Thermal Oxidizer, RTO, thermal oxidizer, thermal incinerator, oxidation equipment, Recuperative Thermal Oxidizer, Oxydateur Thermique Régénératif, Oxidación Térmica Regenerativa, Regenerativ-Thermische Oxidation, GHG, CO2, NOx, CO, N2O, direct-fired thermal oxidizer, afterburner, air pollution control, industrial exhaust treatment, Volatile Organic Compounds (VOCs), Hazardous Air Pollutants (HAPs), emission control system, pollution abatement, combustion chamber, destruction efficiency, Heat recovery, Exhaust gas treatment, Industrial emissions control, Energy efficiency, Furnaces, XTO, TOX, VOC, HAP, used Thermal Oxidizer, Thermal Oxidation, Thermal Oxidizer Service, Thermal Oxidizer Repair, Thermal Oxidizer Maintenance, oxidiser, MACT, BACT, RACT, EPA, Title V Permit, Destruction Efficiency, 99% Destruction Efficiency, Combustion, Combustion Controls, environmental services, DEC, Dynamic Environmental Corporation, DEC IMPIANTI, DEC HOLDING, DEC SERVICE, DEC ENGINEERING, DEC AUTOMATION, DEC LAB, DEC ANALYTICS, DEC Group

Partner with DEC

At DEC, we understand the critical importance of VOC Emission Control in Expandable Polystyrene (EPS) manufacturing: as the leader in the VOC abatemnt processes, we have honed our expertise over the years to offer you the most advanced and efficient technologies available today. Our commitment lies in providing value-driven solutions that not only meet your business requirements but also contribute to a cleaner and greener future.

By harnessing our decades of experience and relentless pursuit of innovation, we have developed a comprehensive range of tailor-made systems for the unique challenges faced by label converting and packaging industry industries. Our state-of-the-art technologies ensure optimal batement efficiencies, allowing you to maximize your resources, reduce costs, and minimize environmental impact.

Partnering with DEC means unlocking a world of possibilities. Our team of experts is dedicated to understanding your specific needs and delivering customized solutions that align seamlessly with your operations. We believe in building strong, long-lasting relationships with our clients, supporting you every step of the way on your journey towards sustainable success.

Explore our website to discover the transformative power of our VOC Emission Control solutions: witness firsthand how our innovative technologies can help you optimize your production processes, improve efficiency, and achieve significant cost savings. Together, let's pave the way for a brighter, greener future in the label converting and packaging industry.

Together, we can make a difference.

Contact DEC

If you are looking for a reliable and efficient VOC Emission Control system, feel free to contact us: we can help you assess your needs and recommend the best VOC Emission Control Technology for your operation.