Solvent Recovery | Lead Acid Battery Separators ♻️ DEC.SRU™

DEC.SRU™ ♻️ SRU | SRS | SRP

Energy Storage

In the manufacturing of lead-acid battery separators, the process involves creating a microporous membrane that prevents the anode and cathode plates from touching while allowing ions to flow through the electrolyte. During this process, a precursor material (often a polyethylene or polyolefin-based polymer) is extruded with a process oil to form a sheet. This oil creates the microporous structure.

Hexane (C₆H₁₄) acts as a supercritical fluid extraction agent (low viscosity and high diffusivity, penetrating solid materials as a gas, while dissolving a wide range of substances as a liquid), effectively dissolving and removing this process oil, leaving behind the microporous structure of the separator.

Hexane is an alkane: it's a straight-chain alkane, which is a type of hydrocarbon that contains only single carbon-carbon and carbon-hydrogen bonds. Hexane is a colorless, highly volatile liquid with a characteristic gasoline-like odor. As a solvent, Hexane is classified as a non-polar solvent, not practically insoluble in water.

Its low boiling point (69°C) makes it easy to evaporate and recover, which is a key advantage for industrial-scale solvent recycling. Due to high volatility and very low flash point (approximately -23°C or -9°F), hexane is highly flammable. It can easily ignite from heat, sparks, or open flames, and its vapors are heavier than air, meaning they can accumulate in low-lying or confined areas and travel to an ignition source. Proper handling requires strict safety protocols, including the use of explosion-proof (ATEX) equipment and excellent ventilation.

Trichloroethylene (TCE) (C₂HCl₃) was a historically popular solvent due to its effectiveness as a degreaser and its non-flammable nature. However, it was phased out in many applications, including battery separator manufacturing, due to its significant risks, health (classified carcinogen and a potential kidney, liver, and central nervous system toxin) and environmental (persistent organic pollutant that can contaminate groundwater).

why DEC?

As the industry leader, DEC has cultivated deep expertise in Solvent Recovery (SRU, SRS, SRP), tailored specifically for the Lead Acid Battery Separators industry. Our aim is to provide innovative, value-driven solutions that meet your business needs while promoting a cleaner, greener and sustainable environment.

Our Innovative Offerings

Our state-of-the-art Solvent Recovery technologies are meticulously designed to maximize the yield of recovered solvents while dramatically lowering VOC emissions, ensuring compliance with the most stringent regulations. This strategy promotes optimal resource use, significant cost savings, and a substantial reduction in your environmental footprint.

Leveraging decades of experience and a passion for innovation, we offer:

Modular Solutions: discover our (SRU_SMS™ • Solvent Recovery skid series), designed for scalability and efficiency;

Custom-Built Systems: explore our (SRU_CBS™ • Solvent Recovery custom series), crafted to meet the unique demands of your operations.

Lead Acid Battery Separators industry, the VOC recovery challenge

Activated carbon is used to recover Hexane solvent through adsorption, followed by desorption and recovery of the Hexane. The process typically involves passing the Hexane-laden air stream through a bed of activated carbon, where the Hexane is adsorbed onto the carbon's surface. The saturated activated carbon is then regenerated, which releases the Hexane for recovery and reuse.

For the Lead Acid Battery Separators industry, we offer different activated carbon regeneration processes for VOC recovery:

DEC.SRU_RSG™ • TSA inert gas N₂ dry regeneration

DEC.SRU_RSV™ • TSA steam regeneration

Selecting the SRU regeneration process is a decision based on several factors: regulatory requirements, the quantities involved, available utilities, the project's footprint, and the resulting cost-effectiveness.

The core advantage of DEC's SRUs lies in their ability to enable the direct reuse of recovered solvents. This paradigm shift from "destruction" to recovery yields substantial benefits across multiple dimensions of sustainability:

Economic Advantages

Reduced Solvent Procurement Costs: direct reuse significantly lessens the need to purchase fresh solvents, leading to considerable operational savings;

Lower Disposal Costs: eliminating or drastically reducing hazardous waste disposal expenses associated with spent solvents;

Potential for Carbon Credits: compliance with GHG reduction schemes and avoidance of direct CO₂ emissions can open avenues for carbon credit accumulation.

Environmental Advantages

Minimized VOC Emissions: effective capture and recovery dramatically reduce the release of harmful VOCs into the atmosphere, improving air quality;

Reduced Carbon Footprint: by avoiding the combustion of solvents, DEC SRUs contribute to a lower carbon footprint, aligning with global climate change initiatives;

Conservation of Resources: reusing solvents conserves valuable chemical resources and reduces the environmental impact associated with their production.

Achieve Superior Solvent Recovery and Environmental Compliance with DEC Advanced Solutions

By harnessing our years of experience and relentless pursuit of innovation, we have developed a comprehensive range of Solvent Recovery solutions modular (SRU_SMS™ • series) or tailor-made (SRU_CBS™ • series) for the unique challenges faced by Lead Acid Battery Separators industries. Our state-of-the-art technologies ensure optimal recovery and purification of solvents, allowing you to maximize your resources, reduce costs (savings), and minimize environmental impact.

Partnership with DEC

Choosing DEC means embarking on a journey towards sustainable success. Our expert team is here to tailor solutions that integrate perfectly with your operational needs, fostering enduring partnerships built on trust and mutual growth.

Making a Difference Together

Join us in revolutionizing Solvent Recovery with DEC.SRU™: together, we can drive change towards a more efficient and eco-friendly future.

a sustainable choice: Solvent Recovery applications in Lead Acid Battery Separators manufacturing

Solvent Recovery Units (DEC.SRU™), also known as Solvent Recovery Systems (SRS) or Solvent Recovery Plants (SRP), are devices used to recover solvents from air emissions of Lead Acid Battery Separators production.

Solvents are used in a variety of industrial processes, including Lead Acid Battery Separators, and can be harmful to human health and the environment if released into the air. SRU systems work by capturing the solvents from the air emissions and then recycling them back into the production process. This helps to reduce air pollution and can also save businesses money on the cost of solvents (ROI).

Solvent Recovery Units (DEC.SRU™) dedicated to Lead Acid Battery Separators industries are the best solution to reduce solvent emissions (VOCs) in a sustainable way: no thermal oxidation, no CO₂ (DECarbonization).

The solvent is recovered, for direct reuse, at a fraction of its purchase cost and with a purity even higher than the fresh virgin solvent.

how it works? Solvent Recovery Units (SRU | SRS | SRP)

SLA (Solvent Laden Air) is pushed by the fans through a multi-adsorber (activated carbon) system, to allow a high efficiency VOC (Volatile Organic Compounds) capture.

Once the adsorbent is saturated (automatically monitored by a VOC analyzer), the system is automatically cleansing the adsorbent, through a regeneration cycle. The system is using an exclusive DEC.PHD™ dehydration process (in gaseous phase), allowing the direct recovery of an anhydrous solvent mix.

For further info: DEC.RSG™ activated carbon Solvent Recovery systems for pharmaceutical industries, nitrogen regeneration.

savings and return of investment: Solvent Recovery Units (SRU | SRS | SRP)

Solvents used in the Lead Acid Battery Separators industries represent a significant cost: DEC Solvent Recovery Units ♻️ SRU | SRS | SRP provide a valuable return on investment by capturing these solvents for direct reuse in the process, leading to reduced operating expenses and improved competitiveness.

To remain competitive and profitable, Lead Acid Battery Separators companies must prioritize sustainability. Solvent Recovery Units minimize waste, significantly reduce CO₂ emissions (potentially to zero), and offer a proactive approach to mitigating the potential impact of future carbon taxes.

Nowadays, Solvent Recovery technology is no longer exclusive to large-scale operations: even companies with relatively low solvent consumption can significantly benefit from a DEC Solvent Recovery Unit. By reducing solvent usage, these units help mitigate the impact of rising solvent costs.

Recent advancements in process technology (such as DEC.ULP) have significantly reduced the energy required for activated carbon regeneration (up to 40%), leading to a substantial decrease in operating costs.

Industry Relevance: the Lead Acid Battery Separators manufacturing

The Lead Acid Battery Separators industry remains a cornerstone in various sectors, from construction and packaging to automotive and insulation. However, its continued growth and viability are increasingly tied to its ability to navigate a complex landscape of stringent environmental regulations. This includes not only addressing the end-of-life challenges of EPS products, such as developing effective recycling streams and promoting circular economy principles, but also minimizing the environmental footprint of the manufacturing process itself. Adhering to these regulations is no longer just a compliance issue; it has become a critical factor for market access, brand reputation, and long-term sustainability within the global EPS industry.

Explore More

Visit our site to see how DEC Solvent Recovery Units (SRUs) can revolutionize your production. Discover how our technology can enhance your efficiency, lower costs, and lead the way in sustainable practices within the Lead Acid Battery Separators industry.

contact DEC

If you are looking for a reliable and efficient Solvent Recovery Unit, DEC.SRUs™ (Solvent Recovery Units) are the right and best option: DEC.SRUs™ are the most advanced and reliable Solvent Recovery Units on the market, with processes, configurations and options to meet the needs of different applications, present and future challenges. Feel free to contact DEC: we can help you assess your needs and recommend the best SRU for your operation.

LTKW

Elevate your lead-acid battery manufacturing with DEC's advanced activated carbon solvent recovery systems. Our cutting-edge technology delivers a high-efficiency hexane recovery process, enabling you to reclaim valuable solvents and significantly reduce operational costs. By capturing volatile organic compounds (VOCs), our solutions not only boost your bottom line but also ensure strict environmental compliance and enhance workplace safety. DEC's deep expertise in industrial solvent recovery provides a seamless, integrated solution tailored for the demanding environment of battery separators manufacturing. Optimize your production, protect your investment, and lead the way in sustainable manufacturing with a trusted DEC solution. Discover how our solutions meet the specific needs of your industry, from the activated carbon solvent recovery process and system design to engineering, installation, and ongoing maintenance. We offer high-efficiency solvent recovery units (SRUs) and expert-led activated carbon regeneration services to maximize your system's performance. Explore our case studies to see the proven cost-benefit of implementing our technology for hexane recovery, and understand the critical role of VOC emissions control in lead-acid battery production. Our solutions include custom-built systems, adsorption technologies, and industrial recovery equipment designed to address your unique challenges. Request a demo or a quote to see the benefits of DEC's solvent recovery technology in your facility. We provide comprehensive solutions for battery separator lines, ensuring you can purchase activated carbon or a complete industrial hexane recovery system from a single, reliable supplier.