Solvent Recovery in the expandable polystyrene (EPS) industry ♻️ DEC.SRU™

Solvent Recovery in the expandable polystyrene (EPS) industry

DEC.SRU™ ♻️ SRU | SRS | SRP

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. Additionally, it is toxic to aquatic life with long-lasting effects. Safe disposal and a commitment to minimizing its release into the environment are critical. To mitigate these impacts, manufacturers must employ various Emission Control Technologies.

Pentane is an alkane. It is a colorless, highly volatile, and flammable liquid with a characteristic gasoline-like odor. As a solvent, pentane is classified as a non-polar solvent, not miscible with water.

Pentane's primary appeal as a solvent comes from its low boiling point (around 36 °C or 97 °F). This makes it easy to remove from a mixture through evaporation, which is particularly useful for separating desired compounds without damaging them with excessive heat. This property makes it a common choice for industrial processes like production of polystyrene and as a blowing agent for foams, and extraction and purification, such as for essential oils or cannabinoids. Due to its high volatility and low flash point, pentane is extremely 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.

why DEC?

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

Our Innovative Offerings

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.

expandable polystyrene (EPS) industry, the VOC recovery challenge

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

For the expandable polystyrene (EPS) 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

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.

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 expandable polystyrene (EPS) 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 expandable polystyrene (EPS) industries

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 expandable polystyrene (EPS) production.

Solvents are used in a variety of industrial processes, including expandable polystyrene (EPS), 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 expandable polystyrene (EPS) 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 or for disposal.

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 expandable polystyrene (EPS) 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, flexible packaging 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.

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.

Recent advancements in process technology have significantly reduced the thermal energy required for activated carbon regeneration (up to 30%), leading to a substantial decrease in operating costs.

Industry Relevance: the expandable polystyrene (EPS) industry

The expandable polystyrene (EPS) 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 flexible packaging 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

DEC's pioneering activated carbon solvent recovery technology is the definitive solution for the expandable polystyrene (EPS) industry seeking to manage volatile organic compounds (VOCs). Our specialized systems are expertly engineered to efficiently recover pentane, a critical blowing agent, from exhaust streams, turning a potential liability into a profitable asset. This not only ensures strict compliance with ever-tightening environmental regulations but also creates a significant return on investment (ROI) by allowing manufacturers to recycle and reuse the recovered pentane. DEC stands as the market leader, providing robust and reliable systems that boost operational efficiency and set a new standard for sustainable manufacturing in the EPS sector. Leverage our expertise in pentane recovery system design to address the unique challenges of your production process, from the pre-expander to EPS bead pentane recovery. Our proven solutions offer exceptional pentane adsorption capacity, making them ideal for managing VOC emissions from EPS foam plants and EPS block molding. Whether you're researching how to recover pentane or need a definitive cost-effective pentane recovery solution, we provide the answers. With DEC, you'll gain a competitive edge by implementing a superior solvent recovery system that not only aids in environmental compliance but also reduces pentane solvent vapor and allows for pentane recycling and reuse. Our systems, powered by high-grade activated carbon, guarantee effective pentane vapor capture technology and efficient activated carbon regeneration, ensuring your EPS production process is both profitable and environmentally responsible. We offer a comprehensive suite of solutions, from technical specifications to detailed case studies and easy installation, positioning us as the premier EPS pentane recovery technology supplier for all your needs.