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Ⅰ. Scheme Background and Applicable Scenarios
Rubber production processes such as rubber mixing, vulcanization and shaping generate composite waste gas containing dust, volatile organic compounds (VOCs) and odorous gas. The dust components mainly include rubber particles and carbon black dust. Organic pollutants consist of benzene series, sulfides and hydrocarbons. Direct discharge will cause atmospheric pollution and endanger human health. This scheme is suitable for waste gas treatment of small and medium-sized rubber product factories and rubber processing plants. The treatment capacity can be flexibly adjusted according to exhaust gas emission (5000-50000m³/h). The core treatment targets are dust removal efficiency ≥99% and VOCs removal efficiency ≥85%. All emission indicators shall comply with the Emission Standard of Pollutants for Rubber Products Industry (GB 27632-2011) and local environmental protection requirements.
Ⅱ. Core Process Flow Chart
Waste Gas Collection System → Pretreatment (Cooling + Oil Removal) → Bag Dust Collector → Activated Carbon Adsorption Tower → Fan → Exhaust Stack (Compliant Discharge)
Ⅲ. Detailed Process Unit Introduction
1. Waste Gas Collection System
Adopt the mode of closed hood + pipeline transportation. Closed collection hoods are installed for pollution sources such as mixing mills and vulcanizing machines to ensure the gas collection efficiency ≥90%. The pipeline is made of PP material or anti-corrosion carbon steel. The pipe diameter is designed according to gas flow with wind speed controlled at 10-15m/s to reduce gas retention and pipeline dust accumulation.
2. Pretreatment Unit
Rubber waste gas features high temperature (40-80℃) and a small amount of oil mist. The flue gas is cooled to 30-40℃ by a cooler at first, and then the oil mist is removed by an oil remover with removal efficiency ≥80%. This procedure prevents high temperature damage to filter bags and avoids carbon pore blockage caused by oil mist, ensuring stable operation of subsequent treatment units.
3. Bag Dust Removal Unit
(1) Process Principle
The filter bag intercepts dust particles in the waste gas. A stable dust layer is formed on the bag surface to further improve filtration efficiency, which can effectively remove particles ≥0.1μm.
(2) Equipment Selection
Pulse jet bag dust collector is adopted. The filter bag is made of PTFE laminated needle felt (max temperature resistance ≤120℃, acid and alkali corrosion resistance). The filtration wind speed is controlled at 0.8-1.2m/min. Compressed air pulse ash cleaning is applied (pressure: 0.4-0.6MPa) to realize timely dust shedding and prevent bag blockage.
(3) Key Technical Parameters
Dust removal efficiency ≥99%; outlet dust concentration ≤10mg/m³; system resistance: 1200-1500Pa. Equipped with ash hopper and screw conveyor, the collected dust such as carbon black can be recycled for rubber mixing production.
4. Activated Carbon Adsorption Unit
(1) Process Principle
Relying on the porous structure and high specific surface area, activated carbon physically adsorbs VOCs and odorous gas in the waste gas. The saturated carbon needs regular replacement or regeneration treatment.
(2) Equipment Selection
Vertical fixed-bed activated carbon adsorption tower is adopted. The carbon filling capacity is calculated according to air volume and concentration with gas residence time ≥1.5s. Honeycomb activated carbon is selected (specific surface area ≥800m²/g, iodine adsorption value ≥800mg/g), featuring large adsorption capacity and low system resistance.
(3) Key Technical Parameters
VOCs removal efficiency ≥85%; outlet VOCs concentration ≤20mg/m³; odor removal efficiency ≥80%; equipment resistance ≤800Pa. Inspection openings and carbon replacement doors are reserved for daily maintenance. An adsorption saturation alarm device equipped with import and export VOCs sensors is installed to remind carbon replacement in time.
5. Fan and Exhaust Stack
Anti-corrosion centrifugal fan is selected. The air volume is matched with the treatment scale, and the wind pressure is designed to overcome system resistance with 10% allowance. Shock absorption base and silencer are equipped to control operating noise ≤85dB(A).
The exhaust stack height is ≥15m. The stack diameter is determined by flue gas flow. Rainproof cap and monitoring sampling port are reserved on the top to facilitate environmental detection.
Ⅳ. Operation and Maintenance Guidelines
1. Daily Operation Management
Regularly check the tightness of gas collection hoods and air leakage of pipelines. Monitor the pressure difference and dust concentration of the bag collector to ensure normal ash cleaning operation. Record the import and export VOCs concentration of the adsorption tower. Replace activated carbon timely according to alarm prompts (conventional replacement cycle: 3-6 months, adjustable according to actual waste gas concentration).
2. Equipment Maintenance
Clean the dust hopper of the bag collector every month and replace damaged filter bags in time. Inspect the carbon adsorption state quarterly to avoid moisture agglomeration. Regularly lubricate the fan and control the bearing temperature ≤70℃.
3. Safety Management
Activated carbon is flammable. The adsorption tower shall be kept away from fire sources with complete fire prevention and ventilation facilities. Waste activated carbon shall be transferred to qualified institutions for hazardous waste disposal with complete transfer records.
Ⅴ. Compliance Guarantee Measures
Optimize the gas collection system to efficiently collect unorganized exhaust gas and reduce gas escape.
Adopt standard filter bags and qualified activated carbon. Regularly detect exhaust concentration to ensure stable compliance.
Establish complete operation ledgers to record operating parameters, consumable replacement and monitoring data for environmental supervision.
Parallel or series adsorption towers can be added to improve treatment efficiency under fluctuating waste gas concentration.
Carry out regular staff training to ensure operators are familiar with operation procedures and emergency disposal measures.
