reactor-exhaust-gas

Reactor Waste Gas Treatment Process

1. Waste Gas Collection
- Utilize "enclosed collection + negative pressure guidance": A sealed exhaust port is installed on the top of the reactor, connected to a flexible, telescopic duct (adaptable to the opening and closing of the reactor), and volatile waste gases are collected via side or top suction hoods.
- A fan provides a stable negative pressure (to prevent waste gas leakage). The duct material is selected based on the properties of the waste gas (e.g., PP for acid and alkali resistance, stainless steel for organic corrosion resistance).

2. Pretreatment
- Dust Filtration: If the waste gas contains material dust (e.g., during powder feeding reactions), it is first removed through a bag filter or cartridge dust collector to prevent clogging of downstream equipment.
- Condensation Recovery (Optional): High-concentration solvent waste gases (e.g., ethanol and acetone) are first passed through a condensing unit (cooled to 0-10°C) to recover some of the liquid solvent, reducing the load on subsequent treatment.
- Demisting/Dehydration: Water-containing waste gas passes through a cyclone separator or demister to remove liquid droplets and prevent them from affecting adsorption efficiency. 3. Core Purification
- Organic Waste Gas (VOCs):
- Low concentration (<300 mg/m³): Use an activated carbon adsorption tower (filled with columnar activated carbon). Replace the tower after saturation or regenerate it through thermal desorption.
- Medium to high concentration (300-2000 mg/m³): Use a combination of adsorption-desorption and catalytic combustion (CO). Desorbed high-concentration VOCs are oxidized to CO₂ and water under the action of a catalyst (200-400°C), with the heat recycled.
- High-boiling-point or viscous VOCs: Use a spray absorption tower (using a specialized solvent or water for absorption) supplemented with activated carbon adsorption for purification.
- Acidic and alkaline waste gas: Acidic waste gas (such as HCl) is absorbed in a spray tower with a NaOH solution, while alkaline waste gas (such as NH₃) is absorbed in a spray tower with a dilute H₂SO₄ solution. The reagent concentration is adjusted through online pH monitoring. 4. End-of-pipe Treatment and Emissions
- The purified exhaust gas undergoes secondary demisting and enters the end-of-pipe activated carbon adsorption tower (to deeply remove residual pollutants).
- It is ultimately discharged through an exhaust stack at least 15 meters tall, equipped with online VOC or acid-base concentration monitors to ensure compliance with relevant industry emission standards.

This process addresses the intermittent emission and large concentration fluctuations of reactor exhaust gas. It focuses on "pretreatment + targeted purification," balancing solvent recovery (optional) with standard-compliant emissions. It also adapts to the varying properties of exhaust gas generated by different material reactions.