The removal of gaseous pollutants generated by industrial processes can be difficult and expensive. The inertial separator for condensed vapors (FumeCatch) is a stand-alone customized air cleaning system providing a solution for capturing condensable vapors in a more efficient way. The vapors are forced to condense in a controlled way and the droplets generated by condensation are removed by inertial devices with high efficiency and reduced maintenance.
The adoption of FumeCatch technology provides several advantages:
– Maintenance is reduced and can be automated to avoid stops in the production process
– Cleaning or regeneration of pollution control devices is reduced so that energy and water can be saved compared to traditional approaches
– Condensed vapors provide materials which can be sold on the market or reintroduced again in the production cycle

Patent Status

SUBMITTED

Priority Number

102020000025957

Priority Data

30/10/2020

License

ITALY

Market

Some of the potential applications and markets of FumeCatch are:

Rubber vulcanization industry (China, India, Germany, Italy, USA)
Vapors released from the process must be captured to prevent environmental pollution

Coffee roasting (Brazil, Italy)
20% of the beans mass is vaporized and lost: if recovered could be sold

Pyrolysis oil from charcoal production (Brazil, China, India)
Alternative to fossil fuels in which from 40% to 70% of mass is lost and wasted
The recovered oil has a commercial value

Recovery of vapors released from asphalting processes
Reduction of noxious substances released in the air for worker’s protection and population in general

Problem

Many industrial production processes cause the emission of gaseous pollutants, sometimes flammable. These substances shall not be released in the workplace to protect the health of workers, nor can they be discharged directly into the outdoor environment to prevent the heavy pollution of the surrounding atmosphere. Consequently, the fumes generated by the production process shall be purified in specific treatment units, and then the residual contaminants that could not be captured by the fumes treatment system are discharged outdoors, usually through a chimney. The invention addresses the problem of capturing gaseous pollutants mainly with an organic base, after having induced, at least in part, their condensation. In this way, an aerosol consisting of liquid particles is generated and then can be captured by inertial devices, such as cyclones. Among the positive outcomes, we highlight the possibility of recirculating the air containing the pollutants generated during the manufacturing process. In this way, in theory it is possible to reduce to zero the environmental impact of the production process generating the gaseous pollutants. Moreover, in some production processes the generated vapors, if condensed, have a commercial value. Therefore, the dispersion of these vapors into the environment is currently a financial as well as an environmental damage.

Current Technology Limits

Existing solutions, typically electrostatic precipitators, adsorbent beds, wet scrubbers, require regeneration processes that require energy and are expensive. Regeneration implies the replacement of materials or components and, consequently, the interruption of the production activity. In addition, all maintenance procedures inevitably involve a cost. The regeneration of an adsorbent consists in heating it at high temperature for a period of time sufficient to release the contaminant to be captured again with another technology. Water from the wet scrubbing process must be treated before disposal, while electrostatic precipitators, in addition to providing removal efficiencies that are not always adequate, must be continually cleaned. None of the technologies listed can be encapsulated in an easily transportable or modular device.

Killer Application

FumeCatch technology can be used to remove condensable gaseous contaminants, primarily in flue gas. Some applications include the capture of:
– Gaseous contaminants produced by industrial processes, such as rubber vulcanization
– Commercially valuable flavors released during coffee roasting
– Condensable vapors with commercial value released from charcoal production
– Hydrocarbons released during asphalting and waterproofing operations

Our Technology and Solutions

FumeCatch technology allows for the efficient and effective capture of organic-based vapors contained in the flue gas from many industrial processes. The fumes are cooled by direct injection of a cooler air flow rate produced by a refrigeration machine or cold storage. The mixing between the two flows induces the condensation of the vapors. It is mainly located in the portion of volume contained between the mixing zone and the cyclonic separator that captures the condensed liquid particles removing them from the rest of the incoming fumes, thanks to the considerable centrifugal force. The liquid particles, after having touched the wall of the cyclone, form a liquid film that drips downwards by gravity. The contaminant now in liquid form can be collected from the lower part of the cyclone with containers that can be easily sealed and removed without interruption of the activity. The fumes purified from most of the contaminant can be reintroduced into the production cycle without the need to exhaust them from the chimney.

Advantages

The induced condensation system requires less maintenance than the technologies listed above because it has no components to regenerate. Its maintenance can be largely automated because the condensed contaminant is collected at the bottom of the cyclonic separator in a continuous manner due to spontaneous gravity fall downward.
The contaminant separated from the flue gas can eventually be reused, which is important if the condensed contaminant also has a commercial value.
FumeCatch technology does not generate materials to be treated separately (wastewater, spent charcoal, etc.) or disposed of later, nor does it require the regeneration of adsorbent materials or devices with complicated and expensive processes.
The installation of the necessary components does not alter the layout of the production process and is suitable for use even on a small scale.
The flue gas treatment unit can generate a purified flow rate that allows a closed cycle of flue gas without its evacuation to the chimney and thus allows the relocation of production processes in a flexible way.
The entire unit is transportable and can therefore be placed on board of vehicles or used for moving applications.

Roadmap

The construction of a prototype was funded through the Proof of Concept call for proposals. A small-scale demonstration device will be built by the end of 2021.
The current team includes a member based in Brazil who plans to install a demonstration prototype at interested companies.
The group in Italy contacted a company in the rubber parts manufacturing sector that has expressed interest in the FumeCatch technology.
In order to build a solid business plan for the creation of a start-up, the inclusion of commercial expertise in the current team is necessary.

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