Duha Color Services: VOC Emission Reduction
This report outlines the "VOC Emission Reduction" project presented by Duha Color Services. Duha Color Services produces color marketing tools for an international market. Part of the production process exposes the tools to a high heat intensive process in order for the paint to dry. This step generates a large volume of volatile organic compounds (VOC) which are exhausted to the outside air. The objective of the project is to reduce the transmission of these volatile organic compounds by 95% as they are harmful to human health and the environment. The method selected to reduce the VOC concentrations from the exhaust air was an activated carbon adsorber system with steam regeneration. Activated carbon adsorbs the VOCs present in the exhaust air, allowing for only purified air to be exhausted to the environment. A steam regeneration system is then used to remove the VOCs from the carbon so it can be re-used for VOC adsorption and handled as non-hazardous waste. Once the steam removes the VOCs from the carbon, the carbon is dried and can be re-used. This report contains a detailed introduction of the project background, the ideal design target specifications, the project constraints, background on activated carbon, a detailed design of the complete activated carbon system, and a final bill of material (BOM). Furthermore, government incentives for the project were determined and a risk analysis for the project was completed. The detail design of the system includes the calculations for the VOC abatement using activated carbon, followed by the design of a vertical carbon vessel and a horizontal carbon vessel. The detail design also includes a complete steam regeneration system design with inlet/outlet parameters, boiler and condenser selection, pressure drop, wastewater, and drying calculations. The final design equipment is summarized as follows: 2 activated carbon beds, one boiler, one condenser, multiple valves, and piping. The final capital cost for the project was determined to be $190,010 and final yearly upkeep cost of $2,980,582. This cost correlates to the 30-day carbon refill scenario. The size of the activated carbon beds was determined to be 4,017 lbs/vessel. The final mass of the design was predicted to be 8,052 lbs. The final design was able to meet the objective of a 95% reduction of VOCs from the rooftop exhaust.