Zeolite Rotor + RTO System for Automobile Parts Painting Waste Gas
Project Overview
The project targets the coating production lines of Lizhong Light Alloy (Anhui). There are 2 painting lines including primer, topcoat, flow-out and drying processes. The waste gas mainly comes from volatile paint and diluents, containing xylene, non-methane total hydrocarbons and paint mist. It is typical large air volume, low-medium concentration VOC waste gas. A single RTO would lead to high operating costs, while paint mist is easy to block conventional treatment equipment.
Core Parameters
- Total gas treatment capacity: 154,000 Nm³
- Max gas temperature: ≤ 40℃
- Emission standards: DB34/4812.6-2024, GB16297-1996
Process Solution
Combined process: Multi-stage Dry Filter + Zeolite Concentration Rotor + Three-Chamber RTO (concentration first, then incineration to cut operating costs).
Process Flow: Painting Waste Gas → Multi-stage Dry Filter → Zeolite Rotor → Desorbed High-Concentration Waste Gas → RTO → Plate Heat Exchanger → Standard Discharge
Pretreatment: Four-stage graded filters (G4/G7/F9) intercept paint mist and particles to avoid blockage of the zeolite rotor.
Concentration Unit: The hydrophobic zeolite rotor runs at 1.1~1.4 rph with a concentration ratio of about 15. Desorption temperature is controlled at 180~220℃.
Incineration Unit: VOC is completely oxidized at 800~850℃ inside RTO, with heat recovery efficiency up to 95%.
Waste Heat Reuse: The heat from flue gas is recycled by the plate heat exchanger to supply heat for rotor desorption.
Main Equipment
Multi-stage bag filter, differential pressure alarm device, large hydrophobic zeolite rotor, three-chamber RTO, low-NOx burner, frequency conversion fans, online VOC monitor, digital twin monitoring system.
Operation Performance
- Emission: Non-methane total hydrocarbon ≤ 60 mg/m³, Xylene ≤ 20 mg/m³, Particulate Matter ≤ 120 mg/m³, all indicators stably meet standards.
- Cost Reduction: The rotor concentrates waste gas and reduces the treatment air volume of RTO, cutting natural gas consumption by more than 40%.
- Intelligent Operation: Digital twin system realizes real-time status monitoring, fault early warning and remote management, supporting unattended operation.
- Stability: Inorganic zeolite material is non-flammable, with excellent adaptability to complex working conditions of painting workshops.
Technical Highlights
- Graded filtration + hydrophobic zeolite perfectly solve the problem of paint mist blockage and extend equipment service life.
- Closed-loop waste heat circulation greatly reduces overall energy consumption.
- Full automatic control plus digital twin technology realizes predictive maintenance.