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Dürr exhaust air purification units with an energy management system provide efficiency in the wallpaper production market

Bietigheim-Bissingen, 30 July 2013 – 50% less energy consumption, longer intervals between maintenance, greater reliability and an extended service life are just a few key reasons wallpaper manufacturer, Tapetenfabrik Gebr. Rasch, chose the new Ecopure TAR recuperative oxidizer by Dürr Clean Technology Systems for their environmental compliance needs.

Very high maintenance and operating costs were among the main reasons why wallpaper manufacturer, Tapetenfabrik Gebr. Rasch in Bramsche, Germany, decided to replace a near decade old, non-Dürr air purification system. Because cost was an important issue for Tapentenfabrik, Dürr chose to present the Ecopure TAR recuperative oxidizer as a solution. The Ecopure TAR allowed for low electricity and gas consumption, as well as long maintenance intervals and reliability. A robust system design with particularly effective exhaust-air heat exchangers and a high-performance burner with a special flame geometry allowed Dürr to achieve these requirements. Compared to their existing system, these measures will reduce the electricity and gas consumption by around half, the heat exchangers can now resist SiO2 clogging for longer than a year, and the thermal-oil replacement interval has almost doubled. The new Dürr Ecopure TAR recuperative oxidizer is designed for a service life of around twenty years.

The Dürr Ecopure TAR recuperative oxidizer is an exhaust-air pollutant incineration system that has proven its worth for more than 40 years. It operates particularly economically when waste heat is re-utilized in the production process through downstream heat recovery systems like thermal oil or hot-water heat exchangers. Dürr has already installed more than 1,800 Ecopure TAR recuperative oxidizer systems for diverse applications in numerous industries around the world, with the fourth system generation now coming into use. Dürr’s many decades of experience flows into the design, construction, and operation of the systems. In addition to planning and commissioning, Dürr also performs all integration and plant maintenance work.

Incorporating the air purification system into an uninterruptible power supply (UPS) guarantees production reliability, which allows continued operation of the Ecopure TAR recuperative oxidzer even in the event of a power failure. The Ecopure TAR operates fully automatically – any interventions can be performed via an operator panel with a user-friendly interface. Emissions are less than 80 mg/Nm³ for CO, and less than 50 mg for NOx, far below the required limits, while the burner’s limit values for hydrocarbons are <20 mg. The integrated energy management system, according to the DIN ISO 50001 standard, measures and documents all consumption values, thereby leading to opportunities for further process optimization measures.

“Although the new air purification system’s design resulted in somewhat higher acquisition costs, these costs will be recouped in as little as two or three years thanks to the much lower operating costs. We were also convinced by the robust design with its optimized maintenance intervals and the long service life,” said facility manager Thorsten Voß.

Design elements for decreasing the amount of condensate in the plasticizer-laden exhaust air pose special challenges for exhaust air purification in the wallpaper industry. Maximum energy efficiency is also a requirement, which is achieved in part through optimal recovery of waste heat for the process.

With more than 60 successfully completed projects in the wallpaper industry, the Dürr Clean Technology Systems division is among the market leaders for efficient air purification solutions in this sector.