Industry Pain Points and Solutions

Frosting and Shutdown Issues Due to High-Humidity Waste Gas

High-humidity waste gas is prone to frosting at low temperatures, blocking heat exchangers, leading to equipment shutdown and production losses of up to 15%.

Traditional equipment lacks effective preventive measures, and companies often miss production peaks due to equipment downtime.

3D Design Drawing of VOCs Cryogenic Recovery Equipment

Process Design of VOCs Cryogenic Recovery Equipment

ASPEN Process Simulation

Process Flow:

Waste Heat Pre-cooling (Zero Energy Consumption)

Principle: Utilizing the -70℃ ultra-low temperature waste gas generated by the equipment itself, through a shell-and-tube heat exchanger with high-temperature original waste gas (40℃) for counter-current heat exchange.

Effect: The original waste gas temperature is reduced from 40℃ to 10-20℃, without any external energy input throughout the process, achieving 100% energy saving.

Three-Stage Cascade Refrigeration

First Stage (0℃): Preliminary condensation of high-boiling-point VOCs (such as benzene, toluene), without defrosting design, reducing subsequent load;

Second Stage (-30℃): Medium and low-temperature condensation of medium-boiling-point components (such as ethyl acetate), integrated with automatic defrosting function;

Third Stage (-70℃): Ultra-low temperature deep capture of low-boiling-point VOCs (such as ethylene, chloromethane), with efficient refrigerant (R23) circulation.

​ Dual-Channel Intelligent Switching

Operating Mode: A/B channels operate independently. When frosting is detected, or according to the time sequence, the channels are switched to ensure 24-hour continuous processing.

Condensation and Recovery

Liquid VOCs are automatically recovered through a collection tank, with a purity >99%, and can be directly reused in production; uncondensed gases enter the next stage.

Emission Compliance

After deep cooling, the tail gas is sent to the adsorption system for safe and compliant emission.

Cold Energy Self-Circulation System

Principle of Zero-Energy Consumption Pre-cooling Technology

★ Waste Cold Recovery After Three-Stage Refrigeration

The -70℃ waste gas after three-stage refrigeration enters a high-efficiency heat exchanger, utilizing the waste cold to pre-cool the original 40℃ waste gas, achieving cold energy recycling. Through waste cold recovery, pre-cooling energy consumption is reduced to 0kW.

★ High-Efficiency Energy Saving Through Counter-Current Heat Exchange

The original 40℃ waste gas and -70℃ waste gas use a new type of high-efficiency heat exchanger for counter-current heat exchange, pre-cooling to 10-20℃, without external energy input, significantly improving energy saving.

The counter-current heat exchange efficiency is 30% higher than traditional co-current heat exchange, and the pressure vessel manufacturing standard makes the equipment operation more stable and extends its service life.

★ Pre-cooling Energy Consumption Comparison

Traditional pre-cooling methods have high annual electricity consumption; this equipment has zero pre-cooling energy consumption.

Based on a processing capacity of 5000m³ and 300 days of annual operation, traditional equipment consumes 360,000 kWh, with electricity costs of approximately 300,000 yuan, while this equipment requires no electricity costs.

Dual-Channel Continuous Operation Guarantee

Dual-Channel Intelligent Switching System

A/B Channel Independent Operation Logic ▶

A/B channels operate independently without affecting each other. When one channel is operating, the other channel is on standby, ensuring continuous operation of the equipment.

During equipment operation, channel A processes waste gas, and channel B is on standby. Once channel A encounters a problem, channel B immediately switches over seamlessly.

Automatic Switching Logic ▶

After a frosting warning in channel A, the system automatically switches to channel B within 5 seconds, with a smooth switching process that does not affect production.

Customer Value and Cost Savings ▶

Production loss is reduced to <1%, compared to 15% for traditional equipment; maintenance labor costs are reduced by 40%, reducing the burden on enterprise operations.

After using this equipment, a certain company recovered over 2.6 million yuan annually, demonstrating significant economic benefits.

Economic Benefits

Industry Benchmark Case

A chemical company with a processing capacity of 2000m³/h and a solvent recovery of 2.4m³/day.