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Environmentally Friendly Printing – Condensing filtration solvent recovery - 24th June 2010
A relatively new development, condensing filtration solvent recovery control systems are gaining in popularity over the control techniques which have dominated the industry to date.

Although not suitable for all printing processes, the condensing filtration solvent recovery system is ideal for the efficient removal of high boiling point hydrocarbons from exhaust air streams.

The system comprises three main elements: a high-efficiency condensation unit, a ‘Printkleen’ moving bed filter and a mist eliminator unit. In practice, the exhaust gases from the print dryer, normally at a temperature of around 160-180ºC and containing the solvent in the gaseous phase, are ducted into the condensation unit where they are cooled to a temperature of around 40ºC by means of a controlled flow of air at ambient temperature.

As the gases cool, the high boiling point solvents condense and form an aerosol mist of liquid solvent droplets. Approximately 60% of the liquid component is removed at the condensation stage with this passed subsequently through a filter which removes any solid particles, and then to a separator where the oil is separated from any water present by flotation techniques. The solvents removed are then passes to a central storage tank for re-use.

The solvents not removed in the condensers are carried along in the exhaust gas stream and passed into the moving bed filtration unit where agglomeration of the droplets occurs in the filter media. Any solids, together with the aerosol solvents are removed from the exhaust stream. The liquid solvents collected are then filtered, separated and pumped into the central storage tank.

In order to maintain optimum efficiency, the filter unit automatically indexes on a new section of filter media whenever that in use becomes soiled.

As a final stage in the cleaning process, the exhaust air is fed into a mist eliminator where any remaining solvent droplets are trapped, collected and passed to the liquid solvent treatment system. The now clean exhaust gases are then discharged safely to atmosphere.

Unlike thermal and catalytic incinerators, condensing filtration solvent recovery systems operate on a low-energy cycle and are therefore significantly less expensive to run. In addition, the system is benign in operation and does not generate environmentally- damaging gases associated with the use of destructive thermal control techniques.

In addition, the system enables the solvent recovered in the cleaning process to be recycled and used either as make-up fuel for boilers and hot air heaters, or reprocessed for black ink reformulation. Also, the heat recovered in the initial cooling stage can be recycled and used for return direct to the dryers for pre-heat purposes, or used for space heating.

Peter Harrison is Joint Managing Director of The Printing House Ltd, and Print Buying Direct of Crewe, Cheshire, UK.

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