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Home / Case Studies / Efficient Air Purification in Foundry Production: Solving the Phenol and Formaldehyde Problem
Efficient Air Purification in Foundry Production: Solving the Phenol and Formaldehyde Problem
Client
The company is a leading manufacturer of steel castings, specializing in steel casting into cold-box molds (Alpha-set process). The company's plant is located in an industrial zone, ensuring the production of high-precision and wear-resistant components for the machine engineering, shipbuilding, and oil and gas industries.
The company pays special attention to environmental standards and strives to minimize harmful emissions into the atmosphere by implementing modern air purification systems.
The company pays special attention to environmental standards and strives to minimize harmful emissions into the atmosphere by implementing modern air purification systems.
Production Process
Alpha-set process is a cold-box process (CBP) used in foundry production. The main stages are:
- Preparation of the molding mixture: Wood fillers or sand are mixed with furan or phenolic resins, which provide molding strength.
- Pouring of molten steel into molds: Steel is heated to 1550–1650°C and poured into disposable molds made from a mixture of sand and binder.
- Cooling and shaking out the castings: After solidification, the castings are extracted, and the used molds are crushed and sent for disposal or reuse.
- Cleaning of castings: The cleaned products undergo finishing operations, including grinding and heat treatment.
Problem
During the thermal decomposition of molding resins, harmful organic compounds are released, such as:
- Phenol (C₆H₅OH) – a toxic substance that irritates the respiratory system and skin.
- Formaldehyde (CH₂O) – a carcinogenic gas with a sharp odor.
- Dust (fine particles from sand molds) – contaminates the air in the work area.
Current system component
- Local exhaust hoods over the areas where castings are shaken out.
- Cyclones for mechanical dust removal.
Disadvantages of the current system
- Does not remove phenol and formaldehyde – organic gases remain in the emissions.
- High concentration of VOCs (volatile organic compounds).
- Insufficient reduction of harmful substances to meet regulatory standards.
Temperature
Gas temperature after the casting shake-out and cleaning sections 50-122°F (10-50°C)
Incoming concentrations
Suspended solids (dust) — 300 mg/m³
Phenol — 6 mg/m³
Formaldehyde — 5 mg/m³
Gas/Dust
Phenol (C₆H₅OH), Formaldehyde (CH₂O), Dust (fine particles of sand, scale)
We have cases that we are very proud of, and which have opened new horizons for the development of our scientific interests. This is one such case.
In 2018, this case led to the establishment of a new direction for air purification in foundry industries where phenols and formaldehydes are emitted. Today, this has grown into dozens of integrations worldwide.
The client approached us with the following technical assignment:
Initial Data
Parameter | Description |
Description of the Technological Process | Foundry Production |
Principle Diagram of the Technological Process | Steel casting into HTS molds (Alpha-set process) |
Volume Flow Rate and Temperature of the Gas-Dust Flow | 18,000 CFM, temperature 50-122°F (10-50°C) |
Equipment Operating Mode | Continuous |
Description of the Existing Dust and Gas Purification System | Cyclone |
Discharge Method (manual/automatic) | Manual |
Discharge System Operating Mode | 2 times per day |
Required Bottom Level of Outlet Flanges | 4.9 feet (1.5 meters) |
Proposed Solutions
Fluidized-Bed Wet Scrubber Torch-Air
FLUIDIZED PACKED BED SCRUBBER
A Fluidized Packed Bed Scrubber is a type of scrubber in which the contact between contaminated gas and liquid occurs within a freely floating bed of packing material.
A Fluidized Packed Bed Scrubber is a type of scrubber in which the contact between contaminated gas and liquid occurs within a freely floating bed of packing material.
Operating Principle
The Fluidized Packed Bed Scrubber operates as follows: the dust-laden gas flow enters the scrubber body through the contaminated gas inlet and encounters a curtain of packing material. This packing is wetted with water or another absorbent from the irrigation system.
To remove sludge, the bottom of the scrubber housing is conical and equipped with a drainage outlet. To ensure the free movement of the packing material within the gas-liquid mixture, its density must not exceed that of the liquid.
The dust capture process occurs in an optimal hydrodynamic mode of the gas scrubber, characterized by a fully developed fluidized bed regime.
To reduce droplet carryover, a demister is installed after the packing layer.
To remove sludge, the bottom of the scrubber housing is conical and equipped with a drainage outlet. To ensure the free movement of the packing material within the gas-liquid mixture, its density must not exceed that of the liquid.
The dust capture process occurs in an optimal hydrodynamic mode of the gas scrubber, characterized by a fully developed fluidized bed regime.
To reduce droplet carryover, a demister is installed after the packing layer.
Tornado-18 Wet Scrubber
The Tornado-18 wet scrubber is supplied in a partially assembled and fully equipped state. Assembly must be carried out according to the instructions and the included drawings of the individual filter parts. When connecting all parts of the filter housing, the contact areas must be sealed with sealant (included in the kit). All threaded connections should be sealed with plumbing thread sealant.
The result and purification efficiency of the aforementioned case ranged from 96.49% to 100%!
The client wrote the following:
The result and purification efficiency of the aforementioned case ranged from 96.49% to 100%!
The client wrote the following:
Client:
Good afternoon
The attached files contain photographs of the wet scrubber and the room from which the contaminated air is being extracted.
Also attached are laboratory test reports demonstrating that the scrubber successfully performs its primary function—removing phenol and formaldehyde.
Additionally, the attached file includes a pyrolysis table for our process.
The emission purification process is working. There are no issues with Torch-Air.
The attached files contain photographs of the wet scrubber and the room from which the contaminated air is being extracted.
Also attached are laboratory test reports demonstrating that the scrubber successfully performs its primary function—removing phenol and formaldehyde.
Additionally, the attached file includes a pyrolysis table for our process.
The emission purification process is working. There are no issues with Torch-Air.
Pyrolysis
Incoming concentrations to our client's scrubber are:
Since 2018, the company has been using our first scrubber, which has been operating flawlessly. After that, we supplied this client with two more identical scrubbers and a large number of dust collectors, including both cartridge and baghouse type.
VENTURI TORNADO-FB
We keep moving forward, and here’s what we offer now — Venturi Tornado-FB Fluidized Bed Scrubber with a Venturi Tube:
- Suspended solids (dust) — 286 mg/m³
- Phenol — 4.4 mg/m³
- Formaldehyde — 3.7 mg/m³
- Suspended solids (dust) — 99.54%
- Phenol — 96.49%
- Formaldehyde — 99.9%
Since 2018, the company has been using our first scrubber, which has been operating flawlessly. After that, we supplied this client with two more identical scrubbers and a large number of dust collectors, including both cartridge and baghouse type.
VENTURI TORNADO-FB
We keep moving forward, and here’s what we offer now — Venturi Tornado-FB Fluidized Bed Scrubber with a Venturi Tube:
Tornado-FB
Characteristics | Information |
Volume | 50 000 cfm |
Scrubbing column pressure loss | Max pressure drop - 6 in.w. |
Maximum vacuum on the body | 5 000 Pa |
Weight | 8000 kg |
Temperature range | 80 ˚C |
Pumps
| Three pumps, each 10 HP, totaling 30 HP Irrigation/pump capacity - 200 m³/h. |
Dosing pump for acid | 41 liters per hour Consumption of 100% acid is approximately from 600 g/hour to 1800 g/hour (depends on pollution fluctuations). |
Sump capacity | 11 m³ |
pH meter | Included |
“Venturi Tornado-FB” Fluidized Bed Scrubber with a Venturi Tube
Principle Diagram of Wet Scrubber Operation
The scrubber is three-stage:
Stage 1 — low-pressure Venturi tube. It effectively knocks down particulate matter directly into the recirculating liquid tank through counterflow irrigation nozzles and the acceleration effect in the Venturi tube.
Stage 2 — a mass transfer column with efficiencies up to 99.9% for various components, conducts mass transfer between the liquid phase and the gas, reducing pollution concentrations.
Stage 3 — mesh pad catcher, retains pollutants and droplets up to 2 micrometers in size.
Stage 1 — low-pressure Venturi tube. It effectively knocks down particulate matter directly into the recirculating liquid tank through counterflow irrigation nozzles and the acceleration effect in the Venturi tube.
Stage 2 — a mass transfer column with efficiencies up to 99.9% for various components, conducts mass transfer between the liquid phase and the gas, reducing pollution concentrations.
Stage 3 — mesh pad catcher, retains pollutants and droplets up to 2 micrometers in size.
Overview | TORNADO FB Fluidized Bed Scrubber
Biological Filters for Cleaning Phenol and Formaldehyde
We also offer wastewater treatment systems using biological filters. These filters utilize special bacteria that break down phenol and formaldehyde into water and carbon dioxide, resulting in a zero-waste production process.
In the scrubber, harmful substances are captured using a water-based absorbent, while in the biofilter, they are neutralized. Additionally, ozone is introduced into the scrubber, which helps to reduce odors by an order of magnitude. The solution circulates in a closed cycle between the scrubber and biofilter, with no discharge into the sewer system.
The components of the biofilter include a sludge settler, an aeration tank, and a collection chamber for the purified solution. Bacteria are introduced into the aeration tank once, before the system begins operation, in the form of concentrated biomass. The purified exhaust air is released into the atmosphere after passing through a demister.
As suspended and condensate substances enter the sludge settler of the biofilter, they are removed using a special sludge removal system.
In the scrubber, harmful substances are captured using a water-based absorbent, while in the biofilter, they are neutralized. Additionally, ozone is introduced into the scrubber, which helps to reduce odors by an order of magnitude. The solution circulates in a closed cycle between the scrubber and biofilter, with no discharge into the sewer system.
The components of the biofilter include a sludge settler, an aeration tank, and a collection chamber for the purified solution. Bacteria are introduced into the aeration tank once, before the system begins operation, in the form of concentrated biomass. The purified exhaust air is released into the atmosphere after passing through a demister.
As suspended and condensate substances enter the sludge settler of the biofilter, they are removed using a special sludge removal system.
Best Scrubbers for Phenol and Formaldehyde
We always perform precise calculations and offer expert assistance in selecting the optimal dust collection or gas cleaning systems, typically completing this process within 1 to 2 days
Head of Engineering,
Vladimir Nikulin
Vladimir Nikulin
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