In the context of pharmaceutical and fine chemical production, solvent agitation, solvent feeding, open transfer, tank respiration, crystallization drying, and other processes all generate solvent volatilization waste gas. The source of the waste gas is dispersed and mixed with various organic solvents such as alcohols, ketones, esters, and halogenated hydrocarbons. Due to the influence of production mode, the exhaust gas is not continuously and stably discharged. The volatilization amount increases during the production operation period, and the concentration of exhaust gas rapidly decreases when the workshop is shut down. The overall air volume and concentration fluctuate significantly. The evaporated airflow will carry small material droplets and saturated water vapor, and some halogenated solvents will hydrolyze upon contact with moisture, generating acidic substances that will continue to corrode pipelines and equipment. All types of organic solvents are flammable and explosive substances, and the exhaust gas collected at multiple locations has complex working conditions. There are strict requirements for the material corrosion resistance, load adaptability, and safety protection system of the treatment equipment. Traditional treatment schemes are difficult to balance emission standards, solvent recovery, and long-term operational stability.
The incineration process can complete exhaust gas purification, but it will directly burn and consume a large amount of recyclable organic solvents, causing loss of raw material resources. Waste gas containing halogenated components will generate corrosive by-products after high-temperature incineration, damaging subsequent pipeline components. It is necessary to build a set of exhaust gas treatment facilities, maintain high equipment investment and daily operation and maintenance costs.activated charcoalAdsorption only completes the transfer of pollutants and cannot achieve solvent recovery. In exhaust gas environments with mixed components, high humidity, and constantly changing concentrations, adsorption materials are prone to premature saturation, leading to adsorption penetration. Frequent shutdowns are required to replace adsorption consumables, resulting in a large amount of hazardous waste and continuously increasing the operating cost burden of enterprises. The simple condensation process relies on low-temperature conditions to liquefy the solvent, which is limited by the partial pressure of organic vapor. The recovery effect is only significant when the exhaust gas concentration is high. Faced with fluctuating solvent volatilization exhaust gas, the overall recovery efficiency is unstable, and there are obvious shortcomings in the treatment capacity during the low concentration stage.
The compression condensation film coupling process adopts a pure physical treatment method, and there is no combustion or chemical reaction in the entire treatment process, which is suitable for the treatment needs of volatile waste gas from pharmaceutical and fine chemical solvents. The exhaust gas first flows into the pre-treatment unit, relying on a multi-stage filtration and foam removal structure to remove liquid droplets, small solid impurities, and free water carried by the airflow, avoiding impurities from entering the back-end core unit and causing blockage and damage to the heat exchanger and membrane components. After purification treatment, the exhaust gas is sent to the compression unit to increase the partial pressure of organic vapor, optimize the physical conditions for solvent liquefaction, and then transported to the multi-stage gradient condensation module for gradient cooling according to the boiling point difference of different solvents. Most of the organic solvents liquefy and precipitate here, completing the preliminary solvent recovery work.
After condensation, the remaining exhaust gas still retains some organic solvents, which will be sent to the organic membrane separation unit. With the help of the membrane material's selective permeation difference between organic solvents and air, the enrichment and separation of solvent components can be achieved. The exhaust gas that meets the purification standards is discharged outward, and the high concentration organic gas flow formed by enrichment flows back to the inlet position of the compressor and enters the entire system for circulation treatment again. The closed-loop operation mode fully releases the potential for solvent recovery. After precipitation filtration and indicator testing, the organic solvents obtained from recycling can be reused in the production process to recover solvent resources lost in exhaust gas. This reduces the generation of hazardous waste from the source, lowers the comprehensive cost of raw material procurement and hazardous waste disposal for enterprises.
Faced with the complex working conditions of volatile waste gas from pharmaceutical and fine chemical solvents, equipment configuration design needs to be in line with the actual production conditions on site. The pipelines, valves, and heat exchange components that come into direct contact with exhaust gas are made of corrosion-resistant materials to resist the acidic corrosion caused by the hydrolysis of halogenated media, ensuring that the equipment can operate stably for a long time. The equipment is equipped with complete overpressure, overtemperature, medium leakage monitoring and automatic interlocking protection mechanisms to cope with safety risks caused by concentration fluctuations and prevent safety accidents caused by flammable and explosive media. The self-control system is equipped with a frequency conversion adjustment mechanism, which can respond in real-time to dynamic changes in exhaust gas volume and concentration, automatically adjust equipment operating load, adapt to the working characteristics of intermittent volatile exhaust gas, avoid equipment overload operation or ineffective idling, and reasonably control energy consumption. The pre-processing system intercepts various types of impurity droplets in a graded manner, forming effective protection for precision core components such as heat exchangers and membrane components, and extending the equipment's service life. Process design requires the collection of on-site measured data on exhaust gas volume, component composition, concentration range, water content and impurities for customized accounting. General models cannot be directly applied to ensure stable and compliant VOCs exhaust gas treatment, and effectively achieve the goal of organic solvent resource recovery and cost reduction.
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