In-service performance assessment of electrostatic precipitators serving a rubber vulcanization process

We examined two emission abatement systems of some vulcanization ovens, serving a unit producing small rubber-based parts for automotive application. Each emission control unit treats the gases exhausted by three to five ovens. A heat exchanger cools down the fumes to a temperature suitable for the correct operation of a couple of two-stage electrostatic precipitators in series. We performed quantitative analysis of concentrations and size distributions in these rubber fumes using aerosol technology instrumentation, namely optical particle spectrometers and electrical mobility particle sizers. The size of sampled particles was mainly between 100 nm and 1000 nm. We evaluated the performance of the exhaust fume abatement units, with focus on the electrostatic precipitator. Concerning batch ovens, the quantitative trend of the emissions follows the thermal cycle of the post-curing process. Time interval since the last maintenance operation causes a gradual reduction in the removal efficiency. The measured data demonstrate the reliability and the adequacy of aerosol instrumentation for the characterization of the emissions from rubber vulcanization ovens. The pair of electrostatic precipitators was shown to be effective in removing most of the particles detected in the fumes stream. The measurement protocol developed in this study allows assessing the influence of the maintenance schedule on the performance of the emission control units. New technologies for treating organic vapors can be evaluated in a reliable and effective way.