Isododecane is widely used in the cosmetics industry as a solvent due to its emollient properties and its rapid evaporation, which leaves no residue in the product. It is therefore used to prepare mixtures that, when dried, result in the finished product (powders, eyeshadows, etc.).
ULIX Innovation has developed a system that completely purifies process air contaminated by isododecane, making it suitable for discharge into the atmosphere in compliance with the European Directive in force since 2004 (Solvents Directive) and the resulting national regulations. The solvent is recovered in liquid form and reused in the production process, replacing virgin solvent. The air emitted from the chimney can be recirculated into the dryer, creating a closed-loop process that provides both economic benefits (savings in solvent purchases) and environmental benefits (regulatory compliance).
The purified air can be reintroduced into the drying ovens, preheated by the exhaust fumes, ensuring the customer significant energy savings.
COMPLETE PROCESS DESCRIPTION
The preparation of the mixture takes place inside special mixing tanks [1]; subsequently, the mixture is loaded into the drying oven [2], where heating causes the solvent to evaporate. The finished product is collected at the outlet of the dryer, while the air polluted by isododecane is drawn through a fan. This air is then filtered to remove any dust, cooled, and sent to the adsorbers [4] (one or more), where the activated carbon beds retain the isododecane, while the clean air is expelled through the chimney [5].
When the activated carbon becomes saturated, it is regenerated by sending a flow of water vapor [6] into the adsorber; the vapor extracts the isododecane from the carbon and carries it away, restoring the adsorbing capacity of the beds. Thanks to a special vapor condensation and separation system [7], the isododecane is recovered with a purity of more than 99.5% [9] and can therefore be reused as a raw material in the standard production process [10]. The purified air can be recirculated into the dryers, preheated by the heat from the cooling chiller and the exhaust fumes.
The system is delivered ready to use, complete with electrical panel, PLC, and HMI, installed, calibrated, and ready for production.
ADVANTAGES OF ULIX INNOVATION TECHNOLOGY:
• Extremely high pollutant reduction efficiency (up to 99.5%)
• Fully ECOLOGICAL system (ZERO EMISSIONS)
• Solvent recovery and reuse in the production process = significant economic savings + reduced environmental impact of the production process
• Energy savings in dryers and reduced operating costs of the system
• Modular system allowing future expansions of the air capacity to be treated (for any increases in production) by adding filter modules
• Return on investment typically between 1½ and 4 years (based solely on the lack of solvent purchase costs)
Technical characteristics of the “DRYING” section:
Type of solvent to be evaporated: Isododecane (or similar solvents)
Operating temperature: 50 ÷ 120 °C
Reference standards: Directive 2004/42/CE of the European Commission
Electrical energy consumption: negligible
Steam consumption: approximately 6 ÷ 10 kg/h (for 10 kg of dry product)
Technical characteristics of the “AIR PURIFICATION AND RECOVERY” section:
Air flow to be treated: from 500 to 10,000 Nm³/h
Type of pollutant to be removed: isododecane (or similar solvents)
Electrical energy consumption: ≈ 10 kW (for every 10,000 Nm³/h of treated air)
Industrial water consumption: ≈ 0.2 m³/h (for every 10,000 Nm³/h of treated air)
Steam consumption: ≈ 100 kg/h (for every 10,000 Nm³/h of treated air)
Services offered by ULIX INNOVATION:
• 2D and 3D plant design
• Study and optimization of the existing production process and suction lines
• Assembly, start-up, and calibration of the system
• Training sessions for staff on system management
• Post-sales support and spare parts service
• Remote assistance and system monitoring
• Management of procedures for White Certificates and incentives for reducing gaseous emissions into the atmosphere
