Manufacturing Compliance: Monitor and Reduce VOC Emissions Effectively

As companies strive to meet environmental standards, VOC (Volatile Organic Compounds) abatement is a critical focus area, particularly for the manufacturing industry. Staying compliant with local and national regulations is more than just ticking a box—it’s about safeguarding public health, improving air quality, and maintaining operational efficiency. 

In this blog, we’ll explore the key steps in understanding regulatory requirements, using advanced monitoring techniques, and implementing strategies to reduce VOC emissions.

Regulatory Requirements: Staying on Top of VOC Emission Standards

One of the key challenges for manufacturers, especially in the wood panel industry, is adhering to VOC emission regulations. The Clean Air Act Amendments (CAAA) of 1990 introduced stringent requirements under the Maximum Achievable Control Technology (MACT) standards. 

For example, under the Plywood and Composite Wood Products MACT and to adhere to the National Emission Standards for Hazardous Air Pollutants (NESHAP), Regenerative Catalytic Oxidation Air Pollution abatement systems (RCO’s) are required to perform annual catalyst testing to comply with these rules, ensuring they are not exceeding permissible emission levels.

Failure to comply with these standards can result in significant fines, loss of operating permits, and even harm to a company’s reputation. The complex nature of these regulations makes it essential for manufacturers to stay informed and continuously monitor their VOC emissions. 

Papers like the MACT Evolution Report demonstrate how complex it gets to navigate regulations. Not only because they constantly change, but because a little detail missed can result in a huge non-compliance penalty. 

Applied Catalysts offers solutions that simplify manufacturing compliance by providing high-efficiency VOC oxidation catalysts designed specifically for industries like wood panelboard production. These catalysts reduce emissions and optimize an RCO’s performance, helping companies meet their compliance goals at as low a cost as possible.

Emissions Monitoring: Track VOC Levels for Manufacturing Compliance

Effective VOC monitoring is crucial for manufacturing compliance and industrial air quality standards. While traditional methods have been foundational, advanced technologies offer significant improvements in accuracy and efficiency.

Advancements in VOC Monitoring

• Continuous Emissions Monitoring Systems (CEMS): CEMS provide real-time data on VOC emissions, enabling immediate response if levels exceed regulatory limits. This continuous approach ensures a comprehensive understanding of emissions patterns and is recommended by the Emissions Measurement Center of the EPA.
• Predictive Emission Monitoring Systems (PEMS): PEMS use data from process variables and historical emissions to predict VOC levels. This proactive approach helps anticipate potential exceedances before they occur, allowing for preventive measures.

A mix of these two systems allows manufacturers to prevent emission exceedances and take quick measures in case they cross the line.

Challenges in Implementing Advanced Systems

• High Initial Costs: The investment required for advanced systems can be substantial, making it a significant consideration for many businesses.
• Complex Integration: Integrating new systems with existing processes can be complex, often requiring specialized knowledge and adjustments to existing infrastructure.
• Scaling Issues: For larger operations, scaling these systems to accommodate increased volumes and varied processes can be difficult and resource-intensive.

Identifying Catalyst Deactivation Causes

Monitoring VOC emissions is just one aspect of maintaining compliance. It’s equally important to pay attention to the crucial machine part when it comes to emissions: the catalyst.

An important compliance parameter to investigate annually is any potential catalyst deactivation. Common catalyst deactivation issues include:

• Thermal Deactivation: The catalyst may degrade due to high temperatures, typically longer excursions above 1500°F.  The higher the temperature and the longer amount of time at that temperature. can cause thermal sintering, deactivating the catalyst performance.
• Surface Contamination: Compounds or elements may accumulate on the catalyst, blocking active sites.

At Applied Catalysts, our analytical lab allows us to diagnose the exact cause of catalyst deactivation. Through our catalyst characterization services, we assess whether the catalyst can be restored to its original performance or if a replacement is necessary.

Test Your Catalyst Regularly

Regular catalyst testing is crucial for maintaining manufacturing compliance with local air regulatory permits. Skipping the annual test can result in operational shutdowns, leading to significant financial losses—potentially in the millions. 

To ensure your catalyst remains effective and compliant, keep these key factors in mind when arranging a test:

• Accuracy: Ensure the test accurately reflects the catalyst’s performance compared to a fresh catalyst sample.
• Condition Assessment: Look for tests that evaluate whether the catalyst has been slightly deactivated or needs replacement.
• Deactivation Indicators: Understand if the catalyst is deactivating due to time, temperature, or accumulation of masking agents.
• Restoration Potential: Determine if the catalyst can be cleaned and restored to near-original condition or if replacement is necessary.

At Applied Catalysts, we offer comprehensive catalyst testing services to help you meet manufacturing compliance requirements and avoid costly interruptions.

Reduction Strategies: Cutting VOC Emissions

There are several strategies that can be employed to optimize VOC reduction and improve operational efficiency. Here’s a closer look at some key reduction strategies:

1. Retrofit Your RTO (Regenerative Thermal Oxidizer) to an RCO (Regenerative Catalytic Oxidizer

Switching to an RCO can significantly lower carbon dioxide (CO2) emissions. Through catalytic conversion, RCOs can reduce CO2 emissions by as much as 50% when compared to RTOs. This is achieved because catalytic oxidation operates at lower temperatures, which cuts fuel usage and delivers notable environmental advantages. These benefits support industries in meeting their sustainability goals and reducing their overall carbon footprint.

2. Optimize Process Conditions

Adjusting operating conditions such as temperature, pressure, and airflow can enhance the efficiency of VOC control systems. By fine-tuning these parameters, you can minimize VOC emissions and improve the performance of your existing equipment. Regularly reviewing and adjusting process conditions ensures that you are operating at peak efficiency.

3. Implement High-Efficiency VOC Control Technologies

Advanced Catalysts: Using high-efficiency catalysts specifically designed for VOC and CO oxidation can enhance your emission control systems. Applied offers Abate VOC™ catalysts that improve the effectiveness of your VOC abatement processes, helping you achieve lower emissions and better compliance.

4. Regular Maintenance and Upgrades

Routine maintenance of process machinery and VOC control systems ensures you operate efficiently and effectively. This includes cleaning, inspecting, and replacing components as needed. Well-maintained systems are more reliable and have a lower risk of failing to meet emission standards.

Cut Emissions, Comply & Thrive With Applied

Applied Catalysts provides tailored solutions to help you stay compliant with VOC emission regulations while enhancing operational efficiency. Our high-quality catalysts for VOC and CO oxidation can significantly reduce emissions and operational costs. 

Our team is ready to assist with:

• Catalyst Solutions: Offering tailored high-performance catalysts for VOC and CO oxidation. Your process is like no other? We got you covered.
• System Retrofits: Supporting retrofits like converting RTO systems to RCOs to enhance operational costs by up to 50%.
• Process Optimization: Providing guidance on optimizing process conditions and upgrading equipment.
• Standard Testing: We test your catalyst to guarantee your facility complies and keeps running year-round.

Get in touch with us to explore how we can help you achieve more effective VOC reduction and maintain regulatory compliance. 

Whether you need a retrofit, expert consultation, or support with catalyst solutions, Applied Catalysts is here to guide you toward more sustainable and cost-effective operations.