Lamination and impregnation of plastic films, papers and fabrics - Bluer Medio Ambiente, S.L.U.

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Lamination and impregnation of plastic films, papers and fabrics


In the process of lamination and impregnation, where the use of resins and varnishes based on solvents is required, a polluted air is generated with a concentration of these solvents that can vary depending on the impregnation systems and the type of resins and varnishes used.

The solvents that are commonly used in these processes are butanone and ethyl acetate. The final mixture of resins with solvents have between 30-40% solids. The solvent is used as a viscosity regulating agent.

The contaminated air generated in the process comes from the forced extraction of the impregnation tray from the film or paper and from the pre-treatment oven, where the solvent is removed and a pre-catalysis of the impregnated resin or varnish is carried out. Both emissions are conducted to a single conduit that leads to the thermoreactor.

The thermoreactor clean the gases by eliminating the organic compounds, present in a concentration of 5 to 6 g/Nm³, by means of a thermal oxidation process. This process is exothermic and, therefore, the clean gases leave the stack at a temperature of about 120 to 150 °C higher than the input. Thanks to this release of heat, the cleaning of the gases can be carried out without any energy consumption in the burner (autothermal operation).

To take advantage of the energy released in the oxidation of the organic compounds, a part of the hot gases leaving the thermoreactor are introduced into the pre-curing ovens of the laminating machine and in the post-curing oven of the laminated materials. The flow of gases sent to the ovens is regulated by means of electronically controlled butterfly valves according to the temperature of the ovens.

The preliminary study of the concentrations of pollutants, temperatures and gas flow rates has been fundamental for the specific final design of the installation, generating clean exhaust gases with a degree of humidity that does not prejudice their subsequent use in the indicated ovens and an enough outlet temperature to allow its use as a heating medium.

With this plant, the following advantages are obtained:

  • The thermoreactor is designed to be autothermic with a concentration of solvents in the gases to be cleaned of 3g /Nm³. In this way, the need for an energy contribution is reduced to the starting periods of the equipment.

  • Energetic valuation of polluting gaseous waste with the consequent global reduction of the energy input necessary for the heating of the pre-curing and post-curing ovens.

  • Adaptation to the regulations on polluting emissions.

  • Amortization of the investment in a short period of time.

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