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U-earth the most efficient solution for industrial emissions

The cost of pollutant control is growing continuously. Environmental and work safety regulations force industrial facilities to treat both the surrounding air and that on the premises . The systems currently in use for indoor air based on ventilation are inefficient as they send emissions to a system outside the facility to be treated. U-Earth air purification system destroys the contaminants within the facility without the need to ventilate or channel polluted air, generating significant energy savings due to reduced air changes and related cooling or heating. U-Earthair purifiers are also widely used for the treatment of VOCs (volatile organic compounds), emissions from solvents from industrial processes, both through channelling and in free form, providing a viable and efficient biological alternative to activated carbon filters and post-incineration treatment.

Industrial emissions and odour control.
Odour control is a major problem for industry and the surrounding community. Some processes operate by masking odours, while others reduce them. U-Earth systems destroy odours at the source through the process of bio-oxidation, helping to reduce costs and improve relations with the neighbours.

Superior to ventilation
Contaminants and persistent odours travel on particulate matter. These particles are electrically charged. Their motion is controlled by electrical fields, not by air flow because the majority of the particles, to the extent of 98% of all particles, are smaller than 0.5 microns, and therefore have a mass too small to respond to gravity or ventilation. U-Earth systems capture and destroy odours and indoor contaminants in real time, saving energy, improving health and safety, and preventing epidemiologic emergencies.

Superior to activated carbon
U-Earth air purification systems incorporate an advanced spiral element design which eliminates the need for channelling and treats contaminants, such as polar compounds, carbon monoxide and formaldehyde, that activated carbon cannot treat. Activated carbon quickly becomes saturated and requires frequent maintenance. U-Earth systems reduce or eliminate the cost of replacing activated carbon filters.

Superior to thermal oxidation
Incinerators often require more space than manufacturing plants. U-Earth air purifiers take up minimal space and are able to fit in very tight spaces. Since U-Earth systems are biological, they do not contribute to additional air pollution as they produce no hazardous waste substances. They work at room temperature and do not increase energy consumption. 

 

PRINTING INDUSTRY

Any type of printing industry, be it gravure, flexo or offset, must efficiently deal with the reduction of emissions from solvents used in the processes.U-Earth air purification systems effectively treat the air on the premises, traditionally treated by activated carbon filters and post-incinerator treatment, as well as ambient air full of fugitive solvent emissions, through the freestanding bio-reactors positioned near the printing presses, capable of capturing both channelled or free emissions, breaking them down by biological oxidation to carbon dioxide, water + traces of any chemical elements - an innovative, clean, sustainable and extremely easy to handle system.

In addition to the bio-reactors, the U-Earth team can provide, through a remote control system, a monitoring service to detect the level of solvents in the air and the correct operation of the bio-reactors in real time, providing the world’s cleanest, safest and most efficient solution.

 

CASE STUDY: Earthcolor, Print Facility USA, Ammonia Emissions

 

Flexographic Printing Machine and Laminator

A great AIRcel biotreatment system, specifically designed for printers, is used to replace catalytic and regenerative thermal oxidizers. In this case it destroys n-propyl acetate and other solvent emissions from the printing and "finish" processes. Moreover, the system influences the savings which in terms of energy consumption and use, account for approximately 1/10 of the system that it replaces, and requires only 1/10 of the space that an incinerator takes up.

 

Printing presses

The U-Earth air purification system destroys smoke and emissions from the products for cleaning the printers, a solvent used to clean the rollers of the small printing machines. The solvent most commonly used by the industry contains petroleum, naphtha and dipropylene glycol methyl ether and is considered an OSHA Class 1B flammable liquid. 

U-Earth system also reduces the odours associated with the use of this solvent while keeping exposure levels below OSHA standard workplace limits.

 

Control of ammonia in ink production processes

A CAP-902X was installed alongside an ink mixer to control ammonia emissions. Pure ammonia is present in the ink production process in one million parts per million.The CAP-902X system treats the fumes leaving the mixer outlet, reducing ammonia emissions to below 50ppm (parts per million), a 99.99%.reduction in concentration

 

CASE STUDY: Ammonia Emissions

 

FOOD INDUSTRY

U-Earth air purification systems are very valid allies in the solution of problems related to the food industry.Wherever there are problems with bacterial contamination during processing, mites or mould, volatile substances used as aroma compounds, fine particles that escape ventilation, or lingering odours that go beyond the boundaries of the production site, generating complaints from the neighbourhood, U–Earth systems are a solution to all these problems through the placement of air purification freestanding bio-reactors, designed by our environmental engineers and performed within a day, without the need for ducting or structural adjustments.The contaminants are captured and completely neutralized in the case of bacteria, mites or moulds, and the compounds transformed into water and carbon dioxide + any chemical elements present, through bio-oxidation.The proven efficacy at reducing odour makes it a system with a globally unique performance.

 

CASE STUDY: Aromi, Panifici US,

 

Food Processing USMould control in a bakery

The owner of a bakery in Milford, New Jersey, sought a solution to reduce the damage caused by mould to his product. After learning that the U-Earth system is a totally natural technology that treats air pollution using a biological process, the owner decided to try an AIRcel600 inside his bakery. The use of the system proved its great effectiveness in controlling the mould and continues to remove the spores from the air, thus preventing contamination of the product.

 

Unpleasant odours eliminated in food production plants

A food production facility in New Jersey uses oleoresins, aroma compounds and other ingredients to improve the flavour, aroma and natural colours of the raw materials. These concentrated liquids and extracts contain volatile components which enhance the aromas. Those same intense aromas become bothersome for those who work immersed in their production day after day and become a health problem. Three AIRcel600 were placed in different rooms and an AIRcel5000 was installed in an extremely odorous transfer area. Due to the success of this technology, the company decided to place additional units in other problem areas. 

 

CLEAN ROOMS

Although industrial clean rooms are controlled by ventilation systems adhering to the strict safety standards of the ISO system for clean room air quality standards, there are often bio-burden problems and peak particle contamination which require continuous monitoring of the environmental conditions in the rooms used for special processing.

Depending on the type of processing, operators are often bothered by lingering odour emissions which, even when not harmful, constitute an obstacle to the workers’ comfort and limit productivity. U-Earth systems installed in the clean rooms ensure control of peaks of bacterial contamination and particulate matter while capturing and destroying volatile compounds such as MMA, cyclohexanone, etc. Where it is possible to decrease the air changes, significant cost savings result.

CASE STUDY: Sister, Clean Room U.S.

 

Indoor air quality control in a clean room

Two AIRcel600 bio-reactors were tested to control contaminants and particulate matter in a room used for the manufacture of computer parts. The company was using HEPA filters without results. U-Earth systems solved their problems, eliminating the fumes released by xylene, tetrahydrofuran (THF), and dimethylacetamide (DMA). At the same time the ventilation was decreased from 9000 to 3000CFM, generating significant energy savings.

Now the employees describe their room as a true "clean room". 

 

METALWORKING INDUSTRY

There are several recurring problems related to air quality in the metalworking industry.

In foundries, fumes spread due to cooling the castings and fine particles spread due to emptying the moulds. In the areas for processing and grinding, as well as in the machining areas, there are always problems due to metal powders and airborne oil particles that ventilation or electrostatic precipitators cannot control.

U-Earth air purification systems, through freestanding bio-reactors appropriately positioned in the processing areas without the need for any ducting or structural intervention, are installed within a day, solving the problems of metal powders and fine particles in general, which, captured at up to ultra-fine size, sink to the bottom of the reactor, while airborne oil is captured due to its molecular electric charge, the emulsion is broken down through bio-oxidation of the organic component and the inert part deposits on the bottom of the tank.

The U-Earth system has globally unique capture and breakdown performance for the metalworking industry, creating a clean and healthy working environment as never possible before.

 

CASE STUDY: Beretta, FAST, NY City subway U.S

 

Separation of oily solids from liquids in a stainless steel plant

The CleanSoil™ purification system has been tested on up to 100 tons per day of waste sludge from the United States’ leading steel company for the recovery of iron products, water and clean oils. This land purifying system incorporates a multi-stage, a continuous extractor of the oils found in high concentrations in the soil, a stripper for oil and water and two filtration plants. The iron products were separated from the sludge to be recycled, purified oils were collected for sale and re-use, solvent recovered for recycling and finally the water was recovered for disposal. 

 

 

AUTO REPAIR AND SERVICE STATIONS

The air quality in auto repair shops is extremely low due to high concentrations of hydrocarbons, particulate matter, ozone, NOx and carbon monoxide. The U-Earth air purification system is able to capture and bio-oxidize all the hydrocarbons generated from the fuel vapours and capture all the fine particles generated by brakes, tyres and exhaust fumes, proving to be efficient where ventilation fails as it is not able to treat the contaminants described above especially in the case of accidental spills and heavy smoke.

U-Earthair purifiers are a complete solution for air quality problems in auto repair shops and service stations.

 

CASE STUDY: Auto Repair

 

Petrol stations

U-Earth systems have replaced activated carbon treatment on the soil vapour extraction project used in the transfer of a gas pipeline in California to clean up soil contaminated by methane, hydrocarbons and glycol. Activated carbon did not prove effective because of the high moisture content and heavy hydrocarbons found, which requires constant replacement of the carbon bed. Two AIRcel600 units replaced the activated carbon, taking up much less space than the carbon bed and saving approximately $400 per day in costs for the replacement of the filters.

 

Car repair and paint shops

Technicians specialized in car repairs and those who work in the car paint industry are constantly exposed to contaminants in the air such as CO, VOCs, NOx and SOx. Recent studies have shown that diesel fumes have a potentially carcinogenic effect on humans. In this regard, U-Earth systems destroy the air contaminants generated by automobile exhaust fumes and eliminate the health risks due to inhalation, during breathing, of these components.

 

AIRcel for car repair shops

The Mechanics Education Association in New Jersey asked Air & Water Solutions (a biotechnology company affiliated with U-Earth that deals with biological treatment systems for industry) to design a small system for monitoring and improving the quality of indoor air in auto repair and paintwork shops. Using the same technology applied to clean highly polluted environments, Air & Water Solutions, in practice, "miniaturized" its industrial design and created CAP™ Clean Air Plant, forerunner of the current AIRcel, the first portable, biological system for air purification that acts on indoor air pollution. Tested on car exhausts, paint fumes, brake cleaners, cigarette smoke and other indoor air contaminants, CAP destroys all types of organic pollution such as CO, VOCs, SOx, NOx and ozone, removes heavy metals and solids from the air and eliminates odours caused by pollution.

 

AUTO REPAIR AND SERVICE STATIONS

 OIL INDUSTRY

 

Control of emissions from tanks

A U-Earth system is used to control the emissions of one of the largest energy transport, storage and distribution companies in North America. Located in Carteret (New Jersey), the company has a storage capacity of 7 million barrels and transports oil and chemical products throughout North America. The new regulations require that the company treat the air circulating in the tank when oil is loaded as well as the other chemical components in the truck tanks.

They previously used activated carbon treatment, but it was discovered that the carbon quickly becomes saturated with chemical vapours and could even catch fire. U-Earth air purification system maintains the levels of emissions from the tanks low enough to meet the requirements and saves on the cost of replacement of the activated carbon.

 

Contamination by MTBE cleaned in areas near a school

Through the extraction of vapours to clean VOCs from the soil, a contractor in the state of Delaware contaminated the ground in a garage next to a public high school and was unable to start the project because the untreated vapours exceeded the permitted levels of VOCs and MTBE in the air.The application of an AIRcel600 system to the existing SVE system has achieved an elimination rate of 35 pounds (about 16kg) of BOD (biological oxygen demand) per day allowing the contractor to begin the cleaning operations.

 

Cleaning of MTBE and hydrocarbons of petroleum origin

The CWP™ Clean Water Plant system was tested, along with several other technologies, for treating methyl-tertiary-butyl-ether (MTBE) and hydrocarbons of petroleum origin. Alisto Engineering Group was called on by a large international company to study and evaluate alternative technologies for the treatment of MTBE and hydrocarbons in the subsoil: CWP and CAP were considered the most effective, also taking into consideration the cost-benefit ratio for the treatment of MTBE compared with the other technologies tested which involved the use of carbon filters, resin adsorption, advanced oxidation and acid treatments.

 

Treatment of chlorinated solvents on Superfund site

In Brockport, New York, on the Sweden-3 Chapman Superfund Site, a combination of CWP (Clean Water Plant) / CAP (Clean Air Plant) systems has been applied to treat the groundwater and gases in the air that contain volatile organic compounds (VOCs).

The project’s goal was to reduce the contaminants present by 50%: in order to treat groundwater on site, two CWPs were installed in the subsoil so that they could work on chlorinated solvents such as TCE, 1, 2, dichloroethane, toluene, acetone, MEK and MIBK, while the CAP™ Clean Air Plant dealt with the volatile organic compounds.

After 11 months, about 80% of the 42 pounds (almost 19kg) of the target compounds was destroyed, passing the milestone of 30%.

 

Separation of fuel PAHs from tar

The Air & Water Solutions company has conducted several comparison studies of tar samples containing more than 500ppm of PAHs. The CleanSoil™ land purification system, through bio-reaction, has produced solid carbonates, which proved excellent as fuels, liquid PAH, which is also an excellent fuel (similar to N.2 fuel oil) and waste water which was then cleaned with a CWP™ Clean Water Plant system .

The main advantage of this process consists in the fact that it treats water, waste and soil in a really efficient way: it is composed of three operating units which include pre-treatment, extraction and fractionation.

 

Biological treatment of contaminated groundwater

A residential property began to be contaminated when the cellars were flooded by water contaminated by fuel oil. Fumes and odours infiltrated throughout the house, making it uninhabitable. For this reason a CAP90 was installed in the cellar to destroy and eliminate odours at the source before they spread around the neighbouring residences. In addition, a CWP-175 was placed in the basement near the water well to clean the water before carbon filtration treatment. Within three days, the odours were eliminated and the oil layer on the surface of the water had visibly disappeared. The time required for cleaning was reduced so drastically and a saving was generated because the CWP was able to eliminate the replacement of carbon filters, suction of the liquid with a fire truck and the need for ventilation. 

 

 
 

 PLASTIC INDUSTRY

Monitoring of methyl methacrylate (MMA) emissions

A plastic manufacturer in New York keeps methyl methacrylate emission levels under control in line with environmental regulations.The company produces reinforced acrylic sheets for lighting and decorative applications, and fibreglass sheets for use in aircrafts and ships. The production of plastic materials emits about 10 pounds per hour (equivalent to 4.54 kg/h). An AIRcel5000 installed on the production line brings emission levels to roughly 2 pounds per day (0.91 kg per day), thus below the limits defined by regulations. An AIRcel600, placed in the dining room for odour control while the workers have lunch, contributes to the creation of a pure air zone. This area attracts lingering odours and cleans the adjacent rooms of MMA emissions.

 

 CHEMICAL INDUSTRY

 

Cleaning of waste water from chemical industry
In Newark, waste water from an industrial chemical plant did not reach the required standards to be released into the public authority sewage system. For this reason, the plant had to collect the water and channel it into a disposal system. After installing a CWP that pretreats the waste water, the company reached the required parameters for directly discharging its waste water into the public sewer system. It is also used to treat the water stored without having to then channel it into a disposal plant.

Treatment of the waste from pesticide production
Due to extremely tight regulations, pesticide producers are obliged to pretreat by-products of their waste production. Using a combination of two bio-treatment systems for air and water, two CWPs and a CAP were used to treat toluene, metal-organic compounds, pesticides and other by-products contained in the flow of waste.
 

CASE STUDY: ADCO 

 

 FURNITURE INDUSTRY

U-Earth air purification systems have proven efficient in controlling emissions from processing laminates, packaging upholstery and in tanning, superbly handling dust, solvent emissions, formaldehyde, emissions from glue and unpleasant odours from the tanning process.

In most cases the only system used by clients to improve air conditions, before using U-Earth systems, was that of increasing air changes in the contaminated areas which increased energy consumption and odours outside the production site.

The installation of the U-Earth air cleaners has allowed odours in all cases to be controlled at the source, considerably decreasing the olfactory nuisance and exposure to substances that are hazardous to human health.

CASE STUDY: Wilsonart

 

Upholstery company

The U-Earth system controls fumes emanating from fabric glues and the particulate matter released from the sewing machines inside an upholstery company in Manhattan. The air quality was the main nuisance for the company employees and the U-Earth system improved the indoor air quality in the workshops eliminating the problem.

 

Bow and arrow manufacturers

The U-Earth system controls the air quality inside the bow and arrow manufacturing workshops in California. During their work the manufacturers use acetone and two to three tubes of glue per day to attach the feathers to the plastic. Inhalation of these substances caused people headaches, nausea and vertigo. U-Earth air cleaners improved the air quality and thus the worker’s problems.

 

Treatment of contaminated groundwater in a wood processing plant

CWP was used to treat groundwater contaminated by PAHs in a wood processing plant at Gainsville in Florida. The target consisted of naphthalene, phenanthrene, fluoranthrene, pyrene, anthracene and acenaphthene. Two CWP ( Clean Water Plant ) units were installed on site in the subsoil to treat the groundwater. After one year, around 65% of 49 pounds (around 22kg) of the target PAHs was eliminated, surpassing project targets. 

 

 URBAN WASTE DEPOSIT AND TREATMENT PLANTS

 URBAN WASTE DEPOSIT AND TREATMENT PLANTS

 

The problem of odours migrating outdoors is a topic widely studied by the engineers at U-Earth because it is so important as to affect the whole neighbourhood, creating major problems for coexistence with neighbouring activities.

Persistent odours travel on particulate matter. These particles are electrically charged. Their movement is controlled by electric fields and not by the flow of air as the majority of the particles, to the extent of 98% of all particles, are less than 0.5 microns in size, and thus have a mass too small to respond to gravity or ventilation.

For this reason the U-Earth air purification systems are able to create a pure air zone within a specific radius of action even in outdoor environments, superbly controlling the odour-causing problems tightly at the source and preventing their spread.

 

CASE STUDY: ARPA Tremosine, Abcwua, Comodepur, Dalena, Recycling Facility

 

Odour control in the recycling of urban solid waste (USW)

Emissions from recycling urban solid waste (USW) in New York are controlled by two AIRcel25000 units. Each single AIRcel, which has a nominal capacity of about 225 kg of pollutant particles per day, was positioned inside the recycling plant at about 3 metres above ground level so as to be outside the area of passage of workers and trucks. Rather, placing them at a distance of about 30m. from one another, the radii of action of the AIRcel overlap, creating a pure air zone.

Inside the offices, small additional AIRcel were installed for odour control. The reduction in the nuisance odours was clearly perceived immediately and this was also demonstrated by a decrease in complaints from neighbours. At the same time the exhaust emissions from the vehicles were also eliminated. 

 

 
 

STORAGE WAREHOUSES AND UNDERGROUND PARKING

Monitoring carbon monoxide levels in storage warehouses

High levels of carbon monoxide are continuously eliminated by an AIRcel600 inside an area of about 90.000m2 in the warehouses of the VA Medical Center in San Diego, California.

Previous to the installation of the U-Earth air purifiers inside the warehouse, CO levels continuously exceeded acceptable limits. Not surprisingly, the warehouse employees suffered from headaches, nausea and dizziness. Continuous monitoring showed that, after installation of the AIRcel600 inside the warehouse, the emissions of CO have been brought to levels that are not harmful and remain within the permitted parameters. 

 

 

WAX FACTORIES

Control of odours in a scented candle factory
The neighbours of a scented candle factory have reported the presence of fumes arising from it. To avoid problems and continue to have good relations with the neighbours, the owner of the plant installed an AIRcel5000 close to the assembly line, while several AIRcel85 were placed in the surrounding offices and storage areas. The U-Earth system controls odours in the assembly line areas to such an extent that the owner now deactivates them periodically so as to not completely eliminate the aroma of the scented candles. 

 

MOTORWAY CUSTOMS TUNNELS AND TOLLBOOTHS

 

The areas at the entrance of the tunnel, as well as border stations and toll booths, have a major problem of pollution due to the traffic queues.

The operators in the toll booths are closed in confined spaces with controlled ventilation that cannot always protect them from the considerable contamination from the traffic.

This is even more evident in the customs areas at the mouth of the tunnel which show peaks of high concentrations of contamination during peak traffic hours as well as undergoing cross-contamination coming from the tunnel itself which acts as a chimney.

In these cases U-Earth air purifiers allow the area to de-saturate, generating considerable savings compared with the traditional use of ventilation which must move and properly channel significant masses of air in order to obtain appreciable results and cannot always solve the problem.

U-Earth air purification systems are extremely effective at dealing with all the problems related to vehicle traffic, including CO, VOCs, NOx, SOx and particulate matter.

 

CASE STUDY: Gran San Bernardo toll booths. 

 

FARMS AND STABLES

An interesting application of the U-Earth air purification system is the chicken or livestock-rearing industry or stables. The polluted environments can be controlled from the inside using AIRcel air purifiers. The ambient air breathed by the animals will be significantly cleaner from ammonia, dust, bacteria and fugitive odours (such as diesel fumes from farm equipment).

This solution is excellent for cattle breeders and stables because the health of the animals which is paramount for healthy growth is ensured thanks to the limitation of bacterial and viral cross-contamination that generates epidemics among animals.

The reduction in ammonia in the environment produces happier and healthier animals and this translates into faster growth of the beasts and lower incidence of disease. Less ammonia inside the stables also reduces the waste in the environment making the farm or stables a healthier place for animals and more sustainable for the environment.

 

CASE STUDY: Monferrato farm