Summer 2015 marked the completion of two years successful operation of an ERG (Air Pollution Control) Ltd designed, installed and commissioned waste gas treatment plant at the Saffil production facility in Widnes.
Saffil Ltd, a wholly owned subsidiary of Unifrax, produces high temperature insulation products, for use in automotive catalytic convertors and other automotive and industrial applications. From a production facility in Widnes, Saffil produces alumina‐silicate polycrystalline wool (PCW) fibres. In 2013 the facility was expanded to add a third line; and a new waste gas treatment system was required to comply with Environment Agency air pollution control limits. ERG had been involved in the waste gas treatment for the second line and built on this experience to win the contract to provide the whole of the waste gas treatment system for the new line. Saffil Project Manager, Richard Nibbs, said “the design and installation of the waste gas treatment by ERG means we can comply with Environment Agency regulations. ERG used an innovative, integrated, approach, building on our operating experience of the previous lines. The gas cleaning package operates in an arduous environment and we are very pleased with the robust system design and after‐sales service ERG provides”.
The manufacturing process produces a highly challenging waste gas stream at high temperature and humidity including the following contaminants:
- Volatile Organic Compounds (VOCs)
- Hydrochloric Acid (HCl)
- Abrasive Fibres
In order to comply with The Environment Agency limits, ERG designed a waste gas treatment system with a number of steps to treat the combination of pollutants. The first stage passes the most highly concentrated process gases through a particulate filter, high temperature quench, subcooler and regenerative thermal oxidiser (RTO). This partially treated air stream is then mixed with secondary process extraction gases for further treatment in a 2‐stage packed tower scrubber.