Rotoplastic machines are designed, from the outset, with an approach of energy optimization and attention to the environment, to counter two factors that traditionally characterize these plants: consuming large amounts of energy and having a high emission index.
The parameters on the basis of which our designers develop the new Rotoplastic machines refer to the EU UNI 10389 standard, which clearly defines the efficiency values and the state of efficiency of the combustion quality. The standard lists all the technical and operational aspects to perform the analysis of burner fumes.
Smoke analysis is an integral part of a process aimed at increasing the safety and efficiency of the burner and, at the same time, reducing its emissions of polluting and harmful gases.
The portable combustion analyzers provide all the data necessary for a complete analysis through the direct measurement in the fumes of the content of O2, CO, SO2, NOx and the calculation of the essential parameters: carbon dioxide (CO2), excess air (λ) and efficiency (η) obtained according to the standards approved by Italian and European legislation.
The gases towards which we concentrate the greatest efforts in terms of containment or reduction of values, are carbon monoxide (CO) and nitrogen monoxide (NO), due to the high potential for toxicity. In the plastic rotomoulding sector, these two gases are continuously dispersed during the opening and closing phase of the oven doors. An action that is repeated during the production cycle and which represents an important critical element from an environmental point of view.
The UNI 10389 standard also defines the parameters of the emission values, setting the maximum limit at 100 milligrams per cubic meter for C02 and NOx.
Our plants, operating at full capacity, can boast 50% lower emissions for CO2, therefore 50 milligrams per cubic meter and 20/30% less for NOx, with values equal to 70/80 milligrams per cubic meter. Important goals, which reflect the experience, competence and commitment of our research and development team right from the design stage.
The emissions data are monitored in real time by the control systems installed on the machines, processed by our software and made available both during operation and recorded in a database that records the efficiency of the plant, creating a flow of information for the entire life cycle of the machinery.
The fume extraction system, unlike traditional machines, is not placed on the roof of the molding chamber, but is positioned on the back of the machine itself. Through a particular circuit of pipes that uses the Venturi principle, the air present in the shed (air at room temperature) is mixed with the air that is extracted with the fumes, creating a completely natural forced ventilation inside the ducts. This process allows to emit an extremely low temperature air (this avoids the dispersion of NO) and above all to mix, even before the emission to the outside, air from the environment, with air containing CO rather than NOx. The goal is to obtain an important advantage in terms of emissions into the atmosphere and the quality of the work of the machine operators.
A further element, subjected to a complete design review by our engineers, is the burner operation process, to also lower the oxygen dispersion value as much as possible.
According to the data collected during operating cycles under different conditions, the traditional systems currently on the market have an average oxygen dispersion value of 10% while the value of the latest generation Rotoplastic systems (under the same conditions of use) is equal to 4%. The ideal percentage for the gas/oxygen mixing that generates the flame is 0 and obviously the closer the value is to 0, the better the result in terms of optimization of the burner operation.