The internationally active Orafol Group is relying on Dürr’s energy-efficient Oxi.X RE system to purify the solvent-laden exhaust air in its new 14,000 m² production hall in Oranienburg, Germany. This new facility, dedicated to laminating and coating special films and adhesive tape systems, is part of Orafol’s significant €160 million investment to meet growing global demand and reduce emissions through cutting-edge building and system technologies.
The Oxi.X RE system uses regenerative thermal oxidation (RTO) to purify exhaust air by oxidizing nearly all organic substances at high temperatures between 800°C and 900°C. Despite the high temperatures, the system remains highly energy-efficient thanks to an integrated regenerative heat exchanger. This system recycles heat from previously purified exhaust air to preheat incoming air, reducing the need for additional energy sources.
The Oxi.X RE System offers significant energy and cost savings by operating autothermally once it reaches the required temperature, eliminating the need for external gas or heating oil. This self-sustaining process makes the system highly energy-efficient and reduces operational costs. Its advanced design ensures that external energy requirements are kept to a minimum, contributing to more sustainable operations.
A key feature of the system is the use of ceramic honeycomb bodies in the heat exchanger, which recover over 96% of the energy required to run the system. This recovered heat is then used to warm thermal oil for ovens, further boosting energy efficiency. As a result, the Oxi.X RE System not only lowers energy consumption but also helps reduce Orafol’s carbon footprint, supporting their commitment to sustainability.
The installation represents Dürr’s largest RTO system for Orafol to date, and it includes advanced energy management features such as the XtraBalance and XtraControl modules. These modules monitor and optimize temperature differences and overall system temperature, ensuring reliable operation and efficient energy conversion, even under fluctuating conditions.
Orafol has a long history of using Dürr’s pollution control technology, with 13 systems currently in operation at their headquarters. “Our longstanding partnership with Dürr ensures that we get tailored, efficient solutions that meet our specific needs, helping us exceed legal emissions standards,” said Marcel Janßen, Senior Vice President of Engineering & Technology at Orafol. Looking forward, Dürr has already planned the installation of an additional Oxi.X RE system to support the ongoing expansion of Orafol’s production capabilities.
