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Exhaust air purification in core foundries – safely controlling pollutants

oxytec systems for reducing VOCs, phenols, and odorous substances from core production

In core foundries, the production and processing of sand cores generates considerable exhaust air pollution: Especially when using organically bound core production processes (e.g., cold box, warm box, hot box), VOC-containing gases, phenols, amines, formaldehyde, and intense odors are released—some of them already during mixing, but mainly during curing and storage.

With oxytec systems, these exhaust air streams can be cleaned in a targeted manner and made compliant with TA-Luft (German Federal Immission Control Act) – with modular, low-maintenance solutions that have been specially developed for resin-containing emissions.

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Typical emissions in core production

Process step Typical pollutants Special features
Resin mixture VOCs, phenols, odorous substances Concentrations vary, diffuse sources
Cold box/hot box/CO₂ process Amines, formaldehyde, VOCs, odorous substances Reactive, hazardous to health, very strong odors
Nuclear storage / Degassing VOCs, amines, phenols Long-term emission, varies depending on temperature/load
Cleaning / transport Dust, odorous substances, oil mist (hydraulic) Technical load on extraction and filter systems

Why exhaust air purification is so important in nuclear power plant construction

  • VOC limits according to TA Luft 2021 are difficult to comply with without active purification
  • Amines and formaldehyde are relevant to health and, in some cases, require approval
  • Organic components accumulate in pipes, heat exchangers, and fans
  • Odors lead to complaints, acceptance problems, and stricter regulations

Legal requirements

  • TA Luft 2021: Emission limits for VOCs, formaldehyde, amines
  • BImSchG / 4. BImSchV: Permit requirement for many foundries
  • Occupational safety limits (e.g., MAK values) for internal safety
  • GIRL: Odor emission assessment in proximity to residential areas

oxytec provides measurable emission reductions, approval-relevant evidence, and support with authorities.

Get advice now – for low-emission core production with oxytec

Would you like to operate your core foundry in a more environmentally friendly, safer, and TA-Luft-compliant manner?

Contact us—we will plan your individual exhaust air solution for cold box, hot box, and more.

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Oxytec solutions for core foundries

UV ozone systems for VOC and odor reduction

Decomposes phenols, amines, formaldehyde, and long-chain hydrocarbons

Works without leaving any residue, without flame or chemical additives

Effective in high humidity, heat, and fluctuating loads

Aerosol separator for oil mist and cleaning dust

Pre-separation of oily particles, dust, and fine droplets

Protects downstream components from clogging or corrosion

Also available in stainless steel for harsh production environments

Activated carbon polish for demanding residues

Adsorbs reaction-resistant or difficult-to-oxidize VOCs

Complements UV modules in particularly polluted production areas

Also available as a mobile unit for temporary production peaks

Typical areas of application

Core shooting systems (cold box, hot box, shell)

Mixing rooms and resin dosing

Core storage and transport routes

Foundries with combined core and mold production

Your advantages with oxytec systems in core production

Effective against phenols, formaldehyde, amines, and VOCs

No thermal afterburning necessary

Ideal for point and area exhaust air sources

Low energy consumption, easy to maintain, robust

Flexibly scalable—even with changing utilization

Suitable for new buildings, retrofits, and temporary solutions

FAQ – Frequently Asked Questions

What emissions are generated during core production?

Typical pollutants are:

  • VOCs from organic binder systems (e.g., phenols, aldehydes, alcohols)
  • Amines (especially in the cold box process)
  • Formaldehyde, especially in the warm box or hot box process
  • Odorous substances and reaction gases during curing and storage
  • Fine dust and oil-containing aerosols during cleaning and handling

These emissions are relevant to health, some of which require approval and are odorous.

What cleaning methods does Oxytec use?

Our multi-stage system consists of:

  1. Aerosol separators for removing oil, dust, and condensates
  2. UV ozone modules that oxidize VOCs, amines, and odors without the use of chemicals
  3. Activated carbon modules for fine cleaning of residual pollutants

The modules are modular in design, scalable, and low-maintenance.

Is UV ozone technology also suitable for amines?

Yes – our UV systems are:

  • highly effective against amines, e.g., triethylamine
  • also tested on formaldehyde, phenols, and VOC mixtures
  • residue-free: no secondary pollutants or reaction residues are produced

How much reduction do the systems achieve?

Depending on the configuration, we achieve:

  • > 90 % VOC reduction
  • Significant odor reduction (verifiable by olfactometry)
  • Reduction of concentrations below TA-Luft or MAK limits

Reference values are available for various binding and casting processes.

Can the systems also be used with fluctuating loads?

Yes – the systems operate:

  • automatically controlled via volume flow and temperature
  • dynamically adaptable to cycle times and production peaks
  • also in combination with time-controlled extraction systems or hood extraction

How can it be integrated into existing halls and facilities?

Our systems can be:

  • integrated into existing extraction lines
  • be installed as a compact unit or container solution
  • be used in parallel at several core shooting stations if required

Oxytec provides support with planning, layout, and conversion.

What legal requirements are relevant?
  • TA Luft 2021: VOC limits for foundries
  • BImSchG / 4. BImSchV: Permit requirement for plants above a certain size
  • MAK values for e.g. formaldehyde, amines, phenols
  • GIRL (Odor Emission Directive) for plants located near residential areas

We provide verifiable emission values and assist with administrative procedures.

How much maintenance is required?

UV lamps generally last for 8,000–10,000 operating hours.

Filter modules can be used for 6–12 months, depending on the load.

Maintenance is carried out by your staff or Oxytec service partners—with remote monitoring available on request.

Is it possible to combine this with heat recovery?

Yes – our systems are compatible with heat exchangers, e.g.:

  • Preheating of exhaust air Fresh air
  • Energy feed into hot water or air systems
  • In combination with oxytec partner solution Condoheat