Partner With Us - Current Themes
Realizing energy saving with a compact and lightweight rotor
Decentralized exhaust gas circulation one-by-one VOC removal system
Recommended for:
- Companies that can undertake equipment design, manufacturing, and sales of a compact distributed exhaust circulation concentration system utilizing Murata's compact and lightweight rotor
- Companies that can undertake design and installation of air conditioning to processes where the compact distributed exhaust circulation concentration system utilizing Murata's compact and lightweight rotor will be installed
- Companies struggling with high investment costs for exhaust circulation concentration systems
About exhaust circulation concentration systems
Various organic solvents are used in the manufacturing processes of manufacturing industries such as printing, semiconductors, and automobiles, and the air containing volatile organic compounds (VOCs) generated at that time must undergo exhaust treatment based on the Air Pollution Control Law.
Exhaust circulation concentration systems are used for this exhaust decomposition treatment. Exhaust circulation concentration systems are used to purify air containing VOCs that flows in via ducts, and the core of these systems is a component called a rotor that adsorbs the VOCs. This rotor rotates slowly to adsorb the VOCs contained in the air and exhaust purified air.
Murata has successfully developed a rotor that has been made smaller and lighter by 20-30% or more while still maintaining VOC treatment capability. This makes it possible to downsize exhaust circulation concentration systems, contributing to both reliable VOC removal and significant energy savings.
Structure of Murata's rotor
Adsorption zone
Air containing VOCs exhausted from a drying oven or other equipment passes through the rotor, where the VOCs are adsorbed. As a result, the VOCs are removed and purified air is exhausted.
Desorption / recycling zone
After adsorbing sufficient VOCs, the rotor rotates to move to the desorption zone, where the VOCs are thermally desorbed from the rotor and separated as very highly concentrated gas. This separated concentrated gas is then treated by a downstream combustion system (RTO, CO, TO, etc.) to convert it to harmless gas.
Cooling zone
The heated rotor is cooled in the cooling zone in preparation for the next adsorption. Meanwhile, the clean air purified in the adsorption zone circulates back to the drying oven while still retaining heat, and is reused.
[Solvents that can be adsorbed by this rotor]
Common organic solvents widely used in the manufacturing industry, including aromatic hydrocarbons such as BTX (benzene, toluene, xylene), hydrocarbons, and esters.
*In addition to the above, the rotor can also be applied to organic solvents specific to various applications, such as NMP in the battery industry and alcohols in the chemical industry. Please feel free to contact us for more information.
Original Murata technology that realizes rotor downsizing and weight reduction
Innovative rotor downsizing and weight reduction has been achieved by combining a number of proprietary technologies cultivated by Murata over many years.
Support made of material with high thermal conductivity, and an original structure
The rotor's support uses material with high thermal conductivity instead of common ceramics. This enables extremely efficient heating and cooling when adsorbing and desorbing VOCs, achieving high treatment capacity even in a small size. Furthermore, Murata's original rotor structure also helps achieve both high performance and downsizing, and rotor downsizing provides the additional benefit of weight reduction.
Highly precise slurry design technology
Slurry (coating) design technology cultivated in the development of Murata's flagship product, multilayer ceramic capacitors (MLCCs), is applied to bring out the fullest performance of the adsorbent. By evenly and uniformly applying a µm-order coating of an easily dispersible, refined adsorbent slurry onto the honeycomb structure of the rotor, the maximum adsorption performance is achieved with the minimum size.
Illustration of rotor interior and particle structure within the slurry
- Other companies
-
- If the particles are large and not uniformly coated, it is difficult to ensure the permeability and fluidity of VOC gases during dispersion.
- Murata
-
- Slurry (coating) design technology makes it possible to reduce the particle size and apply a fine and even coat. This provides easier dispersion for better permeability and fluidity of VOC gases.
Achieves the maximum VOC adsorption performance with the minimum size
Materials Informatics (MI) that accelerates development
AI-based materials informatics technology is used in the selection of VOC adsorbents. For example, this enables swift judgments by using simulations to predict the optimal temperature conditions for adsorption and desorption, which previously required laboratory evaluation, and by calculating the adsorption energy. Material informatics are also applied to various other items, making it possible to exclude inappropriate materials at an early stage to efficiently search for promising materials and shorten development times.
- Simulation image of VOC adsorption by an adsorbent
-
Simulations using a surrogate model based on density functional theory (DFT) enable swift and accurate evaluation of the VOC adsorption levels of various adsorbents.
(Left: Adsorbent before adsorbing VOC Right: Adsorbent after adsorbing VOC (toluene))
Four benefits provided by a compact distributed installation type system
The decentralized exhaust gas circulation one-by-one VOC removal system is an exhaust circulation concentration system that is made possible by Murata's compact and lightweight rotor, and can be installed near various production equipment. Achievement of a compact system provides various benefits in the production site.
Energy savings through reuse of exhaust gas and exhaust heat
Downsizing allows the exhaust circulation concentration system to be placed near equipment that emits VOCs, so the purified clean air can be reused in the drying or other processes while still retaining heat. This eliminates the need for devices such as auxiliary heaters that were previously used to warm the air and humidity control equipment needed to regulate the humidity of the supply air, which therefore helps to reduce energy costs. In addition, it is also effective in reducing scope 1 and scope 2(*) greenhouse gases.
(*) Terms used to understand the greenhouse gas (GHG) emissions of companies. Scope 1 refers to
direct gas emissions due to a company's business activities. Scope 2 refers to indirect gas
emissions associated with the use of electrical, thermal, and steam energy purchased by a
company from other companies.
Reduction of facility investment costs through downsizing of the overall facility
The building and the large ducts installed throughout the factory that were needed for a centralized type system are no longer necessary. Furthermore, the exhaust airflow volume needed to send the concentrated VOCs to a downstream regenerative thermal oxidizer (RTO) can be reduced to 1/10 to 1/20 of the previous amount, which also improves energy efficiency by downsizing the RTO itself. These factors can help suppress costs when updating or introducing new exhaust circulation concentration system equipment.
Flexible factory layout and phased expansion
The system is compact and lightweight, enabling easy installation in limited spaces within the factory. Even when adding new production lines, there is no need to replace large centralized equipment, and instead just the systems needed for the lines can be added. In addition, introduction of this system can help reduce the load on existing centralized systems.
Enhancement of safety through risk dispersion
Distribution of treatment functions across various locations allows the impact to be minimized and the avoidance of situations such as the complete shutdown of production lines in the event of equipment trouble. There is also no need to transport VOCs containing flammable gases through large ducts, which helps to reduce the risk of fires, etc.
Vision for the utilization of the decentralized exhaust gas circulation one-by-one VOC removal system
Achieving a smaller system that is easier to install allows it to be used even in sites where the installation of exhaust circulation concentration systems had previously been a challenge, as well as processes requiring a more detailed response. We believe that managing VOC treatment for the entire factory at an even higher level will provide greater benefits to companies in various industries.
[Areas for application]
- Printing and painting industries: Ink and paint drying processes
- Chemical and semiconductor industries: Various manufacturing and drying processes
- Automotive industry: Paint drying processes
- Various other manufacturing industries with drying processes
FAQ
It can be widely utilized in manufacturing industries with drying processes containing VOCs such as printing, coating, semiconductors, and automobiles.
Re-using waste heat makes auxiliary heaters and humidity control equipment unnecessary. This can significantly reduce energy costs.
Yes. Introducing this system when installing new equipment has major benefits in terms of simplifying the overall intake and exhaust layout and reducing capital investment. Nevertheless, we are also installing this system in existing devices because it reduces the load on existing concentration systems and heat source systems.
We use a special highly thermally conductive material with outstanding heat and corrosion resistance. This ensures a long life and stable performance.
The system can remove over 90% of VOCs. It is also possible to achieve over 99% removal in the system.
Inquiries about the Decentralized Exhaust Gas Circulation One-by-one VOC Removal System
Please feel free to contact us if you are interested in Murata Manufacturing’s unique compact and lightweight rotor or the decentralized exhaust gas circulation one-by-one VOC removal system, or if you want to learn more about this technology.
*This product is under development. Therefore, the specifications are subject to change without prior notice.
Message from the developers
-
Kohei Awaya
Murata Manufacturing Co., Ltd.
Corporate Technology Planning & New Business Development Group
Corporate Technology & Business Development Unit
- We believe that this initiative, which was developed internally to reduce GHG emissions (scope 1 and 2) and prevent pollution while at the same time saving energy, can contribute to creating value in various manufacturing industries, such as in widely-used drying processes. Going forward, we hope to provide these systems to customers as an environmental solutions business that contributes to both environmental and cost aspects as a part of sustainable manufacturing. We want to collaborate with partners who share our desire to create a new market segment consisting of compact distributed installation (one-by-one) types that combine production and facility equipment.
-
Yukio Sanada
Manufacturing Group
Ceramic Capacitor Business Unit - We are also utilizing Murata's manufacturing department to construct a test bed environment and verify reliability, as well as working to clarify the advantages, constraints, and other aspects when introduced to general drying equipment. We intend to continue these efforts in order to provide more useful solutions to external customers.
-
Masahiko Shigaki
Corporate Technology Planning & New Business Development Group
Corporate Technology & Business Development Unit - As societal demands for decarbonization increase, many companies are pursuing energy saving initiatives. However, we hear many voices indicating hesitation to take the next step due to issues related to cost-effectiveness. Murata solutions use new approaches to achieve significant energy savings, and can help to address the challenges your company is facing. Please do not hesitate to contact us if you would like to work together to create new value.
Notices
-
We have published a technical article titled “The Vision for Next-Generation Manufacturing of Murata’s Distributed Exhaust Circulation One-by-one VOC Removal System - Simultaneously Reducing Environmental Impact and Costs.”
-
We have posted the decentralized exhaust gas circulation one-by-one VOC removal system development theme for which we are looking for collaboration partners.
-
We exhibited at CEATEC 2025.
Inquiries
Please feel free to contact us if you are interested in Murata Manufacturing’s unique compact and lightweight rotor or the decentralized exhaust gas circulation one-by-one VOC removal system, or if you want to learn more about this technology.
*This product is under development. Therefore, the specifications are subject to change without prior notice.
