About the Client
A global manufacturer specializing in high-performance materials for protective armor partnered with JOA Air Solutions to advance their solvent extraction process. Known for their cutting-edge fiber technologies with outstanding strength-to-weight ratios, the client supplies materials fundamental to lightweight ballistic and protective solutions for military and law enforcement worldwide. Their focus on innovation drives both personal safety and next-generation infrastructure in the defense sector.
*Due to internal confidentiality policies, the client wished to remain anonymous in this case study.
What is Solvent Extraction?
Solvent extraction is a critical separation technique used in industrial manufacturing, particularly for isolating valuable compounds or removing contaminants. In the defense sector, solvent extraction plays a vital role in the production of specialized fibers and advanced materials, where precise control over chemical processes is essential for achieving high performance in protective applications.
Challenge
In this client’s operations, high-precision ovens are used to manufacture specialized fibers for protective armor. These ovens operate at elevated temperatures, causing solvents to vaporize, especially at yarn exit points. Effective solvent extraction is necessary to:
Operator Safety: Control indoor air quality and minimize worker exposure to hazardous vapors
Product Yield: Prevent operational losses caused by unrecovered solvent
Emission Limits: Achieve stringent environmental compliance
Without a high-efficiency solvent extraction system, manufacturers risk not only increased operating costs but also regulatory non-compliance and compromised worker safety.
How Does Solvent Extraction Work?
In industrial settings, solvent extraction captures vaporized solvents from processes like cleaning or coating before they enter the air. Local extraction systems direct the fumes to filtration or abatement units (carbon filters, oxidizers, or scrubbers) that remove or neutralize them. This reduces emissions, improves air quality, and supports regulatory compliance.
Approach
To effectively tackle solvent vapor emissions in a complex defense industry setting, JOA Air Solutions applied its proven three-step project methodology. This structured approach ensured a tailored solution, balancing operational demands, sustainability goals, and compliance requirements.
Pre-engineering study:
To start, JOA conducted a Pre-Engineering Study to assess solvent vapor challenges on-site. The goal was to identify root causes, evaluate technology options, and define the project scope.
- Smoke tests and flow measurements: Identifying emission hotspots and assessing the performance of the existing extraction system.
- Data analysis: Tracking emissions over time to uncover inefficiencies.
- Systematic evaluation of seven abatement technologies, taking into account:
- Investment costs (CAPEX) and operational expenditure (OPEX),
- CO₂ impact,
- Solvent recovery effectiveness.
Using scenario modeling, JOA narrowed the options down to six feasible solutions. Each scenario was modeled to balance sustainability, technical performance, and budget constraints. A detailed report with findings and recommendations was shared with the client to align on the best way forward.
Design & Engineering:
Based on the pre-engineering insights, JOA developed a tailored extraction system. This phase centered on precision airflow control and efficient solvent capture at the source.
- A CFD model of the current airflow was developed. The insights gained guided the optimal design of new extraction hoods, ensuring efficient containment and redirection of vaporized solvents.
- Mechanical engineering designed a system with:
- New extraction hoods designed to contain and redirect vaporized solvents.
- Pressure-controlled yarn exit valves to minimize vapor escape.
- Electrical Engineering & Software Engineering, making sure the system operates and communicates with existing equipment.
System Realization:
Implementation and commissioning of a new extraction system.
- Manufacturing: Our Dutch manufacturing site produces all necessary parts for the extraction system.
- Project management: Coordinated engineering, installation, and commissioning, aligning all stakeholders to ensure seamless project execution.
The result: a high-performance extraction system tailored to the defense industry’s operational and environmental demands.
Outcome
By implementing this enhanced solvent extraction solution, the manufacturer achieved:
- ~80% reduction in solvent emissions at critical process points, notably the yarn exit zones.
- Marked improvements in indoor air quality, creating a safer work environment
- Substantial solvent recovery and recycling, supporting waste reduction and cost savings
- Reduced energy use through optimized airflow and process control
- Full regulatory compliance with stringent environmental and safety standards
Conclusion
This project highlights the transformative impact of tailored engineering and collaborative problem-solving in solvent extraction for the defense industry. Advanced source extraction and recovery technology enabled the client to raise sustainability and efficiency standards while protecting both workers and the environment. The success of this solution underscores the importance of data-driven engineering and a partner who understands the technical challenges of solvent extraction in high-stakes manufacturing environments.
