Air quality improvement – Plant
Optimizing the extraction of VOC emissions in a refrigerated truck plant
The Jean Chéreau plant is a refrigerated vehicle production facility located in Ducey-Les-Chéris, Normandy. Opened in 1981, the plant’s ventilation system has since been improved and reworked, but is still based on an old-fashioned design. The plant’s production line emits several types of pollutants (gelcoat, resin) at various points, potentially harmful to workers if present in the air in excessive quantities.
Themain objective is to improve the efficiency of the current ventilation system, while respecting the plant’s constraints.
EOLIOS proposes to contribute its technical expertise in understanding and modeling aeraulic movements, in order to analyze the problems identified and propose appropriate solutions to correct them.
Air quality improvement - pollutant ventilation process
Year
2025
Customer
NC
Location
FR
Typology
Industries
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Ventilation system and manufacturing process in the plant
Tables affected by VOC emissions in the study area are shown in red on the diagram.
Significant pollutant emissions occur during gelcoat and resin spraying, and during the manufacture of truck hides. Operations taking place in halls 2 and 3, chosen for the study.
The ventilation system comprises separate supply and return air zones for halls 2 and 3. In hall 2, fresh air is supplied by two ducts with nozzles, which also operate during gelcoat drying. Hall 3 has two supply air points, with a device above the gelcoat spray tables that can be adjusted to direct the air during drying. For recovery, Hall 2 is equipped with exhaust vents and grilles under the tables and on the mezzanine, complemented by mobile hoods. By contrast, Hall 3 uses exhaust ducts under the mezzanine floor, with certain efficiency limitations, wall-mounted grilles and mobile hoods. These installations are essential for effective ventilation, particularly during critical process phases.
Aeraulic expertise: audit, 3D modeling and smoke tests
EOLIOS puts its expertise to good use by carrying out precise measurements using equipment adapted to each situation. During thesite aeraulic audit, the engineers present carried out detailed measurements, 3D modeling of the plant and smoke tests for a complete assessment. External weather conditions were also recorded to ensure accurate simulations.
The results showed that overall air movement in the plant is mainly influenced by the blowers. In hall 2, air tends to converge towards the spray tables, creating disturbances and air lift under the roof, which hampers efficient extraction. In hall 3, a looped circulation was identified, with the air flow splitting into two distinct parts. The suction systems demonstrated good extraction near the tables, but showed limitations due to obstructions between suction points and zones. These results were confirmed by numerical simulations based on on-site measurements.
Simulation of the plant, with doors closed, was carried out using theoretical ventilation rates and on-site measurements. The results showed a high degree of concordance between simulations and actual measurements, with significant aeraulic movements similar in both cases. Air flows from the eastern end of the halls to the west, with transverse air loops in hall 2 and complex movements in hall 3. High concentrations of VOCs are observed to the west of hall 2 and to the east of hall 3, due to inadequate ventilation which prevents the proper capture of emitted VOCs.
Compliance and safety of ventilation systems: a standards-based approach
EOLIOS places compliance with standards at the heart of our approach, because we know that it is essential to guarantee effective, safe solutions that comply with regulatory requirements. Every study we conduct, including this one, is carried out with a particular commitment to prerogatives, especially when it comes to the health and well-being of workers. For this study, our team paid particular attention to good ventilation practice guides upstream of the design stage, such as ED 839 and ED 906, or the French Labour Code, ensuring that our solutions do not compromise the safety of the people and equipment present. This rigorous approach minimizes risks and optimizes working environments, while complying with the highest industry standards.
Advanced CFD airflow efficiency
Following a study of the standards, two designs were proposed to optimize airflow management and ambient air quality. The first design incorporates major improvements over the basic configuration, such as theimplementation of partitions around VOC emission zones, uniform low-velocity blowing by textile ducts, and adjustments to return points. These modifications are designed to keep VOC levels below 25% of the VLEP by using PPE in confined areas. Ventilation rates were adjusted to prevent excessive diffusion of VOCs, thereby controlling air circulation and reducing their concentration at workers’ faces. Measured concentrations show a clear improvement in operator safety.
The second configuration, developed to overcome the limitations identified in the first, introduces suction ducts under the resin and gelcoat tables, eliminating lateral suctions generating space constraints for workers. This designmakes suction more efficient, especially on previously less efficient tables. Supply air ducts have been repositioned for more efficient vertical sweeping of fresh air, eliminating undesirable upward air movements. This approach guarantees more homogeneous air velocities and follows a controlled descent, reducing the dispersion of VOCs outside targeted areas. Simulations show a reduction in VOC concentrations at breathing height, avoiding accumulation between tables and partitions.
This study effectively tested both configurations: one focused onoptimizing rework, and the other also aimed to take into account the clutter and difficulties of employee work, while maintaining a clear separation between work zones, thus improving air quality and worker safety.
Comparison of vertical velocity component between design with side suction (left) and design with under-table suction (right)
Collaborative approach - practices in the field
Listening, compromise and dialogue are at the heart of our collaborative approach between engineers and workers throughout the study. We recognize the importance ofintegrating technical expertise with practical realities in the field. Thus, regular visits were organized at every stage of the project to ensure that all perspectives were taken into account. Our engineers demonstrated an ability to listen attentively, enabling solutions to emerge that were not only aeraulically optimal, but also practical for the workers. This participative approach enabled us to create a safe and efficient solution, while remaining aligned with the needs and expectations of the various stakeholders.
EOLIOS supports you ...
At EOLIOS, we work with you to improve the extraction of VOCs and other pollutants in your plants, taking into account the ventilation systems, filters and equipment in place. We ensure optimum air flow and uniform distribution, minimizing stagnation zones where VOCs can accumulate. By analyzing air flows, we identify the critical zones with the greatest risk of VOC concentration. Our use of CFD also enables us toassess the efficiency of filtration systems by detecting any leaks of contaminated air. Thanks to our expertise, we can validate and optimize the performance of ventilation systems on the premises, ensuring that the required emission levels are met and maintained, in line with the most stringent environmental and safety standards.
Video summary of the study
Summary of the study
The study carried out by EOLIOS concerns the sizing and implementation of cooling towers (TAR) on the roofs of ICPE offices.
ARTs are cooling systems that use outside air to dissipate heat, offering a more energy-efficient alternative to traditional air-conditioning systems.
The study uses CFD simulation to model and analyze the flow of fluids into and out of TARs.
The results of the study highlight the influence of wind on air currents around the building, and show the phenomenon of TAR looping, which affects the temperature and humidity of the air drawn in.
These results enable us to optimize the sizing and layout of the air handling units to ensure efficient cooling of the offices.
Video summary of the mission
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