Made in India: IEEC: How to convert ozone to oxygen

IEEC Power Electronics, which specialises in corona treatment systems, plasma generators, ozone generators, and destructors, has been a key player in power electronics and industrial equipment manufacturing since 1969. Since its inception, IEEC Power Electronics has been manufacturing corona treatment systems, used in surface treatment processes in the converting, packaging and printing industries. These systems utilise high-voltage electrical discharges (corona discharge) to modify the surface properties of materials, enhancing their adhesion characteristics for better printing, coating, and bonding. In addition, IEEC has expanded its expertise into plasma technology. Its plasma generators are used in a variety of industrial applications for surface cleaning, etching and activation. IEEC also manufactures ozone generators for converting industries. In the extrusion coating process, a film is treated with a corona treatment system, but to improve adhesion, the melt is treated with ozone. IEEC's ozone generators produce ozone in precise concentrations needed for these applications, ensuring efficiency in treatment.

Ozonash ozone destructors
IEEC manufactures ozone destructors used in the converting, packaging and plastics industries. Ozone is a byproduct of the corona-treater, which can be harmful to the environment if released without proper treatment. IEEC’s ozone destructors neutralise ozone by converting it back into oxygen. “Over the decades, IEEC has maintained a reputation for innovation, reliability, and quality, serving a diverse range of industries with its specialised equipment. Its commitment to technological advancement has allowed the company to stay at the forefront of surface treatment systems,” Rohit Deshpande, director, IEEC Power Electronics, says. The technology of IEEC's Ozonash is a device that neutralises ozone by converting it back into oxygen.

Ozone is a disinfectant and oxidiser; it is also unstable and can be harmful to both the environment and human health in high concentrations. Ozone destructors are, therefore, essential in ensuring that ozone is safely broken down into its components — oxygen (O2) — before it is released into the environment.

Deshpande says the basic technology behind an ozone destructor is the use of a catalytic process to break down ozone. These processes involve converting ozone molecules (O3) into oxygen molecules (O2) in a controlled manner, eliminating the risk of ozone pollution.

In the process, the ozone enters the destruction system, where a combination of catalysts efficiently converts it to oxygen.

This process occurs at room temperature, thanks to specially designed catalyst granules containing precious metals. No external energy is required to initiate the reaction. The catalyst provides a surface for the ozone molecules to react with, causing them to break apart and form O2 and O [O3 -> O2 + O (oxygen atom)]. In the next step, the oxygen atom reacts with another ozone molecule to form two molecules of oxygen (O + O3 -> 2 O2).

In summary, the ozone destruction system plays a crucial role in controlling ozone pollution and ensuring the safety of the workplace. It also increases the life of the components of the treating station and machines. According to Deshpande, the multi-stage catalytic destruction system Ozonash consists of a pre-filter with filtration of up to 5ų to avoid contamination of the catalyst; a HEPA filter to remove at least 99.97% of dust and other foreign particles up to the size of 0.3ų; activated ceramic beads act as a desiccant and reduce contamination of harmful functional groups with the catalyst; and a bed of metal oxide catalyst granules. “By implementing the Ozonash system, companies can ensure compliance with ozone limits, enjoy cost savings through catalyst regeneration, and maintain a durable infrastructure by utilising suitable materials,” Deshpande says.

The market
Ozonash is aimed at any industry or organisation that generates or uses ozone, whether in industrial production, water treatment, air purification, food processing, or medical applications. The primary goal is to ensure safety, compliance with environmental regulations, and the prevention of ozone related health risks for both workers and the broader environment.

Deshpande says the company’s ozone destructor is suitable for a price-sensitive market like India due to its energy efficiency and regulatory compliance. “It reduces the maintenance cost and increases the life of the treating station and the machine,” he says, adding, “Its minimal maintenance requirements cut down on long-term costs while ensuring compliance with environmental regulations prevents potential fines. With timely delivery and the ability to customise based on local needs, the ozone destructor ensures both cost-effectiveness and efficiency, making it a valuable solution for industries looking to optimise operations while maintaining safety and compliance.”

Deshpande says in both India and globally, customers prioritise regulatory compliance, system efficiency, cost-effectiveness, and environmental impact when choosing an ozone destruction system. “Technological innovation, ease of maintenance, and scalability are also critical considerations, especially as industries face evolving environmental challenges and regulations. Therefore, choosing the right system involves balancing performance, cost, sustainability, and support factors to meet both immediate needs and long-term goals,” he adds.

The productivity
Productivity is a critical factor when evaluating the performance and value of an Ozonash. It refers to the system’s ability to handle ozone efficiently and deliver results with minimal downtime, energy consumption, and labour. Deshpande says Ozonash processes large quantities of ozone-depleting substances quickly. The system is designed for continuous operation without frequent downtime or manual intervention, significantly boosting productivity. “Reliability and longevity of catalyst chamber are the key components that contribute to reduced downtime and higher productivity,” he adds.

He says the system is easy to use. “First, attach the duct to the input of the Ozonash system. Ensure that the blower is connected to a three-phase power supply. Once these connections are made, the Ozonash system should be ready to operate,” he explains. IEEC provides on-site or remote guidance during initial installation. It also offers troubleshooting assistance for operational issues. Service support is also available through the service centres located in the metro cities.

The target
Deshpande says the company received an overwhelming response at Labelexpo India 2024 held in November. “A key concern raised by visitors and label manufacturers was the challenge of managing outlet ducting for ozone extraction outside the premises. Additionally, numerous visitors highlighted complaints about ozone odour affecting the neighbouring industries and frequent issues with duct maintenance and machine upkeep,” he says, adding that Ozonash offers the perfect solution to these challenges.

He adds, “Its innovative design eliminates the need for complex outlet ducting, minimises maintenance requirements, and ensures efficient ozone management.”