Gas Filtering Systems



















































































































Solutions for Ceramic Sector

Eliminate problems to emissions of Acid Fluoride is a practical reality and effective by INTEGRA.

Discover how to get through the most advanced technology in fumes adsorvent.
We will improve the efficiency of your installations, reduce costs and solve a serious environmental problem.

 Identifying the problem

One and the most significant environmental aspects of the ceramics industry, is undoubtedly, the emission of pollutants to the atmosphere.

Compounds of fluorine, sulfur or chlorine (mainly HF, HCl, H2SO4 and SOx) that are generated in the process of manufacturing of products including ceramic tiles or bricks during firing stage kilns operating at high temperature. These emissions are mainly concentrated in the chimneys of kilns where gases are expelled outside.

Fluoride compounds in ceramic kilns, arise as a consequence of the decomposition of clay minerals from temperatures ranging between 500 and 600 °C .

Aided by the presence of water vapor, usual in industrial combustion kilns, the fluoride derivative compound which is mostly hydrofluoric acid (HF).

The HF is a toxic compound, highly corrosive, which is a problem not only for environmental purposes and for the health of people, but also has a negative influence on other aspects of industrial activity, deteriorating equipment due to corrosion and preventing it can take place using the surplus thermal energy at other stages of the process.

From the point of view of environmental regulation, the ceramic industry is affected by the IPPC.E directive BREF document drafted by the European Commission and formally adopted in 2007, establishes limit values for emissions of fluoride as HF, in 5 mg/Nm3 both for the cooking of ceramic tiles and bricks and for roof tiles .


Discovering the solution

Integra company has developed a new practical and effective solution, based on a new family of adsorbents for acid fumes, which not only solves the problem of HF but also can prevent emissions of SO2 and HCl

The magnificent results of these adsorbents have been certified by the National Research Council and Institute of Ceramic Technology of Castellon. In addition, interested customers have the opportunity to visit one of our installations fully operational.

Only the solvency of companies like Integra can offer a full service, which ensures the success of its facilities. Discover the solution, you will be pleasantly surprised.



 Future adsorbents

Integra has developed and patented a new technique for the manufacturing of adsorbents which substantially improve the contaminant elements retention activity, through an enhanced and optimized distribution of macro, meso and micro pores in its structure.

The range of adsorbents HCA-W has been designed specially for elimination of acid gasses such as HCl, SO2 and HF. His presentation like small hollow cylinders, not only improves the contact between the gas and the adsorbent through a significant increase in the contact area and the creation of laminar and turbulent flows simultaneously, but also reduces very significantly load loss and density of the filter, resulting in a significant cost savings.

HCA-W adsorbents act by physisorption, trapping initially HF molecules inside the pores and then by chemisorption, causing the reaction of the material comprising the adsorbent, to transform it into water and calcium fluoride (CaF2 + H2O)

Calcium fluoride is considered a harmless compound due to its extreme insolubility, and can be manipulated and removed from the premises without risk of contamination.


Application. Zero customer concerns 

The Integra gas filtration system takes place by installing a module that incorporates a fixed, interchangeable bed located near the emitting source of the furnace ceramic firing. The adsorption is carried out at temperatures above 150 ° C to avoid condensation of HF.

The system can debug flows between 500 to 250,000 m3 /h. Depending on the flow and concentration of contaminants materials, a filter can maintain a duration between 2 and 6 months, which represents an advantage over the currently used systems, reducing the number of maintenance stops and therefore the operational and logistics costs.

Filter replacement is quick and doesn't involve any intervention by the customer. Integra offers a complete service which includes the supply of new deposits of fresh adsorbent and the removal of deposits of saturated adsorbent, and their controlled arrangement.

The Integra gases filtration system optionally incorporate continuous measurement equipment of gases and also the integration of the measurements totally free that allows customers to view with restricted access, the state of broadcasting in real time from anywhere in the world.



Rechargeable filters


The INTEGRA gas filtering system requires less space, to the extent that filter can be located above the same kiln.








Summary of advantages


  • The new Integra filters allow completely eradicate the problems caused by emissions of hydrofluoric acid . (HF)

  • The installation cost is lower than other alternatives on the market.

  • Operating costs are also more competitive. Lower cost in power consumption and lower overall cost of consumables.

  • It is a flexible and modular solution that can be implemented in phases.

  • The same solution can be extrapolated to other types of gases such as SO2 or HCl. Using filters combined with other varieties of Integra adsorbents can be debugged with the presence of NOx gas, H2S, dioxins, VOC'S...

  • Obtaining a clean gas and HF-free high temperature allows to use the surplus for other processes such as thermal spraying, preheat or pre-drying prior piezaqs inkjet decoration, all without danger of installation.

  • The operators of the company doesn't have to handle toxic or corrosive products.

  • The system can be monitored remotely through a free and unrestricted access to the site of Integra

  • Integra offers a full service for supplying and removing the filter, through a clean and effective solution that avoids customer concerns.

  • Integra's results have been certified by the Institute of Catalysis and Petrochemistry of the CSIC (Spanish National Research Council) and ITC (Institute of Ceramic Technology)




Pressure drop


Packed bed, dry air to 20ºC and 1 bar./ Pressure drop/ Linear speed (m/s)


Due to the optimized design of Integra adsorbents obtained a lower pressure drop. In many cases, the extraction itself of the kiln gases is enough to overcome the filter bed, which involves a negligible energy saving.