Gas and vapor extraction

Many industrial processes release gases or vapors that can have a major impact on the safety and health of people and the environment.

The Callens Group develops industrial gas and vapor extraction systems that capture these emissions at source in a controlled manner and safely remove or treat them. This helps you create a safe working environment, protect your production process, and meet the increasingly strict environmental and safety regulations.

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Industrial gas and vapor extraction as a solution to a safe production environment

Industrial gas and vapor extraction is used in production environments where gases, vapors, or volatile substances are released during the production process. These emissions spread quickly through the production environment and are often invisible, which means they can affect air quality, safety, and working comfort unnoticeably.

The challenge is to capture and remove these gases and vapors in a controlled way, without compromising the continuity or efficiency of the production process.

Depending on the properties of the released gases and vapors and the specific process requirements, the Callens Group develops a custom extraction solution.

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For which applications?

  • Extracting solvent and process vapors in the chemical industry.
  • Removing welding fumes, metal fumes, and process gases in metalworking.
  • Managing vapors from pickling, degreasing, and surface treatment processes.
  • Extracting volatile organic compounds (VOCs) during production and packaging processes.
  • Neutralizing or treating corrosive, harmful, or nuisance gases and vapors.

Technical specifications for industrial gas and vapor extraction

Gases and vapors each place their own technical demands on an extraction installation. Their chemical composition, temperature, concentration, and any corrosive or explosive properties determine how emissions can be safely captured, transported, and treated. That is why every application requires a carefully engineered air technology concept perfectly tailored to the production process.

The Callens Group designs gas and vapor extraction systems where source extraction, ductwork, fans, and emission treatment operate as one integrated whole. Depending on the properties of the released substances, we select the most suitable technologies and carefully align air flow rates, air velocities, and material choices. We also take account of the applicable emission and safety regulations, the operational reliability of your installation, and the most energy-efficient operation possible.

Techniques

  • Source extraction tailored to the production process
  • Extraction arms, extraction hoods, and enclosed extraction systems
  • Industrial ductwork networks
  • Gas scrubbers
  • Activated carbon filtration
  • Thermal or catalytic afterburning
BENEFITS

Benefits of industrial gas and vapor extraction

Gases and vapors can directly affect safety, air quality, and the continuity of a production process. By extracting emissions at source in a controlled manner and treating them correctly, you create a production environment that is safer, more reliable, and ready for the stricter requirements of today and tomorrow.

Safe working environment

A well-designed gas and vapor extraction system prevents harmful or nuisance substances from spreading through the production environment. This reduces employee exposure to hazardous emissions and creates a safer working environment.

More reliable production processes

When gases and vapors are removed in a controlled manner, process conditions remain stable and the risk of process disruptions or unwanted downtime is reduced. This increases the availability and reliability of your production installations.

Compliance with environmental and safety regulations

More and more industrial processes must meet the strict emission, workplace safety, and environmental permit requirements. A correctly designed gas and vapor extraction system helps your company comply with these regulations.

Protection of installations

Certain gases and vapors can cause corrosion, contamination, or damage to machines and technical installations. By removing these emissions in a controlled way, you extend the service life of your installations and reduce maintenance costs.

Less odor nuisance

In production environments where odorous substances are released, a tailored extraction and treatment installation prevents nuisance odors from spreading inside or outside the company. This increases comfort on the production floor and reduces the impact on the surrounding area.

Lower operating costs

A correctly dimensioned installation optimally aligns air flow rates, extraction, and emission treatment. This keeps energy consumption under control, limits maintenance interventions, and allows the installation to perform more efficiently throughout its service life.

Every production environment requires a custom industrial extraction solution

Not all gases and vapors can be captured, removed, or treated in the same way. The chemical properties, temperature, concentration, and behavior of the released substances determine which extraction techniques, materials, and post-treatment systems will be required. That is why every application calls for thoughtful engineering and a custom solution.

During a site visit, the engineers at the Callens Group analyze the full production environment. We map the emission sources, the properties of the released gases and vapors, the airflows, the air flow rates, and the applicable environmental and safety regulations. We also examine which extraction and treatment technologies best suit your process and how the installation can be optimally integrated into your existing production environment.

Based on this analysis, we develop a gas and vapor extraction system that is fully tailored to your situation. We determine the optimal position of the extraction points, dimension the ductwork network, and select the most suitable technologies to treat your emissions. In this way, we create an installation that optimally combines safety, operational reliability, and energy efficiency.

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Callens Techniekers Onderhoud 2

Maintenance after installation

Even after installation, you can continue to rely on the Callens Group for maintenance and service, in cooperation with specialist partners.

During maintenance, we check the extraction points, ductwork, fans, mechanical and electrical components, control technology, and any emission treatment installations, among other things. By detecting wear, contamination, and deviations in time, extraction performance stays at the required level, energy consumption remains under control, and the risk of unplanned downtime or reduced emission control is reduced.

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PARTNERSHIP

Why work with the Callens Group?

60 years of experience in EPCS projects
Independent integrator focused on customer needs
Flexible customer and project approach
Short decision-making lines and a personal approach
Unique service and maintenance support
Always close to customers with 13 locations

“A safe production environment starts with gases and vapors being captured at source, being correctly removed, and treated according to the requirements of your process.”

Projects with industrial gas and vapor extraction

Callens ventilatie labo 1
Air technology Extraction Gas and vapor extraction

Laboratory puts ventilation to the test

Extraction ratemax. 18,000 m3/h
Injection ratemax. 18,000 m3/h
FAQ

Questions? We have the answers.

Although both systems capture contaminants at source, dust and gaseous emissions require a completely different technical approach. Dust particles are mechanically separated using filtration techniques such as cartridge or bag filters. Gases and vapors, however, cannot simply be filtered out and require tailored treatment systems, such as gas scrubbers, activated carbon filtration, or thermal afterburning. The choice of the right technology depends on the properties of the substances being released, the process conditions, and the applicable safety and environmental requirements. That is why the Callens Group develops a custom extraction system for every application.

Yes. As an EPCS integrator, the Callens Group takes care of the entire process: from technical analysis and concept engineering to detailed engineering, production, installation, commissioning, and maintenance. Every project starts with an on-site visit during which our engineers analyze the emission sources, the properties of the substances released, the airflows, and the applicable environmental and safety regulations. Based on that analysis, we develop an integrated extraction solution fully tailored to your production process.

Want to discuss a gas and vapor extraction project? Our experts are happy to think along with you.

Preventive maintenance is essential to guarantee the extraction capacity, safety, and emission performance of the installation. The maintenance frequency depends on the nature of the released substances, the operating conditions, and the extraction and treatment technologies used. During maintenance, the fans, ductwork, control technology, extraction points, and any emission treatment installation, among other things, are checked. This preserves system performance and significantly reduces the risk of faults or unplanned downtime.

Not all gas or vapor emissions can be treated in the same way. The chemical composition, concentration, temperature, and any corrosive or explosive properties determine which extraction and post-treatment technologies are most suitable. During concept engineering, the Callens Group maps these parameters accurately. Based on this analysis, we select the optimal combination of source extraction, ductwork, and emission treatment, fully aligned with your production process and the applicable regulations.

Want to know which solution best suits your production environment? Contact our specialists for customized advice.

Yes. In many projects, a new extraction installation is integrated into an existing production environment without major changes to the production process. We consider the available space, existing duct routes, production planning, and the connection to any existing emission treatment installations. Thanks to thoughtful engineering and project coordination, the Callens Group delivers safe integration with minimal impact on your operations.

For a silicone manufacturer, the Callens Group developed a gas and vapor extraction installation for seven production rooms where aerosol cans are filled. During this process, small quantities of propellants are released and must be safely extracted and routed to a thermal oxidizer in line with the applicable ATEX regulations. The installation processes a total air flow rate of 40,000 m³/h. Each production room was equipped with two or three extraction fans that transport the gases through a central ductwork network to the afterburning installation. The Callens Group also expanded the existing pipe rack to optimally integrate the installation. As a result, our customer now meets the strict environmental and safety requirements while the production environment continues to operate safely and reliably. More information: https://www.callens.eu/en/air-technology/industrial-extraction/extraction-system-takes-on-hazardous-propellants