Technology
The technology used in the Aerox-Injector is cold-plasma injection, employing plasma cells based on DBD (Dielectric Barrier Discharge). In this process, an electrical discharge occurs between two electrodes that are electrically insulated. The (injection) air passed through this field contains oxygen and water vapour. Both gaseous components are ionised in the plasma, generating highly reactive, short-lived oxygen and hydroxyl radicals that oxidise the odour molecules in the exhaust gases. This technology is called cold plasma or cold oxidation because the odour molecules can be oxidised at low temperatures due to the strong oxidising power of these radicals.
The injection technology works as follows: a small airflow is drawn in from outside by the Aerox injection fan. This ambient air is made extremely dust-free using HEPA filters and fully conditioned by a compact, efficient heater. The air then passes through the plasma cells, where radicals are formed. This reactive mixture—referred to by Aerox long ago as “active oxygen”—is injected at high velocity into the odorous process stream and reacts rapidly with the odour molecules. The fast oxidation reaction yields air that is virtually odourless and scarcely perceptible to the human nose.
Technology
The Aerox-Injector is an innovative odor control system based on injection technology that is installed at the end of a chimney. Already more than 250 plants around the world benefit from our proven effective technology.
Our cold-plasma solution: the Aerox-Injector
Continuous innovation
The technology and product are continually improved to meet the specific needs and requirements of our customers as well as environmental authorities. In recent years, the plasma cells have been enhanced to deliver greater plasma capacity—and therefore greater odour reduction—while improving energy performance. Conditioning of the injection air has also produced a highly stable odour-reduction system that operates continuously, reliably and safely for 10,000 operating hours without maintenance.
Aerox R&D never stands still and keeps innovating, with a clear guiding principle: achieve the maximum possible odour reduction per kWh.
Customers are fully relieved of concerns, and maintenance is simple
Aerox Injector systems operate fully automatically, and plasma capacity is continuously adjustable—including remotely. All critical system parameters are monitored by sensors and logged. Using the built-in modem and the Aerox Dashboard, both the customer and Aerox can access and verify system performance remotely.
In practice, apart from replacing a bag filter, the only requirement is to have Aerox perform periodic maintenance once every 10,000 operating hours—without any production downtime.
The foundation of our technology
At Aerox, we believe in the power of advanced technology. Our products, such as the Aerox injector, are the result of intensive cooperation with universities, research centers and our customers. All the solutions we offer use cold-plasma technology, a sustainable and effective method for reducing odor emissions.
What is cold plasma?
Cold plasma is an ionized gas that conducts electricity, responds to changes in electric and magnetic fields, and accelerates chemical reactions. This plasma is generated using electricity and allows odor particles to be burned as early as room temperature. The result is a sustainable and cost-effective solution to odor problems.
Our cold-plasma solution: the Aerox-Injector
In our Aerox injector, clean outside air is passed through specially developed cold plasma modules, which convert the air into an agitated and reactive gas mixture, also known as active oxygen. This reactive gas then enters into a very rapid oxidation reaction with the odor particles in the process air, making people unable to smell the oxidized odor particles.
Continuous innovation
Our newer products also use this breakthrough technology. We continue to develop and improve this technology to ensure that our solutions continue to meet the changing needs of our customers. We look forward to unveiling more innovations in the near future.
Easy maintenance
At Aerox, we pride ourselves on the simplicity of maintenance of our products. Our equipment functions autonomously and optimally for 8,000 hours before maintenance is required, and production can continue as usual in the meantime. The modular structure of our products allows for flexible expansions and updates. Thus, we assure you of state-of-the-art technology with many benefits.
Sustainability
Electricity only
This environmentally friendly odour-reduction system requires only electricity. Compared with systems that use gas, water or chemicals, it is better for the environment. One of the key advantages of our cold-plasma technology is that ionisation occurs at low temperatures, which keeps power demand relatively low and CO₂ emissions down.
Unnecessary energy consumption can be avoided by running the plasma cells at a lower capacity whenever less plasma output is needed.
Waste-free system
By filtering and conditioning the injection air, the service life of the plasma cells—also known as XG modules—has been extended to 10,000 operating hours. Aerox takes back used modules, and most components can be reused, so no waste is generated. Because the system uses no water or chemicals, there is also no wastewater or residual chemicals.
- Runs on electricity only—cleaner and simpler
- Low energy use thanks to cold-plasma technology
- Leaves no waste or residues
- Exceptionally long injector service life
- Quick to install—no structural modifications required
Long-term investment
The Aerox Injector has a long service life. Some systems installed more than 25 years ago are still in operation. Naturally, certain older units have been decommissioned—mainly because the customer shut down the production line or chose to upgrade to a higher-capacity Aerox system. In practice, the lifespan comfortably exceeds 20 years, which keeps the environmental impact of materials very low.
An Aerox Injector is, therefore, truly a long-term investment. Our systems are in use worldwide, and several multinationals operate more than 25 units across multiple production sites.
Easy installation
Aerox systems have a small footprint and can be installed in virtually any production environment. No major modifications to the line are required, and installation takes little time.
Methodology
Feasibility study
To ensure that our Aerox Injector delivers the required odour reduction, a feasibility study will be conducted. This study consists of the following steps:
Send a questionnaire to map out the details of the request.
Hold a meeting to clarify the applicant’s needs and provide an explanation of the technology.
Our chemists and technologists will assess the information and conclude whether the request is feasible.
The second phase of the feasibility study involves on-site testing. Aerox can perform two types of tests:
Suitcase test – Our smallest Aerox odour-control unit, designed for indicative on-site testing. Using this test, process air can be treated, after which your internal odour panel can evaluate the treated air.
Pilot test – A continuous flow of process air is treated. This allows samples to be taken before and after the pilot by an independent odour-measurement agency. By running the test at different settings, Aerox can provide the best recommendation for your specific odour issue.
If our team cannot travel to your site, there’s no need to worry. Through our network of distributors and service centres, we can carry out on-site tests with local professionals. Our experts in the Netherlands can support the testing process remotely from our Vleuten office, ensuring the tests proceed smoothly and successfully.
Design
After the test has determined the capacity required for good odor reduction, design can begin. To arrive at the right design, Aerox’s technical department will work with the customer to determine the configuration.
Test for transportation
Before we send the Aerox injector to the customer, a Factory Acceptance Test is performed. With this test, we can confirm that the Injector is fully functioning properly and ready to solve the odor problem. The customer is invited to be present at this test and can receive instruction on the operation of the system if desired. After all tests have been passed, the system is transported to the customer.
Installation and commissioning
Once the system has arrived on site and installed, Aerox will perform commissioning. When the Aerox-Injector is fully operational, the settings can be adjusted to achieve the best odor reduction in all situations. The commissioning process also includes the training of local operators. The in-house operators must be able to operate the basic functionalities of the Aerox injector.
During this final step, we also perform a Site Acceptance Test. This test shows whether the machine is fully functional and nothing has gone wrong in transportation.
Service and maintenance
After the sale and commissioning, our team will be ready to assist as needed.
The Aerox Injector will be continuously monitored via the IoT platform with online dashboard by our service coordinator to make sure the machine is working properly. In the unlikely event that there are problems, they are noticed immediately and remedied as soon as possible.
Maintenance is planned and performed in close consultation with the customer. Our
Aerox Injector is designed so that maintenance can be performed without interrupting the production process.
Further development
Reducing energy costs
Making our Aerox Injector more energy-efficient is a core focus of our R&D. In addition to lowering the Aerox Injector’s operating costs, a second goal is to reduce our environmental impact. The Aerox Injector is already the most environmentally friendly odour-control solution on the market—but we’re determined to make it even greener.
Increasing achieved odour reduction
The Aerox Injector has proven effective at treating odours across multiple industries. However, some odours are more challenging to neutralise with our cold-plasma treatment alone. Our researchers are therefore working to further improve our cold-plasma odour control and to combine our technology with complementary solutions.
Improving our service quality
Our outstanding service is one of the things that makes Aerox stand out. We aim to maintain—and ideally exceed—the level our customers are used to. Our engineers and researchers therefore keep looking for ways to improve it, combining customer feedback with new technological innovations.
Customising the Aerox Injector to customer needs
We recognise that every factory and every process is different. In the past, we have adapted our products to various environments, different power grids, and new processes. We also know that the customer understands their plant and process best. That’s why Aerox works closely with its customers to deliver the best industrial odour control on the market.
More about our technology?
Further development
With more than 25 years of experience in cold plasma injection technology, Aerox has gained a lot of experience and incorporated it into our Aerox injectors. Consequently, our products are spread all over the world, including some that are still extremely active in odor control after 20 years.
Sustainability
The Aerox-Injector is the most durable industrial odor reduction solution. Specifically designed in view of the environment and the possibility of recycling almost all parts. All an Aerox injector needs is a little bit of energy.
Our products
Aerox-Injector
The Aerox-Injector is an innovative odor control system based on injection technology that is installed at the end of a production process or in the chimney. Already more than 250 plants around the world benefit from our proven effective technology.
