Key Takeaways & Executive Findings
- •• • The hybrid database (MySQL + InfluxDB) reduced storage costs while enabling efficient time-series data handling, critical for long-term monitoring of VOCs emissions and equipment performance. • • Under typical conditions, extraction and ventilation flow rates of 40,000 m³/h and 30,000 m³/h, respectively, created a micro-negative pressure environment that suppressed fugitive emissions, ensuring compliance with GB 27632—2011. • • The purification process (zeolite rotor adsorption + regenerative thermal catalytic oxidation) consistently reduced non-methane hydrocarbon (NMHC) concentrations to below 10 mg/m³, meeting regulatory limits. • • Role-based access control and microservice architecture reduced abnormal response times and enabled precise operational responsibility allocation, improving system reliability and maintenance efficiency.
Abstract
Industrial volatile organic compounds (VOCs) emissions are a major contributor to regional air pollution, and the rubber paste preparation process is a significant source. This study developed an intelligent monitoring system for whole-process VOCs management in a rubber paste preparation workshop, integrating software engineering and Internet of Things (IoT) technologies. The system architecture combines a hybrid database (MySQL relational and InfluxDB time-series), MQTT-based low-power wide-area communication, role-based access control, and containerized microservices. Field deployment at a large rubber enterprise enabled real-time monitoring of adsorption/desorption centrifugal fans and data fusion analysis. Under typical operating conditions, the extraction and ventilation systems achieved volume flow rates of 40,000 m³/h and 30,000 m³/h, respectively, maintaining a continuous micro-negative pressure environment that effectively suppressed fugitive emissions. The purification process, comprising zeolite rotor adsorption and regenerative thermal catalytic oxidation, reduced non-methane hydrocarbon (NMHC) concentrations to below 10 mg/m³, meeting the GB 27632—2011 emission standard. The system's multi-level permission management module precisely allocated operational responsibilities across production, environmental, and management roles, reducing response time to abnormal conditions. An online evaluation model for purification efficiency was constructed based on the actual process. The system demonstrates potential for extension to other high-VOCs industries such as coatings and printing. This research provides theoretical and practical references for applying computer technology to VOCs reduction and whole-process management in typical industries.
1. Introduction
Industrial VOCs emissions, particularly from rubber manufacturing, pose significant environmental and health risks. Traditional monitoring systems often rely on isolated data silos and lack real-time integration, leading to delayed responses and inefficient emission control. The rubber paste preparation process, characterized by high solvent usage and complex emission patterns, demands a more sophisticated approach that can handle heterogeneous data sources and provide actionable insights.
This study addresses these bottlenecks by developing an intelligent monitoring system that integrates IoT sensors, hybrid databases, and role-based access control. The system enables real-time data collection, fusion, and visualization, allowing for proactive management of VOCs emissions. Field deployment at a large rubber enterprise demonstrates its effectiveness in maintaining negative pressure conditions and achieving emission concentrations below regulatory limits. The system's modular architecture and scalable design offer a blueprint for extending similar solutions to other high-VOCs industries, such as coatings and printing, where solvent use and emission profiles vary significantly.
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LI Peixian, DANG Xiaoqing, ZHAI Chen, HAN Wei, LAI Zhiqiang, LI Zhaoyang, QU Jiaxin, WANG He, ZHENG Huachun (2026). Whole-Process Management and Intelligent Monitoring System for VOCs Emissions in Rubber Paste Preparation Workshops: Design, Implementation, and Field Validation. Journal of Environmental Engineering Technology. https://doi.org/10.13205/j.hjgc.202606002
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Frequently Asked Questions
What are the key technical challenges in implementing a hybrid database (MySQL + InfluxDB) for VOCs monitoring, and how does the system handle data consistency and real-time performance?
The hybrid approach leverages MySQL for structured business data (e.g., equipment specs, user permissions) and InfluxDB for high-frequency time-series sensor data. Data consistency is maintained through transactional boundaries and periodic synchronization. Real-time performance is ensured by MQTT-based communication, which provides low-latency data transmission. The system's microservice architecture allows independent scaling of data ingestion and processing components, preventing bottlenecks during peak data loads.
How does the system ensure the accuracy and reliability of VOCs concentration measurements under varying process conditions?
The system employs calibrated sensors and regular maintenance schedules. Data fusion algorithms integrate readings from multiple sensors to reduce noise and outliers. Additionally, the system includes preventive maintenance alerts and abnormal condition warnings, which help identify sensor drift or malfunctions early. The purification efficiency model is continuously updated based on real-time data, ensuring that the reported NMHC concentrations are accurate and reliable.
What is the scalability of this system for other industries like coatings or printing, and what modifications are required?
The system's modular design allows easy adaptation. For coatings, which involve high solvent usage, data collection strategies and monitoring parameters can be adjusted to track specific VOCs species. For printing, where VOCs composition varies, the database model can be optimized to accommodate multiple pollutant types. The core architecture—hybrid storage, MQTT communication, and role-based access—remains unchanged, reducing implementation costs and time.
How does the system's permission management module improve operational efficiency and accountability?
The role-based access control (RBAC) module aligns with the enterprise's organizational structure, assigning specific permissions to production, environmental, and management roles. This ensures that only authorized personnel can modify system settings or access sensitive data, reducing the risk of human error. It also enables precise tracking of actions, which accelerates response times to abnormal conditions and enhances accountability.
What are the long-term maintenance and operational costs associated with the system, and how does it contribute to cost savings?
The system's preventive maintenance alerts and abnormal condition warnings help avoid overloading or improper start/stop of purification equipment, extending the lifespan of core components like zeolite rotors, catalysts, and fans. This reduces replacement costs and downtime. The hybrid database reduces storage costs by efficiently managing data. Overall, the system lowers operational expenses while ensuring compliance with emission standards.
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