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ENERGY RECOVERY AND ODOUR REDUCTION IN PETFOOD PRODUCTION
Tjitze Smit
PROGRAMME
1. About Graintec 2. Odour reduction3. Energy recovery4. Summary remarks
Independent, privately owned company Engineering, contracting and project management company Design – Execute – Install – Maintain Turnkey supplies More than 250 references worldwide Serving two main segments – producers of
Extruded Fish feedExtruded Pet food
ABOUT GRAINTEC
Worldwide assignments …
OUR KEY CLIENTSAll Internationally Operating Companies
And many more …
ODOUR Reduction
0
20.000
40.000
60.000
80.000
Aqua Feed Plant Pet Food Plant Animal Feed Plant
Aqua Feed Plant 5000 75000 60000 27000 2000
Pet Food Plant 4000 25000 50000 25000 1500
Animal Feed Plant 2600 12500 1500
Hammer mill
Extruder flash-off
Dryer exhaust
Cooler exhaust
Plant vent.
ODOUR CONCENTRATIONS OU/M3
Odour concentration may fluctuate significantly from plant to plant!
0
1
2
3
4
5
6
0 20 40 60 80 100 120
Extremely strong
Very strong
Strong
Odour Intensity:When the concentration of (odorous) compounds is several times higher than the odour threshold, the human nose does not perceive it like that.
The figure shows the relationship. It also explains why a relatively high reduction of the odour emission (in percentage) will not necessarily be perceived as such.
Perceptible
Weak
Very weak
No odour
Odour concentration Ou/m³
ODOUR PERCEPTION AND INTENSITY
ODOUR EMISSION OU/H PET FOOD FACTORY 2 LINES
13% of total odour emission
Solution: Cleaning efficiency
1. Chimney 0 % (Only dilution)
2. Ozone Reactor (Plasma) 70 – 85 %
3. Bio or Chemical Scrubber(s) 70 – 90 %
4. Bio Filter 70 – 95 %
5. RTO Oxidizing 90 – 98 %
6. Recirculation/Condensation incl. Coal Filter 98 – 99 %
ENVIRONMENTAL SOLUTIONS
1. CHIMNEY: EFFICIENCY 0%
Dryer/cooler
Cyclone/filter
Chimney
Photo left:Plume of smoke (winter conditions)
Photo right:Stack/chimney taller than 100 m is not unusual
2. OZONE REACTOR (PLASMA): EFFICIENCY 70 - 85%
Dryer/cooler Cyclone/filterChimney
Reactor
Photo left:APP plasma unit
3. BIO/CHEM. OR SEA WATER SCRUBBER:EFFICIENCY 70 - 90%
Dryer/cooler Cyclone/filter ScrubberChimney
Photo left:Sea water scrubbers
Photo right:Chemical scrubber located indoors
4. BIO FILTER: EFFICIENCY 70 - 95%
Dryer/cooler Cyclone/filter Scrubber Bio filter
Photo left:Bio filter with wood chips
Photo right:Fresh water scrubber
5. RTO OXIDIZING: EFFICIENCY 90 - 98%
Dryer/coolerCyclone/filter
Chimney
RTOoxidizer
Photo left:Regenerative thermal oxidizers
6A. TOTAL RECIRCULATION INCL. COAL FILTER: EFFICIENCY 98 – 99%
Dryer/cooler Cyclone/filter Air treatment Bio/ Coal filter
Photo left:Air treatment unit incl. bag filter
Photo right:Cooling tower
6B. ENERGY RECOVERY AND ODOUR REDUCTION
Reduction in odour emission: 85 - 98%Thermal energy recovery: ~ 15 – 50 kWh/ton
Solution: Cleaning efficiency
Capital investment costs for each cbm air/h to be cleaned
Annual operating costs for each cbm air/h to be cleaned
Chimney 0 % Very low Very Low
Ozone/plasma Reactor 70 – 85 % Low High
Bio/Chemical or Sea Water Scrubber(s)
70 – 90 % High High
Bio Filter 70 – 95 % Medium High
RTO Oxidizing 90 – 98 % High Very High
Recirculation/Condensa-tion incl. Coal/Bio Filter
98 – 99 % High Low*
SUMMARY
* The annual operating cost for this solution is very low because the solution includes energy recovery!
ENERGY RECOVERY
81 102130141
189
250222
291
380
050
100150200250300350400
Low Average High
kW
h/t
on
of
fin
al
pro
du
ct
Energy Consumption Extruded Feed Production
Electrical
Thermal
Total
ENERGY CONSUMPTION
The total energy consumption (thermal and electrical) can normally be reduced to less than 220 kWh per ton of final product in extruded feed, and drying is the most energy consuming process
ENERGY DISTRIBUTION
THERMAL ENERGY CONSUMPTION
ELECTRICAL ENERGY CONSUMPTION
Thermal energy for drying accounts for 60% of the total thermal energy consumption 4 solutions to recover energy from drying:
1. Cross flow air/air heat exchanger2. Air/water heat exchanger3. Air/water heat exchanger in combination with high temperature heat pumps 4. Air/water heat exchanger and recirculation of dryer air
All 4 solutions will in addition to energy recovery have an odour reduction effect off 30 – 85%Additionnal air treatment system can increase odour reduction effect to 99%
THERMAL ENERGY RECOVERY SOLUTIONS
Cross flow air to air exchanger (HE)Up to 50% energy recovery possible Condensation in air and low temperature energy may be a problemOdour reduction effect below 50%
SOLUTION 1: CROSS FLOW AIR/AIR HEAT EXCHANGER
HE
DRYER/COOLER
Air to water exchangers (HE)Up to 40% energy recovery possibleCondensation and low temperature energy may be a problemOdour reduction effect below 50%
SOLUTION 2: AIR/WATER HEAT EXCHANGER
HE
HE
DRYER/COOLER
SOLUTION 3: AIR/WATER HEAT EXCHANGER IN COMBINATION WITH HIGH TEMPERATURE HEAT PUMP
Air to water exchangers (HE) in combination with high temperature (80 – 110°C) heat pump (HP) Up to 70 % energy recovery possible Condensation in air may be a problemOdour reduction effect above 50%
DRYER/COOLER
HE
HE
HP
Air to water exchangers in combination with recirculation of dryer air Up to 20% energy recovery possible Condensation in air may be a problemHygiene risk in recirculation air to be consideredOdour reduction effect above 85%
SOLUTION 4: AIR/WATER HEAT EXCHANGER AND RECIRCULATION OF DRYER AIR
DRYER/COOLER
HE
SIMULATION PROGRAM AND PINCH ANALYSES
Energy recovery of dryer exhaust air and other process air sources may save 20 – 100 kWh of thermal energy per ton of final product Integration of energy, odour and carbon dioxide reducing technologies are in most cases a very cost effective solutionNew technology inventions in the fields of heat exchangers and heat pumps will bring further future possibilities to recover energy and reduce carbon dioxide emissions from the pet food industry
SUMMARY
QUESTIONS ?
THANK YOU FOR YOUR ATTENTION !