Efficiency Options for Thermal & Catalytic Oxidizers

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1 Efficiency Options for Thermal & Catalytic Oxidizers Kyle Momenee / Application Engineer Anguil Environmental Systems Inc. EPA Roundtable March 25 th,

2 Background-Anguil Environmental Systems Founded in 1978 Headquartered in Milwaukee, WI with additional offices across the world Industrial Air Pollution Control (Oxidizers) and Energy Recovery (Heat Exchangers) Systems Design, Manufacture, Install and Service Deb,Gene and Chris Anguil 2

3 Motivation Why Now Rising Utility Costs Tighter Emission Regulations Stimulus & Grant Money Availability Media Coverage (Marketing Bonus) 3

4 Oxidizer Technologies Regenerative Thermal Oxidizer (RTO) Direct-Fired Oxidizers: Multi-Jet & Flameless Catalytic Oxidizers: Recuperative & Regenerative Thermal Recuperative Oxidizer Concentrators: Zeolite & Carbon Technology Selection Should Be Based On: Effectiveness Energy Efficiency Affordability 4

5 Oxidizer Technology Overview Regenerative Thermal Oxidizers (RTO) Direct-Fired Thermal Oxidizers / Flares Concentrators Thermal Recuperative Oxidizers Catalytic Recuperative Oxidizers 5

6 Energy Efficiency Minimizes Greenhouse Gas Emissions 6

7 How is the RTO so efficient? 7

8 Optimization Strategies Zone Approach: - Zone A: Upstream of Oxidizer - Zone B: Internal to Oxidizer - Zone C: Oxidizer Exhaust Stack Consider the ways in which an Oxidizer Systems use energy in each of these Zones 8

9 Optimization Strategies Zone A: Reduce Airflow Re-establish proper balance (Follow up with training and indicators) Traditional methods: tighter capture, recirculation, cascading Variable exhaust methods: Pressure control, LEL Control 9

10 Optimization Strategies Zone A: Concentrate Emissions VOC Concentrators Large Flow / Low Concentration Airstream Small Flow / High Concentration Airstream Concentrators Reduce the Oxidizer Size & Operating Cost! 10

11 Optimization Strategies Zone A: Concentrators Technology Applicability: Airflows > 5,000 SCFM. Lower flow rates generally make this technology uneconomical. Inlet Temperature < 100ºF (40ºC) VOC Concentrations < 500 ppm. Higher concentrations reduce concentration factor making this technology uneconomical. DREs < 99% Relative Humidity < 90% 11

12 Optimization Strategies Zone B: Internal to Oxidizer Primary Heat Recovery: Hot, purified air leaving the retention chamber is used to pre-heat the incoming Solvent Laden Air (SLA) Thermal Recuperative Oxidizers Catalytic Oxidizers Regenerative Thermal Oxidizers 12

13 Optimization Strategies Zone B: Internal to Oxidizer Increasing Oxidizer Primary Heat Recovery Adding high-efficiency ceramic media to a Regenerative Thermal Oxidizer Replacing the hottest pass of the Shell-and-Tube heat exchanger in a Thermal Recuperative Oxidizer 13

14 Optimization Strategies Zone B: Internal to Oxidizer Focus on Combustion Air Consider Process Air as Combustion Air Consider Pre-Heating Combustion Air (By blending with stack air directly or through a stack HX) Added Duct System to Allow Blend of Stack Air with Combustion Air Reduce Combustion Air with Enhanced Firing Rate Controls Eliminate Combustion Air (RTOs) 14

15 Optimization Strategies Zone B: Internal to Oxidizer SFI (Supplemental Fuel Injection) Also known as: NGI Natural Gas Injection or Flameless Operation Custom Designed Injection Quill Additional Fuel Train Piping Why Use SFI? Reduces combustion air- flow, lowering operating costs Lower pilot rate for large burners Ultralow NOx emissions 15

16 Optimization Strategies Zone C: Downstream of Oxidizer Air-to-Air Heat Exchangers Air-to-Liquid Heat Exchangers Air-to-Steam Heat Exchangers Combined Heat and Power (CHP or Cogeneration) 16

17 Zone C: Secondary Heat Recovery Practical Uses for Recovered Heat: Preheated Makeup Air for Process Ovens or Dryers Preheated Air or a Preheat Coil for Makeup Air Units Preheated Combustion Air for Process or Oxidizer Preheated Process Water or Boiler Feed water or Steam Preheated Oil for a Hot Oil Loop Plant Power Generation Optimize Payback by Employing the Energy in Processes Related to the Oxidizer! 17

18 Summary: 10 Tips 1. Know how much your oxidizer is supposed to be costing you to operate. 2. Pay attention to the percentages Especially primary TER (Thermal Energy Recovery) 3. Know your VOC emission profile Especially the amplitude and duration of peaks. 4. Know what oxidizer system would be specified for your process today. 5. Know what grant money is available to you for optimization projects. 18

19 Summary: 10 Tips 6. Reduce exhaust airflow to oxidizer wherever possible. Consider concentration of high volume, low concentration and low temperature airstreams prior to oxidizer. 7. Focus on combustion air. Consider the source and temperature. Reduce, eliminate or pre-heat if possible. 8. Improve primary heat recovery when feasible. 9. Consider secondary heat recovery. 10. Properly maintain existing systems. 19

20 Questions? ANGUIL ENVIRONMENTAL SYSTEMS, INC N. 55 th Street Milwaukee, Wisconsin Phone : Fax :

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