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ENERGY RECOVERY AND ODOUR REDUCTION IN PETFOOD PRODUCTION Tjitze Smit.

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Presentation on theme: "ENERGY RECOVERY AND ODOUR REDUCTION IN PETFOOD PRODUCTION Tjitze Smit."— Presentation transcript:

1 ENERGY RECOVERY AND ODOUR REDUCTION IN PETFOOD PRODUCTION Tjitze Smit

2 PROGRAMME 1.About Graintec 2.Odour reduction 3.Energy recovery 4.Summary remarks

3 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 feed Extruded Pet food ABOUT GRAINTEC Worldwide assignments …

4 OUR KEY CLIENTS All Internationally Operating Companies And many more …

5 ODOUR Reduction

6 ODOUR CONCENTRATIONS OU/M 3 Odour concentration may fluctuate significantly from plant to plant!

7 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

8 ODOUR EMISSION OU/H PET FOOD FACTORY 2 LINES 13% of total odour emission

9 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

10 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

11 2. OZONE REACTOR (PLASMA): EFFICIENCY % Dryer/cooler Cyclone/filter Chimney Reactor Photo left: APP plasma unit

12 3. BIO/CHEM. OR SEA WATER SCRUBBER: EFFICIENCY % Dryer/cooler Cyclone/filterScrubber Chimney Photo left: Sea water scrubbers Photo right: Chemical scrubber located indoors

13 4. BIO FILTER: EFFICIENCY % Dryer/coolerCyclone/filter Scrubber Bio filter Photo left: Bio filter with wood chips Photo right: Fresh water scrubber

14 5. RTO OXIDIZING: EFFICIENCY % Dryer/cooler Cyclone/filter Chimney RTO oxidizer Photo left: Regenerative thermal oxidizers

15 6A. TOTAL RECIRCULATION INCL. COAL FILTER: EFFICIENCY 98 – 99% Dryer/coolerCyclone/filter Air treatmentBio/ Coal filter Photo left: Air treatment unit incl. bag filter Photo right: Cooling tower

16 6B. ENERGY RECOVERY AND ODOUR REDUCTION Reduction in odour emission: % Thermal energy recovery: ~ 15 – 50 kWh/ton

17 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 Chimney0 %Very lowVery Low Ozone/plasma Reactor70 – 85 %LowHigh Bio/Chemical or Sea Water Scrubber(s) 70 – 90 %High Bio Filter70 – 95 %MediumHigh RTO Oxidizing90 – 98 %HighVery High Recirculation/Condensa- tion incl. Coal/Bio Filter 98 – 99 %HighLow* SUMMARY * The annual operating cost for this solution is very low because the solution includes energy recovery!

18 ENERGY RECOVERY

19 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

20 ENERGY DISTRIBUTION THERMAL ENERGY CONSUMPTION ELECTRICAL ENERGY CONSUMPTION

21 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 exchanger 2.Air/water heat exchanger 3.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

22 Cross flow air to air exchanger (HE) Up to 50% energy recovery possible Condensation in air and low temperature energy may be a problem Odour reduction effect below 50% SOLUTION 1: CROSS FLOW AIR/AIR HEAT EXCHANGER HE DRYER/COOLER

23 Air to water exchangers (HE) Up to 40% energy recovery possible Condensation and low temperature energy may be a problem Odour reduction effect below 50% SOLUTION 2: AIR/WATER HEAT EXCHANGER HE DRYER/COOLER

24 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 problem Odour reduction effect above 50% DRYER/COOLER HE HP

25 Air to water exchangers in combination with recirculation of dryer air Up to 20% energy recovery possible Condensation in air may be a problem Hygiene risk in recirculation air to be considered Odour reduction effect above 85% SOLUTION 4: AIR/WATER HEAT EXCHANGER AND RECIRCULATION OF DRYER AIR DRYER/COOLER HE

26 SIMULATION PROGRAM AND PINCH ANALYSES

27 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 solution New 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

28 QUESTIONS ?

29 THANK YOU FOR YOUR ATTENTION !


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