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Energy recovery and odoUr reduction in petfood production

Energy recovery and odoUr reduction in petfood production. Tjitze Smit. programme. About Graintec Odour reduction Energy recovery Summary remarks. About graintec. Independent, privately owned company Engineering, contracting and project management company

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Energy recovery and odoUr reduction in petfood production

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  1. Energy recovery and odoUr reduction in petfood production Tjitze Smit

  2. programme About Graintec Odour reduction Energy recovery Summary remarks

  3. About graintec 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 Worldwide assignments …

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

  5. ODOUR Reduction

  6. Odour Concentrations OU/m3 Odour concentration may fluctuate significantly from plant to plant!

  7. ODOUR PERCEPTION AND INTENSITY Extremely strong Very strong Strong Perceptible Weak Very weak No odour Odour concentration Ou/m³ 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.

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

  9. Environmental Solutions

  10. 1. Chimney: Efficiency 0% Chimney Dryer/cooler Cyclone/filter Photo left: Plume of smoke (winter conditions) Photo right: Stack/chimney taller than 100 m is not unusual

  11. 2. Ozone Reactor (Plasma): Efficiency 70 - 85% Chimney Cyclone/filter Reactor Dryer/cooler Photo left: APP plasma unit

  12. 3. Bio/Chem. or Sea Water Scrubber:Efficiency 70 - 90% Chimney Dryer/cooler Cyclone/filter Scrubber Photo left: Sea water scrubbers Photo right: Chemical scrubber located indoors

  13. 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

  14. 5. RTO Oxidizing: Efficiency 90 - 98% Chimney Dryer/cooler RTO oxidizer Cyclone/filter Photo left: Regenerative thermal oxidizers

  15. 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

  16. 6B. Energy recovery and odour reduction Reduction in odour emission: 85 - 98% Thermal energy recovery: ~ 15 – 50 kWh/ton

  17. 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 RECOVERY SOLUTIONS • Thermalenergy for dryingaccounts for 60% of the total thermalenergyconsumption • 4 solutions to recoverenergy from drying: • Cross flow air/air heat exchanger • Air/water heat exchanger • Air/water heat exchanger in combinationwithhightemperature heat pumps • Air/water heat exchanger and recirculation of dryer air • All 4 solutions will in addition to energyrecovery have an odour reductioneffectoff 30 – 85% • Additionnal air treatment system canincrease odour reductioneffect to 99%

  22. SOLUTION 1: Cross flow AIR/AIR HEAT EXCHANGER • 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% HE DRYER/COOLER

  23. SOLUTION 2: AIR/WATER HEAT EXCHANGER • 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% HE 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% HE HP HE DRYER/COOLER

  25. SOLUTION 4: AIR/WATER HEAT EXCHANGER AND RECIRCULATION OF DRYER AIR • 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% HE DRYER/COOLER

  26. Simulation program and pinch analysEs

  27. summary • 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

  28. QUESTIONS ?

  29. THANK YOU FOR YOUR ATTENTION !

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