Problem
A producer and supplier of corrosion resistant piping systems
was looking to improve the reliability and lower operating expenses
of an existing air pollution control system at their facility.
During their manufacturing process, centrifugally cast mortar pipe
systems are reinforced with a fiberglass polymer. This makes the
pipe ideally suited for most corrosive piping applications but also
produces a significant amount of styrene emissions that need to be
destroyed. Plant personel knew that their existing 40,000 SCFM
fixed-bed concentrator and catalytic oxidizer could not handle
future expansion plans and the decision was made to look for a
replacement.
Action
After speaking with several vendors, the RTO (Regenerative
Thermal Oxidizer) was selected as the best available control
technology. It not only far exceeded the 95% destruction efficiency
required in their permit but also dramatically reduced operating
costs. The pipe manufacturer then identified what qualifications
they were looking for in a solution provider:
- Styrene Experience
- Proven Performance
- Stable Supplier
- Cost-Effective Equipment
- Turnkey Capabilities
Anguil was selected based on their ability to meet these
equipment and supplier requirements.
Solution
Anguil's engineering staff worked closely with the customer
throughout the design and manufacturing processes to ensure that
the system precisely met their requirements and expectations.
An Anguil Model 500 RTO (50,000SCFM) was selected based on
the process airflow concentrations, destruction rate
requirements and for its overall energy-efficient
operation.
Special considerations were taken to deal with the particulate in
the process stream. A 48-cartridge collector was put upstream of
the oxidizer to collect fiberglass pieces that could clog the RTO.
Once filtered, process gases with VOC contaminants enter the
oxidizer through an inlet manifold. Dual disk poppet valves direct
this gas into energy recovery chambers where the process gas is
preheated, then progressively heated in the ceramic beds as they
move toward the combustion chamber.
The VOCs are oxidized in the combustion chamber, releasing thermal
energy in the structured ceramic media beds that are in the outlet
flow direction from the combustion chamber. These outlet beds are
heated and the gas is cooled so that the outlet gas temperature is
only slightly higher than the process inlet temperature. Fasting
acting, vertical poppet valves alternate the airflow direction into
the ceramic beds to maximize energy recovery within the oxidizer.
The VOC oxidation and high energy recovery within the oxidizer
reduces the auxiliary fuel demands and operating costs. For
example, at 95% thermal energy recovery, the outlet temperature may
be only 70`F (40`C) higher than the inlet process gas temperature
with an RTO. The oxidizer can reach self-sustaining operation with
no auxiliary fuel usage at low concentrations.
Allen Bradley, Programmable Logic Controllers (PLCs) control the
automatic operation of the oxidizer from startup to shutdown, so
minimal operator interface is required. These controls also provide
for remote telemetry to enable the system's operation to be viewed
and altered via a modem connection to reduce maintenance
costs.
The customer is achieving 98% destruction rate
efficiency and the oxidizer is operating extremely efficient
at 95% thermal rate efficiency. Low operating costs and equipment
reliability have resulted in another satisfied Anguil customer.