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  • Oxi.X RC Regenerative Thermal Oxidizer (RTO)

References

Project / Case Feature Item

Particleboard plant emissions control

Challenge

A North American wood products facility relies on steam to produce multiple grades, thicknesses and sizes of melamine panels. The facility has three wood waste boilers, each followed by cyclone dust collectors. Process gas from each set of cyclones feeds into an induced draft (ID) fan; where the streams are combined and then sent through a common duct connected to the stack.

The facility needed to reduce emissions from burning wood waste, but plant performance and environmental requirements also needed to be in balance in order to hit production targets. The customer had precise operational goals so it was critical that the design of the emissions control solution accommodate current and future production variability.

Solution

Dürr Megtec specified and installed a new dry electrostatic precipitator (DESP) to treat the process gas from the three wood-fired boilers. The equipment was installed downstream of the ID fans and included inlet ductwork, along with an outlet plenum-mounted stack.

Results

It was critical the facility not experience any affiliated downtime. The dry ESP and related systems work as designed and achieved all of the stated goals. The system has easily surpassed the environmental test requirements and has been operating in accordance with local environmental legislation since commissioning.

Design Details

The design of the Dürr Megtec DESP collecting plates offers more efficient cleaning and dust removal during rapping. To ensure optimized particulate and ash collection, the rigid discharge electrodes feature a specific geometry and special pin distribution configuration to accommodate the process conditions.

Dürr Megtec engineers had to accommodate site-specific system requirements, which included access and ease of maintenance, as well as working within the existing plant footprint. These were key factors in routing ductwork and equipment placement. The job site also required the team to design around existing elevated bark conveyors and other equipment.

Project / Case Feature Item

Emissions solutions for CHP conversions

Situation

When Siouxland Ethanol, located in Jackson, Nebraska, USA decided to invest in a combined heat and power system (CHP), or cogeneration, it needed to make decisions regarding the plant’s air abatement and compliance. The company wanted to take its current system, a heat recovery steam generator (HRSG), offline and replace it with a boiler to form a cogeneration plant. With this approach, the steam generated by the new boiler requires a regenerative thermal oxidizer (RTO) to process the dryer’s emissions, which are produced when dry distiller’s grain with solubles (DDGS) are dried.

Siouxland’s overall goal was to find a better way to create steam and destroy emissions other than the traditional HRSG/thermal oxidizer (TO) system. The company decided to invest in a CHP system, which produces efficient steam with a cogeneration system, and required an RTO to handle the dryer emissions. This solution offered more flexibility to the operation.

Solution

Dürr proposed a rotary RTO, the Oxi.X RC, to handle the volume and type of emissions associated with the new CHP system.

Choosing a partner

When deciding on an RTO technology partner, Siouxland considered price, guarantee, reliability and recommendations provided by other partners in the industry.

Design

Siouxland already had a wet scrubber built into its existing system, which complimented the Oxi.X RC by providing cleaner, dryer air to it. The new RTO brought a reliable abatement system with added value features specifically for ethanol processing, including an upgraded process fan design, plug resistant media and controls.

Result

The equipment performs well and has met Siouxland’s expectations. The first six-month inspection completed by Dürr found the Oxi.X RC to be one of the cleanest RTOs seen in this application. The team has found that less bakeouts are warranted when the wet scrubber and Oxi.X RC work together.

Project / Case Feature Item

Ethanol facility replaces VRTO-C with new Oxi.X RC

Situation

Red Trail Energy, an investor group from North Dakota, operates a corn-based ethanol facility that produces up to 64 million gallons of ethanol per year. It was looking to increase ethanol production, which would require increased dryer and dried distillers’ grain solubles (DDGS) output. The existing competitor VRTO-C was slightly undersized, had reliability issues and would require a very expensive rebuild to meet the new output goals. Therefore, the plant’s executive team investigated and decided to pursue more reliable abatement solutions, outside of their existing supplier’s capabilities, that would meet their new requirements.

Solution

Dürr proposed an Oxi.X RC 50 (CS-500) regenerative thermal oxidizer with mechanical installation. It supplied this new, larger capacity RTO to replace the former competitor VRTO-C unit. The new Oxi.X RC 50 made it possible to increase production, while also providing a more reliable abatement system with value added features specific to ethanol processing, including an enhanced process fan design, plug resistant media and controls.

The Oxi.X RC is also capable of treating additional impurities associated with commercial grade ethanol. This allowed Red Trail to create a cleaner and more pure product for use as hand sanitizer during the pandemic.

Choosing a partner

Red Trail was introduced to Dürr by its service department, which completed VRTO-C preventative maintenance visits and opened the door as an alternative partner. When deciding on an RTO technology provider, the key factors were reliability, recommendations within the industry and past performance.

Result

The equipment performs well and has met Red Trail’s expectations in terms of EPA compliance, reliability and extra capacity for future growth.

Project / Case Feature Item

Fiberglass mat manufacturing formaldehyde emissions control

Challenge

An Oregon-based roofing company, which manufactures rubberized asphalt shingles, needed to reduce the amount of formaldehyde emitted by its manufacturing process. The rubberized asphalt shingles are made by laying down chopped glass, adding a binder, and then oven curing the mat. Formaldehyde is a byproduct of the fiberglass mat manufacturing process. The off gas is captured and sent to an oxidizer. When choosing a solution, the company‘s two most important factors were energy efficiency and simple mechanical design.

Solution

Dürr proposed an Oxi.X RM regenerative thermal oxidizer, which provides a low-pressure pulse when cycling, ensuring the fiber mat will not wrinkle during the manufacturing process. In addition, the Oxi.X RM had the proven uptime (>99%), high destruction efficiency (98+%) and energy efficiency (97+%) to meet this customer's stringent permit requirements. The Dürr team worked closely with the customer’s plant engineering team to ensure that all ducting was designed to keep condensation to a minimum. The oxidizer materials of construction were also upgraded to maximize service life, while keeping capital to a minimum. Working with the customer‘s local energy providers, Dürr was able to get the company a substantial rebate due to the Oxi.X RM's high energy efficiency.

Solution

Dürr proposed an Oxi.X RM regenerative thermal oxidizer, which provides a low-pressure pulse when cycling, ensuring the fiber mat will not wrinkle during the manufacturing process. In addition, the Oxi.X RM had the proven uptime (>99%), high destruction efficiency (98+%) and energy efficiency (97+%) to meet this customer's stringent permit requirements. The Dürr team worked closely with the customer’s plant engineering team to ensure that all ducting was designed to keep condensation to a minimum. The oxidizer materials of construction were also upgraded to maximize service life, while keeping capital to a minimum. Working with the customer‘s local energy providers, Dürr was able to get the company a substantial rebate due to the Oxi.X RM's high energy efficiency.

Design

The Oxi.X RM is fed by a dryer that emits both high temperatures and high humidity. The high humidity can lead to condensation, which can cause two problems - corrosion and lowered destruction efficiency. The RTO is designed such that the valves remain at a higher temperature than the process exhaust, which minimizes condensation, reduces corrosion, and increases service life and destruction efficiency.

Result

Installed in Q1 of 2020, the unit has performed flawlessly, exceeding emission requirements set forth by Oregon - a state which is becoming more stringent with hazardous air pollutant and volatile organic compound emissions. The project is the first oxidizer installed in a fiberglass mat manufacturing facility in that state.

Project / Case Feature Item

Challenge

A pioneering leader in the window-film industry was literally burning money to operate its coating lines. The company produces thin solar-control laminated films used to screen UV rays, block heat, reduce glare, increase occupant comfort, and enhance aesthetics. The company also produces multi-ply safety and security films that reduce hazards when glass shatters. The products are used in vehicles, homes, and buildings worldwide.

The company was using a decades-old recuperative thermal oxidizer to destroy solvents from the drying ovens on its three process lines. Thermal energy from the oxidizer exhaust was recovered by heat exchangers and used to operate the process ovens and other in-plant systems. Unfortunately, the operating efficiency and capacity limitations of the oxidizer created problems.

The plant was using more than 100,000 therms of gas monthly. The 20,000-scfm oxidizer used a single two-speed exhaust fan to serve three processes. The fan caused capacity and continuity conflicts between lines. This demanded continuous monitoring and adjustment by operators, and caused 25 percent lower line speeds at times.

In addition to productivity issues, air temperatures from the exchangers exceeded 800°F, which was much hotter than the dryers needed. The oxidizer yielded more heat than the plant could use and valuable energy had to be vented to the atmosphere.

Solution

Dürr Megtec proposed a 40,000-scfm CleanSwitch® regenerative thermal oxidizer (RTO). This unit has a proprietary switch valve that delivers high VOC destruction without a flush system. The Dürr Megtec engineering study determined the RTO exhaust could be safely used in the drying ovens. Also proposed was a new heat recovery system and operating sequence that would run more efficiently without wasting energy. Upgraded equipment was also supplied, including T-dampers, exhaust fans, and the hot and cold fans for the heat recovery system.

The customer agreed with the recommendations and based its decision on the benefits of the CleanSwitch® design, combined with the extensive process coating and drying knowledge of Dürr Megtec and its willingness to take on non-routine problems.

Results

The CleanSwitch® RTO achieved VOC destruction efficiencies above 99 percent. The fan design enabled the three production lines to run independently with no operator involvement. And the RTO capacity eliminated the need to reduce line speeds, which helped the plant see higher production.

The RTO provides process air at a more useful 400°F. And when all processes are on line, the CleanSwitch® RTO spends approximately 40 percent of the time in self-sustain, which does not use any gas at all. The RTO and heat recovery system reduced typical monthly gas by 93 percent. The energy savings provided full return on investment in only 18 months.

Project / Case Feature Item

Engineering a better way to coat battery electrodes

Challenge

An electrode manufacturer was looking for a better method of electrode coating and requested a collaborative effort with Dürr Megtec in an effort to develop a simultaneous two-sided coating and drying process that did not require a vertical web path through the dryer. The potential customer approached Dürr Megtec because they were familiar with its patented air flotation drying equipment and R&D pilot line capabilities.

The traditional tandem coating process is characterized by coating and drying one side of the current collector, then re-running the foil through the entire coating and drying process for the second side of the foil. Tandem coating also requires a longer manufacturing line that takes up more factory space.

Technology previously developed for simultaneous two-sided battery electrode coating dictated the need for a vertical air flotation dryer. However, the customer did not want a vertical web-path dryer because of the substantial building height required and the increased difficulty in providing operator access for tending purposes compared to a dryer with a horizontal web path.

Solution

The engineering goal was to develop a simultaneous two-sided coating method that uses a horizontal air flotation dryer instead of a vertical dryer. Dürr Megtec engineering and R&D teams developed a new coating concept and refined it through extensive testing on the Dürr Megtec R&D pilot line.

The new Dürr Megtec process required just a single pass. There was only one coating station, one dryer, and all equipment was located on the same level of the facility, all within a small footprint compared to a traditional tandem coating line.

Potential benefits of the single-pass feature of the Dürr Megtec slot-die tension web coating line include:

  • Reduced electrode manufacturing costs
  • Effective doubling of production volume without changing line speed
  • Reduced waste
  • Lower capital and operating costs
  • Improved overall production

 

Questions? Contact Us

Contact
Dürr Systems, Inc.
Dürr Systems, Inc. - De Pere
830 Prosper Street
54115 De Pere, WI
United States