Energy recovery and odour reduction in petfood production
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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

Energy recovery and odoUr reduction in petfood production

Tjitze Smit


Programme

programme

About Graintec

Odour reduction

Energy recovery

Summary remarks


About graintec

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 …


Our key clients

OUR KEY CLIENTS

  • All Internationally Operating Companies

And many more …


Odour reduction

ODOUR Reduction


Odour concentrations ou m 3

Odour Concentrations OU/m3

Odour concentration may fluctuate significantly from plant to plant!


Odour perception and intensity

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.


Odour emission ou h pet food factory 2 lines

ODOUR EMISSION OU/H PET FOOD FACTORY 2 LINES

13% of total odour emission


Environmental solutions

Environmental Solutions


1 chimney efficiency 0

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


2 ozone reactor plasma efficiency 70 85

2. Ozone Reactor (Plasma): Efficiency 70 - 85%

Chimney

Cyclone/filter

Reactor

Dryer/cooler

Photo left:

APP plasma unit


3 bio chem or sea water scrubber efficiency 70 90

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


4 bio filter efficiency 70 95

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


5 rto oxidizing efficiency 90 98

5. RTO Oxidizing: Efficiency 90 - 98%

Chimney

Dryer/cooler

RTO

oxidizer

Cyclone/filter

Photo left:

Regenerative thermal oxidizers


6a total recirculation incl coal filter efficiency 98 99

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


6b energy recovery and odour reduction

6B. Energy recovery and odour reduction

Reduction in odour emission: 85 - 98%

Thermal energy recovery: ~ 15 – 50 kWh/ton


Summary

Summary

* The annual operating cost for this solution is very low because the solution includes energy recovery!


Energy recovery

Energy recovery


Energy consumption

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


Energy distribution

ENERGY DISTRIBUTION

THERMAL ENERGY CONSUMPTION

ELECTRICAL ENERGY CONSUMPTION


Thermal energy recovery solutions

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%


Solution 1 cross flow air air heat exchanger

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


Solution 2 air water heat exchanger

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


Solution 3 air water heat exchanger in combination with high temperature heat pump

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


Solution 4 air water heat exchanger and recirculation of dryer air

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


Simulation program and pinch analyses

Simulation program and pinch analysEs


Summary1

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


Energy recovery and odour reduction in petfood production

QUESTIONS ?


Energy recovery and odour reduction in petfood production

THANK YOU FOR YOUR ATTENTION !


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