christopher a. anguil - metal decorator's · christopher a. anguil ... compliance strategies...
TRANSCRIPT
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Christopher A. AnguilVice President - Sales & Marketing
Anguil Environmental Systems
Compliance Strategies for air quality for the 3-P Metal Decorator, specifically volatile organic compound (VOC) and hazardous air pollutant (HAP) control can be
overwhelming. This seminar will cover new environmental legislation, the best available control technologies and energy reduction methods relating to air pollution control in the
metal decorating industry.
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Christopher A. AnguilIn the past ten years Chris Anguil served as Inside Sales Coordinator, Regional Sales Manager, Director of Sales and is currently the Vice President of Sales and Marketing
for Anguil Environmental Systems. Chris is responsible for Anguil’s new equipment and major Aftermarket sales throughout the Midwest, Western US, and Canada. Equipment
sold includes direct-fired, regenerative thermal, recuperative and catalytic oxidizers, concentrator systems, acid-gas scrubbers, heat exchangers and air capture systems. Anguil’s innovative and technical systems have effectively improved air quality for 28
years. Chris holds a bachelor’s degree from Indiana University, Bloomington. He has also
served as a member of the FTA’s Environmental Committee as well as the Environmental Director for AIMCAL.
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Presented By: Christopher Anguil / Vice President-Sales & Marketing
Anguil Environmental Systems
Introduction
For: Attendees of the
2007 IMDA Convention
Compliance Strategies for Air Quality:
Flat Sheet & Two-Piece
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Background
Founded in 1978
Family owned and operated
Headquartered in Milwaukee, WI with additional offices across the world
Committed to providing quality air pollution control solutions.
ANGUIL
Deb,Gene and Chris Anguil
Over 20 Years of Experience in the
Metal Decorating Industry!
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Regulations
NESHAP:National Emission Standards for Hazardous Air Pollutants: Surface Coating of Metal Cans
ANGUIL
http://www.epa.gov/ttn/atw/mcan/mcanpg.html
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Industry History
Coating, Printing and Oven Emission Control
Common VOCs:AcetatesAlcoholsMEK (Methyl Ethyl Ketone)TolueneXylene
ANGUIL
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CAPTURE:Use Air Volume Reduction Strategies Whenever Possible
• Close Capture Hoods
• Wet End Enclosures
• Permanent Total Enclosure (PTE)
Why? Oxidation is priced on cost per CFM exhaust.Less CFM ⇒⇒⇒⇒ Smaller Oxidizer ⇒⇒⇒⇒ Lower Operation Costs
CONTROL:• Properly Characterize and Identify the VOC Laden Air Stream
• Oxidation Technology Selection:
Effectiveness, Energy Efficiency, Affordability
ANGUIL Selecting A VOC Control System
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ANGUIL Close Capture Hoods
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ANGUIL Wet End Enclosures
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ANGUIL Permanent Total Enclosures (PTE)EPA Guidelines - Method 204
In 1990, the EPA issued a capture efficiency guideline which would earn the user the legal presumption of 100% capture without the requirement for formal capture testing. Many states have already issued permits based on it and it has acquired de facto status.
Specifically, the following definition applies:If a source is located inside a “total enclosure” and all emissions are directed to a control device, the requirement to measure the efficiency of capture is waived and presumed 100%. By definition then, a “total enclosure”precludes fugitive emissions. Such an enclosure can be described as a structure that completely surrounds or enshrouds an affected facility such that all VOC emissions are contained and directed through an exhaust stack or into an oven. An entire building can function as a total enclosure (see Item e below) if the conditions above are satisfied.
To qualify for the presumption of 100% capture, the following criteria must be met:a. Any natural draft opening (NDO) shall be at least four equivalent diameters from each volatile organic compound
(VOC) emitting point.b. The total area of all NDOs shall not exceed five percent of the surface area of the enclosure’s four walls, floor
and ceiling.c. The average facial velocity of air through all NDOs shall be at least 3,600 m/h (200 ft/min). The direction of air
through all NDOs shall be into the enclosure.d. All access doors and windows, the areas of which are not included in Item 3 and are not included in the
calculation in Item 4, shall be closed during routine operation of the process.e. All VOC emissions must be captured and contained for discharge through a control device.
In effect, one builds a house around the VOC source.
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ANGUIL Permanent Total Enclosures (PTE)
–Some MACT standards require 98% overall capture and control efficiency, requiring PTEs
–PTEs can reduce plant-wide emissions limits, providing more flexibility
–Lower emission fees with reduced rates from plant
–One-time PTE expense are quickly offset by routine testing required when PTEsare not used.
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ANGUIL Permanent Total Enclosures (PTE)
Considerations:– Plant-wide emission limit
– Capture efficiency testing expense
– Improved work environment
– MACT requirements may dictate PTEs
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ANGUIL What is Oxidation? Definition: CnH2m + (n + m/2) O2 ⇒⇒⇒⇒ n CO2 + mH2O + heat
Temperature:Based on the VOCs that need to be destroyed there is a temperature at which the compounds can be oxidized.
Time: Relates to how long a compound needs to be at a certain temperature in order for it to be oxidized.
Turbulence:A fixed condition built into the equipment design that ensures a
proper mixture of VOCs and oxygen for combustion.
Specific compounds and desired destruction rate efficiency determine temperature and residence time. Proper Oxidation converts hydrocarbons to CO2 and H2O (vapor).
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ANGUIL Applicable Technologies
• Regenerative Thermal Oxidizer (RTO)
• Catalytic Oxidizers: Recuperative and Regenerative
• Thermal Recuperative Oxidizer
• Concentrators: Zeolite and Carbon
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ANGUIL Regenerative Thermal Oxidizer
• Air Flow Range:
3,000-75,000scfm / Single Unit
70,000-500,000scfm / Multiple Units
• Concentration Range: 0%-25% LEL
• Energy-Efficient Operation (True 95%+ Thermal Energy Recovery)
• High Destruction Rate Efficiency (DRE)
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ANGUIL RTO Options & BenefitsOptions:
• Random Packed or Structured Ceramic Heat Transfer Media
• Forced or Induced Draft Configurations
• Standard Steel or Alloy Construction for Corrosive Applications
• Supplemental Fuel Injection
Benefits:
• Factory Tested
• PLC-Based Controls with Multiple Safety Functions and Recording Features
• Fast Acting, Reliable Valves
• Self Sustains at LELs as low as 3%, Reducing Operating Costs
• Low Pressure Drop Reduces Electrical Consumption
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ANGUIL RTO Mode of Operation
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ANGUIL ValvesTypes of Valves:
Poppet Valves (Horizontal and Vertical)
Butterfly Valves
Rotating (Single) Valves
Modes of Operation
Pneumatic
Hydraulic
Why Vertical Poppet Valves?
Maintenance
Design
Cost
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ANGUIL Poppet Valve Operation
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ANGUIL Poppet Valve Photos
Dual Sealing Disks minimizes the
valve’s overall stroke length.
(12” Maximum)
Upper and Lower Machined Seats are removable for easy
replacement.
Bolted Service Access Opening provided on other side. (Door is attached in this picture.)
Seal Disk
Support Disk Machined Seat
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ANGUIL Poppet Valve PhotosLinear Actuator
4-way Solenoid
Valve Assembly
Actuator Supports
Poppet Valve Assembly attached to RTO Canisters
Bolted Access Doors provided for service of Sealing Disks.
Bolted Access Doors provided for lower bearing service.
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ANGUIL
Process
99.5% D.R.E. –3 CHAMBER
DESIGN Purge Blower
Process
Purge Blower
Process
Purge Blower
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ANGUIL99.5% DESTRUCTION EFFICIENCY –
3 CHAMBER DESIGN
� Six controlled butterfly valves
� Third can is purged following valve change to direct untreated VOCs into purification chamber
� 90 second cycle time per bed
� Shorter cycle time leads to higher thermal efficiency
� Higher destruction efficiencies than 2 chamber design
� Higher capital cost than 2 chamber
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ANGUIL 3 Chamber Design
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ANGUIL Butterfly Valves
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ANGUILFluid Flow Modeling for Proper
Airflow Distribution
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ANGUIL RTO Media
Types of Heat Recovery Media– Random Packing
– Extruded Honeycomb Monolith
– Multi-Layered Media
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ANGUIL
Media: Random Packing / Saddles• Typically 1” or 1½”
• ½” – 3” available
Types Of Heat Recovery Media
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ANGUIL
Media: Random Packing-Others
• Ty-Pak
• Gravel, Rings,
Spheres
Types Of Heat Recovery Media
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ANGUIL
Media: Honeycomb Monoliths
• Variety of cell sizes and wall widths
• Typical block size: 150 x 150 x 300
Types Of Heat Recovery Media
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ANGUIL
Media: Multi-Layered
Koch Flexeramic
Lantec MLM
Types Of Heat Recovery Media
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ANGUIL Media Characteristics
Heat Transfer Efficiency & Rate
ft2/ft3Area /
Unit VolumeSurface Area
Pressure Drop%Open Volume /
Unit VolumeVoid Fraction
Thermal Storage –Heat Transfer
Ratelb/ft3
Weight / Unit Volume
Bulk Density
Primary Influence in Heat Transfer
English Units
Measurement
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ANGUIL
• Control fuel flow to burner
• Control air – fuel mixture
• Pilot Line
• Main Line size:
1”, 1½”, 2”, 3”
• Designs-Factory Mutual (FM)
-Industrial Risk Insurers (IRI)
• Supplemental Fuel Injection (SFI)
Fuel Train
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ANGUIL Supplemental Fuel Injection (SFI)
Why Use Supplemental Fuel Injection?• Reduces combustion air- flow, lowering operating costs
• Lower pilot rate for large burners
• Ultralow NOx emissions
Custom Designed Injection Quill Additional Fuel Train Piping
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ANGUIL Bake-Out Feature
Recommended for process streams with high boilers or condensables
Off-line bake-out feature
• Runs on reduced airflow of 25%
• Run until cold face reaches 600-900°F then redirect airflow
• Organics will volatilize
• Inorganic ash will remain
Valves and duct need to be insulated or guarded for personnel protection
For induced draft fan, dilution air added prior to reduce temperature
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer
Model 50
5,000 SCFM
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer – 3 Chamber
Model 50
5,000 SCFM
Wastewater Treatment Plant
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer
Model 75
7,500 SCFM
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer
Model 250
25,000 SCFM
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer
Model 350
35,000 SCFM
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer – 3 Chamber
(2) Model 350
70,000 SCFM
With Acid Gas Scrubbers
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer
Model 600
60,000 SCFM
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ANGUIL RTO Installations
Regenerative Thermal Oxidizer
Model 500
50,000 SCFM
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ANGUIL Catalytic Oxidizers
• Air Flow Range: 100-100,000scfm
• Concentration Range: 0%-25% LEL
Generally Used With:
• Low Process Volume
• High VOC Concentrations
• Weight & Capital Cost Limitations
• Dilution Air Is Available & No Catalyst Poisons Exist
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ANGUIL Catalytic Options & Benefits
Multiple Catalyst Options:
• Pelletized
• Monolith
• Precious & Base Metals
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ANGUIL Catalytic Oxidizer Installations
Catalytic
Recuperative Oxidizer
Model 75
7,500 SCFM
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ANGUIL Catalytic Oxidizer Installations
Two Catalytic
Recuperative Oxidizers
Model 350
35,000 SCFM
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ANGUIL Catalytic Oxidizer Installations
Catalytic
Recuperative Oxidizer
Model 800
80,000 SCFM
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ANGUIL Thermal Recuperative Oxidizers
• Air Flow Range: 100-40,000scfm
• Concentration Range: 0%-50% LEL
Generally Used With:
• High Process VOC Concentrations
• Captial Cost Limitations
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ANGUIL Heat Recovery
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ANGUIL Thermal Recuperative Oxidizers: Direct Heat Recovery
High exhaust temperature allows for direct heat
recovery back to ovens
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ANGUIL Thermal Recuperative Installations
Thermal Recuperative Oxidizer
Model 50
5,000 SCFM
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ANGUIL Thermal Recuperative Installations
Thermal Recuperative Oxidizer
Model 70
7,000 SCFM
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ANGUIL Thermal Recuperative Installations
Thermal Recuperative Oxidizer
Model 110
11,000 SCFM
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ANGUIL Concentrators
Technology Applicability:• Airflows > 5,000 SCFM. Lower flow rates generally make this
technology uneconomical.• Inlet Temperature < 100ºF (40ºC)• VOC Concentrations < 500 ppm. Higher concentrations reduce
concentration factor making this technology uneconomical.• DREs < 99%• Relative Humidity < 90%
Converts high process air volumes with low VOC concentrations into a low volume, higher concentration stream.
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The Zeolite WheelANGUIL
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ANGUIL Concentrators
Industry Applicability:• Concentrators handle increased exhaust flow caused
by capture requirements or PTEs.• Concentrator allows existing oxidizer to be utilized
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ANGUIL Concentrator Installations
Model 400 – 40,000 SCFM – Rotor Concentrator
Coupled with an 5,000 SCFM Regenerative Thermal Oxidizer
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ANGUIL Concentrator Installations
Model 450 – 41,000 SCFM – Rotor Concentrator
Coupled with an existing 2,750 SCFM Regenerative Thermal Oxidizer
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ANGUIL Concentrator Installations
Model 800 – 80,000 SCFM – Rotor Concentrator
Grouped with two Model 250 – 25,000 SCFM –Regenerative Thermal Oxidizer
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ANGUIL Concentrator Installations
Model 1300 – 127,000 SCFM Rotor Concentrator
Coupled with a Model 75 – 7,500 SCFM Thermal Recuperative Oxidizer
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ANGUIL Heat & Energy RecoveryAir To Air, Heat Exchangers!
Typical Applications Include:
• Recover exhaust stack heat for use in industrial ovens and dryers
• Recover exhaust stack heat for other plant and/or process heating applications
• Upgrade Heat Efficiency of existing VOC control equipment
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ANGUIL Heat Exchanger Types
Plate Shell-and-Tube
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ANGUIL Heat Exchanger Options
Material: Typically Specified For:
304SS Non corrosive applications up to 1200°F (650°C)
316SS Chloride corrosion resistance up to 1200°F (650°C)
321SS Non corrosive applications up to 1800°F (980°C)
309SS Additional temperature resistance
Hastelloy Specialty alloy for corrosive airstreams
Other Alloys 254 SMO, AL6XN, 600 & 800 Alloy, 2205 Duplex, and others available upon request
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ANGUIL Heat Exchanger Options
• Multiple Flow Patterns
• Vertical or Horizontal Orientations
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ANGUIL
Thank You!Thank You!Thank You!Thank You!
ANGUIL ENVIRONMENTAL SYSTEMS, INC.
8855 N. 55th Street · Milwaukee, Wisconsin 53223
Phone : 414-365-6400 · Fax : 414-365-6410
www.anguil.com
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