How to Optimize Plant Production Through Air Pollution Control Integration

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Improved overall operating results of your facility are attainable by considering the entire plant operation rather than sub-optimizing choices around the air pollution control (APC) equipment. By taking a holistic view of the entire facility, it is possible to develop and execute innovative air control solutions that reduce overall energy consumption and improve plant operability.

Key APC System Aspects to Consider

Each pollution control technology has strengths and weaknesses, which depend upon the application and the process conditions for which it’s used. When assessing air treatment equipment, do not overlook system aspects such as: suitability with the exhaust stream composition, reliability and maintenance of the equipment, the degree of equipment automation, its effects on production processes, and opportunities to integrate with other process heating requirements.

Standard Air Abatement Technology for VOCs

Many industrial processes involve a heating stage during production that generates an exhaust gas containing Volatile Organic Compounds (VOCs) or other pollutants that must be treated prior to its discharge into the atmosphere. Thermal oxidation of VOCs to less harmful carbon dioxide and water typically occurs at 1250 – 1650 °F to achieve target air emission requirements.  Standard air abatement equipment used to destroy VOCs and HAPs includes:

• Regenerative thermal oxidizers
• Recuperative thermal oxidizers
• Direct-fired thermal oxidizers
• Enclosed Flares
• Catalytic oxidizers

How Can Recovering Energy with Air Pollution Control Equipment Optimize Facility Performance?

Due to the high temperatures needed to destroy VOCs, APC technology can recover the energy and use it in different ways. Some recovery scenarios include:

• Using Recovered Energy to Preheat Fresh Air – This approach, often via a secondary heat exchanger on a high-efficiency recuperative thermal oxidizer, was shown to reduce overall fuel consumption by more than 50 percent for an animal feed-products manufacturer.
• Using Available Energy for Process Ovens – Utilizing a recuperative thermal oxidizer with parallel heat exchangers can provide preheated air to process ovens (e.g., 950°F), eliminating the need for auxiliary oven burners while providing stable pressures and low maintenance.
• Using Energy From Exhaust for Process Boilers – Where process stream content (particulate/condensables) requires a direct-fired oxidizer (DFTO), the high-temperature exhaust can be routed to a boiler system to recapture significant energy and offset high DFTO operating costs.

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