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Case Studies - Solutions in The Field
Wood Products - Veneer Dryers
Situation
As part of a large wood products manufacturers MACT compliance project PEI supplied Thermal Catalytic Oxidizers for the veneer dryers located at three different facilities. These applications required a system providing the lowest overall cost of operation capable of handling the difficult process stream while meeting all MACT requirements.
Solution Provided
A two canister TCO was supplied for each facility, each was supplied with corrosion resistant materials of construction to handle the high moisture content in the process steam. A precious metal catalyst specially designed for higher destruction efficiency and a higher tolerance to masking agents was installed.
Industry
Wood Products
Type of Product
Thermal Catalytic Oxidizers
EPA - Compliance
All three systems were installed and started-up on schedule. Performance testing was conducted and all three met or exceeded permit requirements. A series of tests were conducted to determine the minimum operating temperature and therefore lowest fuel cost necessary to achieve the permit requirements. In all three applications we were able to operate the units at a control temperature which required zero supplemental fuel.
Distillers Dried Grains with Solubles Dryer Emissions /Ethanol Production
Situation
The process stream being treated is the exhaust from the DDGS (Distillers Dried Grains with Solubles) rotary dryer. This application provided special challenges for the RTO design: 1: Constantly varying and very low oxygen content, 2: High moisture content with corrosive compounds, 3: High required destruction efficiency
Solution Provided
Three canister, purged design fabricated completely from corrosion resistant materials. The burner systems and combustion air blower were specially designed to address the constantly varying combustion air requirements.
Industry
Ethanol
Type of Product
Custom designed, 3 cylinder Thermal Oxidizer
EPA - Compliance
Unit was installed and started up on schedule; performance testing was conducted a few weeks after the equipment was fully operational and met or exceeded the EPA standards.
Converting & Coating - Chlorinated Solvents
Situation
A major coater of plastic film needed a large RTO to handle emissions comprising chlorinated solvents and conventional (non-halogenated) solvents.
Chlorinated solvents, when oxidized at high temperatures, are converted to hydrogen chloride gas (HCl).
When HCl is present, any moisture in the air flow would create hydrochloric acid. Failure to design properly for this would result in excessive corrosion and shortened life for any wetted metal surfaces.
Solution Provided
A multi-canister RTO, sized to handle 170,000 SCFM was provided, as was a caustic scrubber designed to convert the acid gas to harmless sodium chloride (NaCl) that could be legally sewered.
It was decided that we would use a combination of acid brick, insulating blocks, and an engineered polymer shield to prevent acid from damaging the inside of the RTO shell.
Industry
Converting & Coating
Type of Product
Regenerative Thermal Oxidizer and Caustic Scrubber
EPA - Compliance
Extensive testing was conducted to prove compliance with all governmental regulations. Additional testing, over and above any regulatory requirement, was done to ensure that the presence of chlorides did not result in formation of dioxins and furans.
 

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