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Reducing Emission Costs on Coffee Roasting, Fishmeal, Rendering and Bakery Plants
Many coffee roasting, rendering, fish meal and bakery facilities when installing additional equipment or when
adding or starting a new plant find themselves having to control emissions and odor. Emissions and Odors
where earlier controlled by afterburners or flares. However, with the rising costs to operate these flares or
afterburners, alternative innovative air pollution control technologies has become an effective means to plants
emissions, likely in large by economical consideration.
Comparative Flare (Afterburner) To Regenerative Thermal Oxidizer and Carbon Filtration System
Manufacturers of air pollution control equipment have realized the need to design a solution for the rendering,
fishmeal, coffee roasting and baking industry. With Odor and VOC compliance and permitting in mind the focus
was placed on a cost effective means. Both the ReGen (RTO) Series and Carbon Filtration System was
introduced in these industries more recently, changing from the flare or afterburner system to a more
economical system that will operate on a very small percentage of previously installed flare operating costs.
Comparing a typical coffee roasting, fishmeal or bakery waste process application with an operating exhaust
requirement of 10,000 SCFM direct fired or afterburner oxidizer will generally have costs range over $50.00 per
hour. Regenerative Thermal Oxidizers and the no fuel Carbon Filtration system has a much lower operating
cost and generally will operate from the $3.00 Carbon Filtration System to the ReGen (RTOs) $18.00 per
Most often with Odor Control and VOC abatement a DRE of 98% will meet all State and Federal permitting
requirements. This means that a two can regenerative thermal oxidizer system may be utilized on these types of
projects or the carbon filtration system. On the regenerative thermal oxidizer the waste stream is preheated as it
passes through the heat recovery chamber lined with structured ceramic media on its way to the burn chamber.
The burn chamber will oxidize the volatile organic compounds which releases BTU energy into the combustion
chamber on its way to the second heat recovery chamber before exhausted into the environment. When
discussing the Carbon Filtration System the plant process waste gases will pass through the granulated carbon
bed where the emissions are trapped then cleaned as part of a going cleaning process. Microbes digest the
emissions within the cleaning process and provide a 99%+ destruction rate.
When considering equipment upgrade or change, one should understand the makeup of the waste process
stream. Commonly when converting from a flare or afterburner system your water process vapor may
occupy a concern and consideration should be given in the design phase the new system. When the waste
process has a high moisture content of water, precautions should be taken into consideration and removal of
some of the excess moisture upstream from the system. When the plant has high levels of excess moisture it
may require a knock out tank and associated discharge pump to recycle the water back into the plant process.
Regenerative thermal oxidizers are able to accept large amounts of moisture within the oxidation process and a
satisfactory operating range is between 35% to 85% RH without the use of a condensation tank.
Often in these types of plant operations considerations should be given to the amount of particulate
matter in the waste stream. When plant operations have higher levels of particulate matter special ceramic
media should be utilized or a separate bag house should be adopted. Regenerative Thermal Oxidizers should
adopt a burn-out cycle which acts as a self cleaning feature by super heating the lower areas of the ceramic
media bed and burning off any particulate matter that has not been able to cycle through the system. This self
cleaning feature will prevent any plant down time from media bed plugging and reduces any unwanted pressure
drops within the system.
If a bag house is not in place and the regenerative thermal oxidizer equipment is adopted, the burn out cycle
should be part of a regular maintenance program and will only require a few hours per year. On the
regenerative thermal oxidizer system the fully automated burn out cycle can be operated from the HMI screen or
control room and requires no manual intervention.
Often plants require the use of steam in their operations. Regenerative Thermal Oxidizers may be fitted
with in line duct heat exchanger; these heat exchanger's provide heat used in the plant process.
Heat exchanger's can provide cost revenue savings within the plant and provide heat during the winter
months. Other plant applications may include direct air waste heat from the stack to an application such as
roasters. This direct use of exhaust heat will also assist in the reduction of fuel consumption on plant operations.
Air Pollution Control Equipment
American Environmental Fabrication & Supply, LLC
ReGen (RTO) Series
Filtercrobe I Series
Call +1 (918) 708 - 1253