1. Energy recovery and odoUr reduction in petfood production
Company Presentation
Energy recovery and odoUr reduction in petfood production
Tjitze Smit

2. programme About Graintec Odour reduction Energy recovery
Company Presentation
programme
About Graintec
Odour reduction
Energy recovery
Summary remarks

3. About graintec Worldwide assignments …
Company Presentation
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 …

4. OUR KEY CLIENTS All Internationally Operating Companies
Company Presentation
OUR KEY CLIENTS
All Internationally Operating Companies
And many more …

5. ODOUR Reduction

6. Odour Concentrations OU/m3
Odour concentration may fluctuate significantly from plant to plant!

7. 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.

8. ODOUR EMISSION OU/H PET FOOD FACTORY 2 LINES
13% of total odour emission

9. Environmental Solutions
Cleaning efficiency
1. Chimney
0 % (Only dilution)
2. Ozone Reactor (Plasma)
70 – 85 %
3. Bio or Chemical Scrubber(s)
70 – 90 %
4. Bio Filter
70 – 95 %
5. RTO Oxidizing
90 – 98 %
6. Recirculation/Condensation incl. Coal Filter
98 – 99 %

10. 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

11. 2. Ozone Reactor (Plasma): Efficiency 70 - 85%
Chimney
Cyclone/filter
Reactor
Dryer/cooler
Photo left:
APP plasma unit

12. 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

13. 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

14. 5. RTO Oxidizing: Efficiency 90 - 98%
Chimney
Dryer/cooler
RTO
oxidizer
Cyclone/filter
Photo left:
Regenerative thermal oxidizers

15. 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

16. 6B. Energy recovery and odour reduction
Reduction in odour emission: %
Thermal energy recovery: ~ 15 – 50 kWh/ton

17. Summary
Solution:
Cleaning efficiency
Capital investment costs for each cbm air/h to be cleaned
Annual operating costs for each cbm air/h to be cleaned
Chimney
0 %
Very low
Very Low
Ozone/plasma Reactor
70 – 85 %
Low
High
Bio/Chemical or Sea Water Scrubber(s)
70 – 90 %
Bio Filter
70 – 95 %
Medium
RTO Oxidizing
90 – 98 %
Very High
Recirculation/Condensa-tion incl. Coal/Bio Filter
98 – 99 %
Low*
* The annual operating cost for this solution is very low because the solution includes energy recovery!

18. Energy recovery

19. 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

20. ENERGY DISTRIBUTION THERMAL ENERGY CONSUMPTION
ELECTRICAL ENERGY CONSUMPTION

21. THERMAL ENERGY RECOVERY SOLUTIONS
Thermal energy for drying accounts for 60% of the total thermal energy consumption
4 solutions to recover energy from drying:
Cross flow air/air heat exchanger
Air/water heat exchanger
Air/water heat exchanger in combination with high temperature heat pumps
Air/water heat exchanger and recirculation of dryer air
All 4 solutions will in addition to energy recovery have an odour reduction effect off 30 – 85%
Additionnal air treatment system can increase odour reduction effect to 99%

22. 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

23. 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

24. 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

25. 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

26. Simulation program and pinch analysEs

27. 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

28. QUESTIONS ?

29. THANK YOU FOR YOUR ATTENTION !