Embed Size (px)
Citation preview
T H E R M A LOX IDAT ION FOR THE ABATEMENTOF VOLATILE ORGANICCOMPOUNDS (VOC)AND ODOURS INGASEOUS EFFLUENTS
A POINT OF REFERENCEIN ENVIRONMENTALT E C H N O L O G Y
B A B C O C K W A N S O NSOLUTIONS TROUGHOUT
THE WORLD
Sist
ema Certificato
Certified Syst
em
ISO 9001
Italy
BABCOCK WANSON ITALIANA S.p.A.Via Roma, 14720040 Cavenago Brianza (MI)ItalyTel. : 0039 02 95912.1 r.a.Fax: 0039 02 [email protected]
Central Europe
CNIM BABCOCK s.r.o.Evropská 175/115160 00 Praha 6Czech RepublicTel. : 00420 2 25 43 31 12Fax: 00420 2 25 43 31 [email protected]
France
BABCOCK WANSON SA106/110, rue du Petit Le Roy94669 Chevilly Larue CedexFranceTél.: 0033 01 49 78 44 00Fax: 0033 01 46 86 14 [email protected]
• Nerac:7, bld du Midi - B.P. 5247600 Nerac - FranceTél.: 0033 0553 65 19 00Fax: 0033 05 53 65 17 33
Portugal
BABCOCK WANSONCaldeiras LdaRua dos Transitários, 182Salas BS e BT4455 - 565 Perafita - PortugalTel.: 00351 22 999 94 90Fax: 00351 22 999 96 [email protected]
United Kingdom
BABCOCK WANSON UK Ltd7 Elstree WayBorehamwoodHertfordshire WD6 1SAUnited KingdomTel. : 0044 208 9537111Fax: 0044 208 [email protected]
Morocco
BABCOCK WANSON MAROC SAPiste d’Ain BordjaAin Sebaa - 21600 - CasablancaMoroccoTél.: 00212 22340101Fax: 00212 [email protected]
Spain
CALDERAS Y PROYECTOSBABCOCK WANSON SABarrio San Martin Avda. Pinoa S/N48170 Zamudio (VIZCAYA)SpainTel.: 0034 94 4523036Fax: 0034 94 [email protected]
BABCOCK WANSONThe companies forming our International Group combineunparalleled experience and expertise in ThermalEngineering applications gained over 60 years ofprogressive development. Group companies are active inItaly, France, United Kingdom, Spain, Portugal,Switzerland, Morocco and Central Europe.Our Group activities are principally in the fields of processair treatment, steam and thermal fluid industrial boilers andwater treatment.With many hundreds of installations for VOC and Odourabatement we hold an ideal position to provide completeand tailor made solutions for each industry following theenvironmental and safety regulations in force in thecountry of installation.
The Babcock Wanson Thermal Oxidiser Range
Gas and VOC effluents produced by variousmanufacturing processes have to be treated in order toachieve the quality required by prevailing regulationsbefore discharge to atmosphere.The pollutants concerned contain mainly carbon,hydrogen and oxygen linked as compounds dangerousto the natural ecosystem.In order to make these compounds safer, it is necessaryto break up the links which keeps groups of atomschemically together to produce more acceptableproducts such as water (H2O), Carbon Monoxide (CO),Carbon Dioxide (CO2), Oxygen (O2) and Oxides ofNitrogen Oxide (NOx).Among the options offered by technology andregulation, the most effective and widely used is thermaloxidation where pollutant gases are treated by heatingthem in a combustion chamber at high temperature.Babcock Wanson has a very wide and successfulexperience of VOC and Odour Thermal Oxidation usinga variety of thermal methods combined with heatrecovery systems.
The local and national regulations developed fromEuropean Directives concerning emissions toatmosphere of VOC and Odours are progressively beingenforced by all member countries of the EuropeanCommunity.Babcock Wanson Oxidisers are designed to comply withthese directives and to provide the answer to manyprocess problems with both classical and advancedinnovative solutions amongst which includeRegenerative Oxidisers for deodorisation, RegenerativeOxidisers for high VOC concentrations and CombinedRegenerative/Recuperative plants.
FUELCONTAMINATED AIR
GASVAPOURAND VOC
INTERNALENERGY
RECOVERYRECOVERY
TYPE
EXTERNALENERGY
RECOVERY TOSteam
Thermal OilAir
Pressurised water
BABCOCK WANSONTHERMAL OXIDISERS
EMISSIONS TOATMOSPHERE
COMPLIANT WITHREQUIRED STANDARDS
AND REGULATIONS
CHAMBER TEMPERATURE 700÷1100° CRESIDENCE TIME 0,6÷2 seconds
REGENERATIVETYPE
A Complete Service for Industry
• Preliminary project study• Gas effluent analysis• System circuit proposals for pipework and ducting• Installation design including pipework, thermal fluid
systems, steam boilers and electrical and process andinstrumentation design
• Equipment manufactured in our factories, utilising latestmanufacturing techniques
• Complete pre-assembly and works testing• Start up, commissioning, training, certification and
approvals• Planned maintenance or on call service• Spare parts
Babcock Wanson factory - ItalyRecuperative oxidiser of 45,000 Nm3/h under construction.
1
2
B A B C O C K W A N S O N
Recuperative Thermal Oxidisers
The number and position of the heat recovery units ineach plant varies according to specific individual designrequirements. These recovery devices are also designedand manufactured by Babcock Wanson.
Advantages
• Continuous regulation of emissions.• Simplicity of control and management.• Quick start up.• Heat energy recovery.• Safety and reliability with full hazard audit.• Range of effluent 1,000 to 60,000 Nm3/h.
CONTAMINATED AIR & GAS TO BE TREATED
FUEL
FAN
COMBUSTION CHAMBER PROCESS GASSTREAM PRE-HEATER
HEAT RECOVERY UNIT
HEAT RECOVERY TO:• Hot water• Pressurised high
temperature water• Steam.• Thermal Fluid.• Air
CHIMNEY
SAFETY BY-PASS
Aluminium foil printing. Effluent gas • 45.000 Nm3/hThermal fluid heat recovery.
The process plant includes:
• A fan with inverter speed regulation to vary the inputflow.
• A pre-heater for the effluent air.• The Oxidiser.• Control panel for system regulation with PLC for the
management of the operating cycles plus operatorinterface panel with LCD touch screen and temperaturerecorder/controller.
• Heat recovery units which can recover heat into thermalfluid, steam hot water or high temperature pressurisedwater and/or air.
The simplest and safest method of treating polluting VOCs is to oxidise them by heating in a combustion chamber at a temperaturein the range 700÷1100 °C (typically about 750 °C) with a residence time of between 0.6 and 2.0 seconds (typically about 0.8”).
3
Pharmaceutical Industry • Twin Oxidisers with recovery toair and water • Effluent gas • 6,000 Nm3/h
Leather cloth Manufacturing • Effluent gas20,000 Nm3/h • Thermal Fluid Heat Recovery
Flexible Packaging PrintingEffluent gas • 18,000 Nm3/h • Thermal Fluid Heat Recovery
Petro-Chemical PlantOxidiser with integrated thermal fluidheat recovery
4
B A B C O C K W A N S O N
Ceramic Regenerative Oxidisers
Superficial coils treatment • Twin regenerative oxidisers45,000 Nm3/h installed in different period of times
Lithography on metal support • 36,000 Nm3/h
Chemical industry • 18,000 Nm3/h
Ceramic Regenerative Oxidisers are used in cases wherethe requirement for heat recovery does not exist or is toosmall to justify employing a Thermal Recovery Oxidiser.
The Regenerative Oxidiser includes:
• Effluent fan with automatic output control system.• Heat storage towers filled with ceramic, which may be
saddles or honeycomb structures selected to suit therequirements of the application.
• A system of automatic valves for effluent distributionthrough the towers. These are of exclusive BabcockWanson design and manufacture. The valves can be fittedunder or next to the towers, according to technical and sitespace requirements.
• Combustion chamber with one or more modulatingautomatic gas/fuel burners.
• Control panel with: PLC for the management of theoperating cycle, operator interface panel with LCD touchscreen and temperature recorder.
Advantages
• The effectiveness of the abatement of VOC emissions isequal to that of a thermal recovery oxidisers, whilst theNOx emissions results are lower
• Continuous regulation of the emissions• Simplicity of management• Reduced maintenance• Reduced gas/fuel consumption: the Regenerative
Oxidiser can achieve auto-thermal conditions with lowconcentrations of VOC
• Self contained plant which does not produce waste heatfor reuse in the production cycle and therefore does notneed an additional heat distribution system
• Range from 1,000 to 150,000 Nm3/h.
EXHAUSTGAS
OUTLET
AIRPROCESS
INLET
S 1 S 2
FRESHAIR
AIRPROCESSBY-PASS
INLETGAS
VOC EMISSION
inversion time for air dampers
mN/
gm
3 TOWERS
2 TOWERS + COMPENS
2 TOWERS
AIRPROCESS
INLET
S 1 S 2
FRESHAIR
AIRPROCESSBY-PASS
EXHAUSTGAS
OUTLET
INLETGAS
S 1 S 2 S 3
INLETGAS
EXHAUST GASOUTLET
PROCESS AIRINLET
PROCESS AIRBY-PASS
FRESHAIR
INLETGAS
5
Ink production • 50,000 Nm3/h Rubber vulcanising • 30,000 Nm3/h
Regenerative Oxidisers can be constructedin the following configurations:
• 2 tower• 2 tower plus compensation tower to
reduce the emission peaks• 3 tower to achieve lowest emission levels • 5 tower for high volumes of effluent
The choice depends on:
• Concentration and nature of the VOC to betreated
• Available space
The following chart indicates the rate of VOCemission for the different arrangements.
6
Regenerative Oxidiser with heat recovery
In many cases the polluted air contains very highconcentrations of VOC demanding the disposal of largequantities of heat. It is therefore essential to provide acontrol system for the temperature in the combustionchamber (hot gas by-pass) and sometimes it can bebeneficial to fit an additional heat recovery unit to heatair, water or thermal oil.
Babcock Wanson specialise in the design andmanufacture of these heat recovery systems, whichhave been part of our production programme for manyyears.
01BSA
SCI01
01PT
PSH01
01
BV01
TCV02
03
04
FV401
TE302
TRI01.3
301TE
302TISH
202TE
TISH20201.2
TRI
201TETE
101
TISH102
TRI01.1
TE102
PDSL01
505TE
TISH505 01.4
TRI
02PDSL
S 1 S 2 S 3
EXHAUSTGAS OUTLET
01TIC
01TIC
V01
01TRA
BSH01
BV05
03
08
07
TCV04
TRA02
BSA02
BSH02
PIC01
02 06
FV101
102FV
FV201
FV202 302
301FV
FV
103FV FV
203 303FV
PSL01
PSL02
402
403FV
FRESHAIR
03PSL
PSH02
04PSL
02VPS
INLETGAS
INLETGAS
VPS01
PDSL502
503TISH
503TE
501
VO2
SCI02
TE502
TI502
FV FV504
OUTLETWATER
INLETWATER
V03
TSHH503
PSHH503
501TE
501TISH
FV501PSL PSL
504
PROCESSAIR BY-PASS
PROCESSAIR INLET
TCV
BV
BV
BV
BV
BV
BV
TCV
Fabric coating • 50,000 Nm3/h Thermal fluid heat recovery
Rotogravure printing on flexible support • 40,000 Nm3/hAdesive tape production • 13,000 Nm3/h
7
Paint production • 70,000 Nm3/h
Car industry • 120,000 Nm3/h Special paper • 10,000 Nm3/h
FILTER
M
PI
PROCESS AIR
CONCENTRATOR
TI PI
TI PI
PI
SCI
M
M
DPS
RT
DPS
TE TIS
TE
INLET GAS
DPS
DESORBSION
AIR
PRE-HEATER
TE TICS
TICSTR
TE
PIC
SC
PT
TI
SSLH
ALL. BLOC.
DPS
FRESH AIR
CHIMNEY
POLLUTED AIR
PRE-HEATER
COMBUSTION
CHAMBER
Rotoconcentrator
When the quantity of the air to be treated is very high and theconcentrations of VOC very low, it is necessary to employ adesign which reduces the volumes of air to be treated in theOxidiser and at the same time increases the concentration ofVOC in order to reduce operational and capital costs.The rotoconcentrator with zeolite allows this to be achieved,reducing the volume of air and increasing proportionally theconcentration of VOC.The rotoconcentrator is coupled to a Thermal RecoveryOxidiser or a ceramic Regenerative Oxidiser with reducedflow, which treats an effluent gas stream with high VOCconcentration and therefore consumes very little support fuel.The quantity of effluent delivered to the oxidiser falls toapproximately 1/10 to 1/15 of the total amount of effluentfrom the process.
8
B A B C O C K W A N S O N
Deodorising OxidisersRendering industry • Recuperative oxidiser
Rubber industry • Regenerative oxidiser
These applications can usetraditional fuels and/or inmany cases, special burners.An example of this is theburning of animal tallow asthe support fuel.
Frying • Recuperative oxidiser
Rendering industry • Regenerative oxidiser
Recovery and Regenerative Oxidisersare also utilised to eliminate odours andvapour emissions generated by manyproduction processes.These are specially designed plantstailored to meet the particular requirementsof these industrial processes.Babcock Wanson is the leadingcompany in Europe in this field havingcompleted many successful installationsoperating in the following industries:• Animal tallow production (rendering).• Industrial frying processes (potatoes,
meat products etc.).• Food industries.• Various chemical processes.• Coffee and barley roasting.• Rubber vulcanising and moulding.Babcock Wanson technicians areavailable to offer the most suitablesolution for each specific case.
CONTINUOUSCOOKER
BATCH COOKER
WASH WATEREVAPORATOR
DECANTER
PRENSAS
MULINO
BINS AND SCREWS
EFFLUENT(VAPORS+INCONDENSABLES)
QUENCH SYSTEM
EFFLUENTFAN
FRESH AIR
BY-PASS
CHIMNEY
COMBUSTION CHAMBER
AIR COMBUSTIONFAN
CONDENSATE RETURN
STEAM
FEEDWATER
BURNER
VAC
EFFLUENT(VAPORS+INCONDENSABLES)
QUENCH SYSTEM
CONTINUOUSCOOKER
EFFLUENTFAN
MP
THERMAL OIL
BATCH COOKER
WASH WATEREVAPORATOR
DECANTER
PRENSAS
MULINO
BINS AND SCREWS
FRESH AIR
BURNERCOMBUSTION CHAMBER
BY-PASS
CHIMNEY
AIR COMBUSTIONPRE-HEATER
RECOVERY UNITTHERMAL OIL
AIR COMBUSTIONFAN
9
Rendering industry • Heat recoveryoxidiser for steam production
Rendering industry • Heat recoveryoxidiser for steam production
Rendering industryThermal fluid heat recovery oxidiser
RENDERINGOur Deodorising Oxidisers are well known all over Europe as thebest technology to eliminate the odours from the effluents of:cookers, sterilisers, presses, decanters, material storagehoppers, etc. The option to select a system with heat recoveryor a ceramic regenerative oxidiser is determined by the specificrequirements of each customer and according to the quantity ofvapour and air to be treated.A major factor in the choice is the type of fuel that is availablee.g. gas, heavy fuel oil or tallow.
Industrial frying of vegetable oils and meats
These normally use COMBI oxidisers for relatively low effluentinput, serving one or two deep-fryers. For large industrialoperations where multi cookers may be installed and the volume ofpolluted air to be treated is large, an installation incorporatingRecuperative Oxidisers with separate heat recovery units orRegenerative Oxidisers would usually be required.
10
Application fields
Babcock Wanson plants, which have been shown toachieve emission levels (TOC, CO NOx) in line withdiverse European regulations are employed in a widevariety of applications, such as:
Metal finishing • 12,000 Nm3/h Rotogravure printing • 20,000 Nm3/h
• Printing on metal cans and containers with productscontaining ketones, acetates and hydrocarbons.
• Flexible packaging manufacture (paper, carton, plasticfilms and aluminium), where coating, laminating andprinting take place with inks containing acetates,glycols and hydrocarbons, together with solvent basedlaminate adhesive.
• Timber composite production using solvent basedsprays and lacquers containing VOCs of several classesand concentrations.
• Plastic laminating and forming processes with resinscontaining phenol, formaldehyde, methanol, MEK, MIBK,glycol and various other VOCs.
• Adhesive tape coating lines and adhesive productioncontaining toluene, acetates, alcohols, silicones,hydrocarbons and other VOCs
• Metal treatment industries, which utilise systems for thespraying, immersion or impregnation application ofsolvent products (epoxy, alkyd and polyurethane)containing VOCs of several types.
• Glass-resin and/or reinforced manufactured goodswhere resins containing styrene and ketones are used.
• Textile and clothing where surfaces are chemicallytreated with resins containing various VOCs.
• Simulated leather production using printing lines withinks containing acetates, ketones, glycol andhydrocarbons.
• Production of printed paper by roto-off-set androtogravure processes using products containingketones, acetates, alcohols and hydrocarbons.
• Various applications in the pharmaceutical andrelated industries including dyestuffs and rubbermanufacture. High temperature vitreous enamellingof household articles, the production of expandedhydrocarbons based material and other chemicalindustries. These emissions can contain VOCs of anumber of different types.
• Automotive spray finishing booths where sprayapplication of solvent products containing VOC ofvarious classes takes place.
11
Other Babcock Wansonproducts and technologies
• Thermal oil heaters; vertical and horizontal coil ormulti-tubular with high efficiency
• Heat exchangers• Steam and high temperature hot water boilers;
vertical and horizontal coil or fire tube, instantsteaming and high efficiency
• Design and supply of thermal plants and turnkeyinstallations
• VOC Recuperative and Regenerative ThermalOxidisers.
• High temperature air generators for drying andcuring.
• Oxidisers for exhaust treatment from gas turbines.• Gas burners in air stream ducts.• Heat recovery from process gas streams and from
cogeneration plants, coil or multi-tubular. • Supply only or turnkey plants
• Filtration and settling• Total softening• Decarbonisation• Total demineralisation• Reverse osmosis• Thermal degassing• Biological monobloc treatments• Potable water plants• Design and supply or thermal power plants and
turnkey plants
Industrial boilers
Air treatment
Water treatment
12
Babcock WansonServices
Annual maintenance contracts with extended burner guarantee:
• Planned preventive maintenance
• Supply/installation of burner wear parts
Water treatment follow-up contracts
• Performed by specialised teams
• Guarantee of water quality through regular checks
• Reduction of costs through optimised consumption ofconditioning products and reagents
• Regulation and refinement of treatment regime as part ofan ongoing contract.
Global offer total guarantee contracts
• A total guarantee.
• Peace of mind for the operator.
• Controlled, fixed costs.
• Improved standards of quality and safety.
Preventive and corrective maintenance contracts to suit customer needs.BABCOCK WANSON offers:
2
3
4
Customised annual technical assistance contracts:
• For Oxidisers and peripheral equipment
• With monitoring of operating parameters, safetysystems, emissions and performance levels
• Advanced planning for scheduled inspections duringoperation or shutdown
• With or without supply of consumable materials, wearparts, and conditioning products
Performed by qualified teams within the scope of theISO 9001 QUALITY standard.
Advantages of these contracts
• Greater savings:Regular checks and appropriate adjustments reduceconsumable material consumption and the operatingcosts of the plant
• Improved safety:Planned inspection of the regulating, control andmonitoring systems helps prevent costly shutdowns.
• Compliance with regulations is ensured on acontinuous basis.
• Improved reliability and longer service life.With regular maintenance by professionals your plantwill have a higher availability and a longer service life.
• Training of your site staff.Operating and maintenance personnel can completetheir technical knowledge and benefit from the detailedinformation and advice given by our technicians duringtheir visits.
1
YEARS EXPERIENCE OF FORMAL TRAINING30
An approved training establishment for your service, maintenance and operating personnel, either in-house or externally.
13
Customer Support is a complete service extendingfrom the design activity to the manufacture andmanagement of the thermal equipment.
Services include
Approved Training Centre
• Design and proposals.
• Replacement of existing plants.
• Equipment optimisation.
• Water treatment installation management and service.
• Technical assistance and rapid response with technicians located throughout Europe.
• Spare parts.
• Maintenance contracts.
• Statutory inspections.
• Upgrading of existing plants.
• Training.
• Site installation and turnkey plants.
BA
BC
OC
K W
AN
SO
N r
eser
ve t
he r
ight
to
mod
ify t
hese
spe
cific
atio
n w
ithou
t no
tice
