Feasibility Viability Study

A Pet Food Processing site came to us with the issue of foul-smelling odour complaints from local residents and was looking for a new odour treatment system across all process lines.

A Pet Food Processing site came to us with the issue of foul-smelling odour complaints from local residents and was looking for a new odour treatment system across all process lines.

The odour issue had been ongoing, and in the past electrostatic precipitation and deodorizing chemicals were trialled alongside the original absorption column, however, these methods were unsuccessful. Incineration of the waste gases was one of the methods being investigated, but it wasn’t in use on site.

We investigated the use of incineration, combined with heat recovery to access the suitability and viability of this method for the site and we came to the conclusion that a brand new treatment system was needed in order to fix the problem. Incineration of the waste gases works very effectively as an odour remover.

We were provided data from the previous site survey on the waste gas and from this information, the incinerator was sized and methods of heat recovery was analysed in order to maximise the heat recovery.

The best payback came from recovering 500 kW of waste energy to 13,000 kg/h hot water production.

The combined foul gases flow rate was circa 300,000 m3/h and we figured that the gases needed to be incinerated to 820-degree Celsius for two seconds to ensure full incineration. This leads to a large flow rate of natural gas being required, although this was minimised by pre-heating the waste gases and combustion air from the incineration exhaust. However, even after this, there was scope to implement another heat exchanger to further recover heat to another process.

A number of cases were created using different heat exchanger designs recovering waste heat to produce hot process air and hot water production, for use on site.