Most manufacturing facilities utilize a Volatile Organic Compound (VOC) or Hazardous Air Pollutant (HAP) in their production process. These emissions are common in wood processing, coffee roasting, coil coating, ethanol production, roofing, printing, surface coating, municipal wastewater treatment, food processing, cement manufacturing, and many other major industries.
No two facilities are exactly alike; each has specific needs and objectives. Tailoring designs to their unique specifications is the only way to ensure optimum performance and achieve the best and most economical solution for their operation.
The shifting nature of many industrial emission sources and the potential for wild fluctuations among particular exhaust stream variables (such as air volumes, pollutant loadings, and varying combinations of pollutants) create additional challenges in terms of choosing the optimum system, managing stable operations, and managing costs.
NESTEC offers a complete review and analysis of the air emission control and energy conservation needs for each facility it studies, along with suggested options to achieve the desired results based on multiple conditions/requirements:
- The primary facility project objective:
- Regulator emission requirements
- Capital installation cost
- Operating cost
- Uptime reliability
- Maintenance
- Safety (link: Safety First | Nestec, Inc.)
- Emissions from multiple sources (which are often spread out over a wide area
- Emissions from batch operations)
- Multiple batch processes (each of which vents pollutant-laden emissions in unpredictable concentrations whenever the process is initiated or terminated)
- Unpredictable fugitive emissions
- Centralization of the control system (disparate airborne sources are often collected and concentrated)
- Creating as few streams as possible with the lowest overall exhaust air volume requiring treatment
- Presence of multi-component emissions and the nature and concentrations of hydrocarbons present
- Operating characteristics of the emitting process
- Method of emissions collection
- Number and magnitude of the different sources
- Recovery or destruction of organic pollutants
- Reuse of the chemical components
- Recovered hydrocarbons are eventually burned to offset fuel consumption at the facility
NESTEC Equipment design features
- Direct Fired Thermal Oxidizer (DFTO) (link: Thermal Oxidation Modular Systems | Nestec, Inc.)
- RTO/RCO Uniform air flow throughout the entire RTO unit is essential for maximizing performance
- Uniform Air Flow reduced NOx (link: Thermal Oxidizer NOx Emissions | Nestec, Inc.)
- Single Actuator, center horizontal shaft poppet valve design, located in the center beneath the heat recovery chambers promotes uniform air distribution into and out of the heat recovery chambers with a single valve disk, actuator, and dual seat per chamber
- Multi-Combustion Chamber design
- Even tower (chamber) design
- 95-96% Thermal Energy Recovery (TER)
- Up to 99% Destruction Removal Efficiency (DRE)
- Multiple Heat exchange media layers designed specific for the application
- Forced draft fan design
- Regenerative Catalytic Oxidizer (RCO)
- Unique online bake out and catalyst regeneration system
- Multiple burner control (uniform temperature profile)
- Thermal Alignment Feature with reduce fuel consumption.
- Retention Time at purification temperature (link: The Three T’s of Oxidation | Nestec, Inc.)
- Easy access for maintenance and inspections
- If the Flow control valves do not work, the entire unit does not work. A simple, rugged, and reliable valve design will maximize performance and ensure maximum up time.
- Single fast acting actuator per chamber
- Shaft spring shock absorption
- Thermal expansion compensation
- Disc leaf spring design helps absorb. seat closure
- Open and close valve position switches
- No leak housing shaft seal
- Zero or nil seat leakage
- Self-cleaning seats
- Heated disk
- Large, easy opening valve access doorNESTEC‘s RTO / RCO design has optimized the benefits of the heat recovery media, simplified the flow control, and condensed the configuration into a smaller, prepackaged unit, greatly improving on the original design. The NESTEC team’s more than three hundred and sixty-five combined years (365+) of key experience has produced RTO / RCOs designs that offer:
- Smaller, more compact units for a lower capital investment
- 30-50% reduction in energy consumption
- Increased destruction efficiency
- Shop-assembled modules or skid mounted units with a shorter field-installation time
- Increased reliability and uptime
- Lower maintenance
NESTEC Inc. has helped successful companies increase their air emission control operating efficiencies and reduce both capital and/or operating costs. We are confident that we can help your facility as well with any present or future air emission control issues that could or are eroding your bottom line.
NESTEC, Inc. | Smart Solutions for Clean Air
For assistance from our extensive experience, call or e-mail NESTEC Inc. (Office: 610-323-7670) for a free evaluation of your VOC/HAP and/or particulate control equipment and service needs.
Nestec, Inc. | Smart Solutions for Clean Air
wholden@NESTECinc.com 610-323-7670 ext. 103 (service)
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