All too commonly, design engineers and consultants evaluate the need for Air Pollution Control (APC) after the process plant has been established and/or the design is near completion, virtually mandating end of-pipe solutions. (see NESTEC’s Nov 2018 Newsletter discussing the drawbacks of end of pipe APC https://www.nestecinc.com/news/end-of-pipe-control/ ).
However, if you invest in an APC system that provides the best and most economical solution, you’ll see the effects on your bottom line. Lesser alternatives are created with a cookie-cutter approach that does not truly address your specific process and logistical needs.
NESTEC’s 345+ years of combined key staff experience with APC (RTO/RCOs) design and application ensures you’re using the latest technology and a system specific approach that yields the best and most economical solution for your APC application, every time.
NESTEC’s Smart Solutions resolve air emission control obstacles as part of the total process plant design, and eliminate or minimize the effect of air emission control on your bottom line. Optimal efficiency simply isn’t possible without evaluating the air emission control equipment up front as part of the total plant process design. The process design engineer/consultant and the APC equipment supplier must work together in the planning stage to establish the best and most economical approach.
NESTEC’s solutions take into consideration:
- Total potential air emission sources
- Air emission conditions
- Moisture content
- Total particulate matter (TPM)
- VOC and HAPs loading
- Turn down requirements
- Location relative to each of the process air emission sources
- Potential for mixing the sources prior to the required APC equipment
- Overall energy requirements
- Potential energy reuse in the process
- Overall safety
- All system variables
NESTEC’s solutions have led to substantial cost reductions in required capital equipment as well as long term operating overheads. Our proven approach offers a total air emission control system with alternate options for the capital equipment and associated operating costs. Thus, providing a matrix of potential solutions that can lead to the best and most economical solution for the specific plant APC needs.
NESTEC has provided Smart Solutions for existing plants as well. For example, we recently studied two alternatives to meet a wood pellet plant’s APC requirements. NESTEC’s proposal compared the efficiency of two separate, original APC systems (one for the pellet coolers and one for the hammer mills) to a single total APC system.
NESTES’s evaluation of a single APC system versus two separate APC systems, both of which required some special considerations, revealed a substantial capital and operating savings.
Depending on the individual, optional items selected included:
- Local control room
- Start up and commissioning
- Equipment easy access doors
- Area lighting
- Isolation dampers
- Broken bag detection
- Fire suppression system
- Mechanical installation
- Electrical installation
- Process exhaust collection ductwork and installation
- Spare parts
- Condensable dropout and minimization system
- Explosion relief system
A single APC alternative offered a capital savings of ~$790,000 to ~$1,100,000 over the two separate individual APC systems. It also included a ~$28,000/yr energy savings.
If you have an application that requires air pollution control and energy conservation and want a system that will:
- Provide alternate solutions to minimize your capital expenditure
- Reduce your energy bill
- Reduce stack testing with a single stack
- Reduce your carbon footprint
- Include easily maintainable equipment
- Provide simple, durable, and reliable components
- Feature 24/7 service and engineering support
- Access to NESTEC’s warehouse replacement components
If you have an application that requires air emission compliance and would benefit from conservation technologies that will substantially reduce your energy bill, contact NESTEC today for a free process analysis.
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