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Author Archives: Mary.Hickey

  1. What Is a Rotary Concentrator?

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    rotary concentrator with rtoMany industrial processes produce emissions that must be neutralized before they can be safely released into the environment. Thermal and catalytic oxidizers are technologies that perform this crucial operation in many industrial air pollution control applications. Rotary concentrators are an add-on technology that enhances the efficiency and effectiveness of these oxidation processes. This blog explores rotary emission concentrators, including their applications, features, and benefits.

    Emission Concentrator Overview

    A rotary concentrator is an air pollution control system that converts large volumes of air with low concentrations of solvents or volatile organic compounds (VOCs) into small-volume, high-concentration airstreams. The rotary concentrator is a front-end, pre-conditioning unit located upstream of a thermal or catalytic oxidizer, which destroys the pollutants. A smaller oxidizer can be used since the VOCs are concentrated from a large airstream into a smaller airstream, saving on fuel auxiliary energy, and space.

    The most significant benefit of using a rotary concentrator in conjunction with an oxidizer is reduced operating costs. This comes from ​​providing a much richer airstream to the combustion device that acts as fuel, saving on operating costs. Rotary concentrators also eliminate the need for larger oxidizer systems, which allows for more efficient space management. The smaller-sized oxidizer also reduces the capital costs of the combustion device. Manufacturers can avoid unnecessary expenses while making space for production growth.

    How Do Rotary Emission Concentrators Work?

    The low-concentration, high-volume airstream first passes through the rotary concentrator, where VOC emissions are stripped away from the air and adsorbed onto the zeolite media. At this point, the process air is about 90-99% clean and exhausted into the atmosphere. Removal efficiencies from the rotor vary on the emission constituents. To increase efficiency at this stage, additional rotors can be put in series upstream of the oxidizer.

    Spinning continuously at a slow rate, the concentrator wheel is comprised of two sections; absorption and desorption. As air passes through the Adsorption section, VOCs at normal temperatures will attach to the zeolite wheel while the clean air goes directly into the atmosphere. A small portion of the contaminated air is heated to elevated temperatures and used to desorb those VOCs from the wheel in the desorption section. The desorbed VOCs are in a much smaller airflow; roughly 5-10% of the original flow, and sent to the downstream oxidizer for final VOC destruction.

    Rotary Concentrator Applications

    Rotary concentrator systems work great for high-volume air streams with low VOC concentrations, ideally below 500 ppmv and when temperatures are below 100 °F.

    Common applications include:

    • Semiconductor manufacturing
    • Chemical processing
    • Fiber-reinforced plastic (FRP) manufacturing
    • Manufacturing paints & coatings
    • Paint Booth Overspray
    • Surface coating
    • Wood finishing
    • LCD panel manufacturing

    Rotary Concentrator Features & Benefits

    Using an oxidizer in conjunction with a rotary concentrator is typically the most cost-effective solution when dealing with low-concentration, high-volume airstreams. Its upfront cost may be similar, if not less, than an oxidizer designed at full flow capacity. The real benefit of the concentrator is the reduced operational costs and secondary pollutant emissions. A paired concentrator/oxidizer uses much less auxiliary energy because the much smaller airflow being sent to the oxidizer has more thermal energy in the concentrated stream.

    Regulations are increasingly mandating higher VOC control efficiencies. With most air pollution control systems focusing on inert VOC and destruction equipment, combustion devices must be able to handle larger volumes of air with lower VOC concentrations, and this machinery can be expensive. The Anguil rotary concentrator allows manufacturers to remain compliant with these regulations, save money and energy, and increase efficiency. As an add-on to existing thermal oxidizers, the rotary concentrator can reduce the amount of treated airflow by up to 95%.

    Since oxidizers are designed for specific projects according to maximum airflow, manufacturers can save a significant amount of capital costs. Single rotor systems can handle up to 150,000 SCFM with multiple stages of zeolite reaching up to 99% VOC removal. Larger flow rates can be handled with multiple rotors in parallel.

    Rotary Concentrator Options

    Anguil Environmental Systems offers multiple technology options for destroying hazardous air pollutants, VOCs, and odors. We can help you select the most applicable equipment for your manufacturing operation. Our consultative approach with clients ensures they receive the best possible solution for the abatement objectives so you receive the best possible solution for your specific needs. Our options include:

    • Multiple rotors in series or parallel for higher DRE/airflow
    • Numerous zeolite media options to prevent polymerization
    • High-efficiency filter plenums for protection against particulate exhaust
    • Multiple options for desorption of air heat
    • Completely integrated and automatically controlled concentrator and oxidizer systems

    Emission Concentration Solutions From Anguil Environmental

    Anguil Environmental Systems is a leader in providing engineered environmental equipment. We are fully committed to providing solutions for cleaner air at competitive prices. Our rotary concentrator solutions help clients remain fully compliant with regulations while providing the best possible capital and operating cost, as well as the lowest emissions of secondary pollutants.

    At Anguil, we believe in clean water and air. Public health, sustainability, and economic prosperity are interconnected, and we are committed to promoting these values together. To learn more about how we can help your business with emission concentration, contact us today.

  2. Anguil & Canmaker JL Clark Teamwork Highlighted in The Canmaker Magazine

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    canmakerThis is how J L Clark exceeded the US EPA’s VOC abatement requirements at its Rockford, Illinois, litho plant: a PLC controlled RTO from Anguil Environmental Systems

    Canmakers in the US are increasingly concerned about the need to comply with regulations issued by the Environmental Protection Agency (EPA) on air quality, specifically volatile organic compound (VOC) and hazardous air pollutant (HAP) control.

    Last November the EPA issued a final rule that established national emission standards for coating operations in regions that generated large volumes of VOCs. The standards (5,700 litres or 1,500 gallons of coatings per year) outline various control requirements based on usage of affected VOCs but also provide for emission reduction by using a capture system in conjunction with pollution control devices.

    With legislation looming on the horizon, Rockford, Illinois-based lithographer and canmaker J L Clark last year began a thorough review to find a system that would exceed the minimum EPA requirements cost-effectively. “This was not the first time that J L Clark had taken steps to control their emissions,” said Gordon VerWeyst, J L Clark’s vice president of product development & engineering.

    “Years earlier, the company had installed several recuperative thermal oxidiser (RTO) systems that had satisfied earlier requirements but had, over the years, become outdated and were a significant drain on the plant’s operations budget. Costs to operate the systems had become a major component of J L Clark’s annual fuel usage.”

    J L Clark chose Anguil Environmental Systems, based at Milwaukee in Wisconsin, to supply a bigger 50,000 scfm regenerative thermal oxidiser to control the emissions, and a permanent total enclosure (PTE) to capture the emissions from the plant’s six printing and coating lines.

    The RTO destroys VOCs with high temperature oxidation, converting them to carbon dioxide and water vapour, and reusing the released energy. Anguil’s vice president of sales & marketing, Chris Anguil explains how it works: “Process gas with VOC contaminants enters the two chamber RTO through an inlet manifold. Aflow-control valve directs this gas into an energy recovery chamber which preheats the process stream. The process gas and contaminants are progressively heated in the ceramic bed as they move toward the combustion chamber.

    “The VOCs are then oxidised, releasing energy in the second ceramic bed, thereby reducing any auxiliary fuel requirement. The ceramic bed is heated and the gas is cooled so that the outlet gas temperature is only slightly higher than the inlet temperature. The flow-control valve switches and alternates the ceramic beds so each is in inlet and outlet mode.

    “If the process gas contains enough VOCs, the energy released from their combustion allows self-sustained operation. For example, at 95 percent thermal energy recovery, the outlet temperature may be only 77 deg F (25 deg C) higher than the inlet process gas temperature,” he says.

    PLC-based electronics automatically control the RTO’s operation, from startup to shutdown, reducing the necessity for operators to be involved.

    Meanwhile, the permanent total enclosure contributes significantly to the reduction in VOCs released to the atmosphere.

    VerWeyst says: “We selected the PTE system because it enabled our litho lines to run without individual burdensome enclosures and exhaust hoods over each line. This allowed the operator’s room to do their job without interference. The PTE also allowed us to forgo the yearly EPA capture inspections that are required on a singularly captured line.”

    Adds Anguil: “The PTE at J L Clark has proven effective at capturing the emissions from the wet-end coating operations of the process lines: that exhaust is combined with the exhaust from the ovens at the inlet of the RTO. This results in 100 percent capture efficiency of the VOC/HAP emissions assuring capture efficiency requirements and eventual destruction.

    “The RTO itself has proven to be similarly effective, achieving destruction efficiency in excess of 99 percent while exceeding all fuel usage reduction objectives. The combined capture and destruction efficiency has therefore exceeded 99 percent for the facility, minimizing the overall VOC/HAP emissions from the plant and allowing it to meet their emissions cap,” he says.

    Originally published in October of 2004 in Canmaker Magazine.

  3. Milwaukee Paper Highlights Anguil’s Growth

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    Clearer skies overseas;
    Anguil Environmental finds niche in global air pollution control


    At a time when many Wisconsin companies are alarmed about business and technology being exported to Asia, a small Brown Deer firm is proving that it can compete overseas through contracts in Taiwan, Korea and China.

    With only about 35 employees, Anguil Environmental Systems Inc. has become a global player in its field of designing and installing air pollution control equipment. About 25% of the company’s $20 million in annual sales comes from overseas business, including contracts from large conglomerates such as Hyundai Motor Co.

    In December, Anguil landed three Asian orders to provide air pollution control equipment for Formosa Chemical Co. in Taiwan. The orders, totaling just under $4 million, followed a $1.5 million order from Hyundai for equipment at one of the Korean company’s plants in China. A weak U.S. dollar and strong economies in various regions of the world have helped American companies get overseas business, said Gene Anguil, founder and chairman of Anguil Environmental Systems.

    “Exporters can do much better,” he said. “In some cases it’s cheaper to build something here and ship it overseas,” than to have the same product built in another country that’s closer to the end user.

    Anguil designs and installs oxidizers, which look like large metal boxes perched atop the roofs of factories and printing companies. Pollutants that are emitted during manufacturing are channeled into the oxidizer, which uses heat to destroy the chemicals and convert them into carbon dioxide and water vapor.

    Anguil has installed about 1,500 pollution control systems around the world, with its key markets being the United States, Taiwan and Europe.

    The company has sold equipment in Taiwan for about 10 years, largely because that country has some of the strictest environmental standards in Asia.

    The migration of international companies into China has helped Anguil’s sales, since the multinational organizations are already familiar
    with pollution control requirements in their home countries.

    “When these large companies establish plants in China, they don’t want to be perceived as having one set of environmental standards at home and another set of (weaker) standards for China,” Anguil said. “So that’s been a driver” of sales.

    China has a pressing need for pollution control equipment. It has some of the world’s dirtiest air and is trying to clean things up in a short period of time, partly to gain acceptance by the international political community and the World Trade Organization.

    Not all developing nations are trying as hard to improve the environment. Often there’s a constant battle between the economy and the environment, with clean air losing out to factories that produce jobs and contribute to a country’s economic growth.

    “I think that will always be the situation,” Anguil said. “Even in this country, when the economy is not that good and our federal government is not that strong on the environment, we see companies dragging their feet for years” on installing pollution control equipment.

    Anguil designs its own equipment, and company officials say aspects of the designs are sophisticated enough that it’s difficult for foreign competitors to copy them.

    “We recognize the risk is there,” Anguil said. But companies that need pollution control systems usually don’t want to risk buying imitation systems, only to find out they weren’t effective and resulted in millions of dollars in air pollution fines.

    Emphasis on engineering and problem solving can give U.S. companies a competitive edge, said Dale Wiza, chairman of the Milwaukee chapter of the Society of Automotive Engineers.

    “There are things that can’t easily be copied,” he said.