Thermal oxidation saves $500,000, lifts capacity, upholds compliance
The age and destruction of the heat recovery system dictated the replacement of the original fume incinerator at the Congoleum Resilient Flooring Division Plant in Trenton, NJ. The original unit, installed in 1967, had a conventional air-to-oil heat recovery system. Plant personnel placed high priority on finding a replacement with a higher thermal efficiency while still maintaining environmental integrity. A proprietary software program was used to obtain values for NPV (net pressure value) for several competitive equipment systems. The NPV allows simple comparison of equipment based on data such as purchase pgsrice, cost of installation, operating costs, and maintenance costs for the predicted life span of each unit. Based on NPV analysis, a regenerative thermal oxidation unit was selected. To assure expansion capability, Congoleum opted for a 30,000 scfm system. The regenerative thermal oxidation unit consists of a central combustion chamber with five lobes extending radially outward. Each lobe is packed with ceramic refractory elements (saddles) which serve as heat exchange media. The elements are retained by perforated refractory blocks on the hot combustion chamber side and by a grating on the cold side. Estimated savings from the system, about a half million dollars the first year, are expected to significantly exceed Congoleum's original estimates. About half of the total savings will result from reduced consumption of natural gas since the unit is fueled mainly by the organic material in the process exhaust. The other half of the savings has resulted from improvements in production efficiency and the recycling of waste heat from the thermal oxidizer.
- Research Organization:
- Congoleum Corp., Trenton, NJ
- OSTI ID:
- 5457434
- Journal Information:
- Chem. Process. (Chicago); (United States), Vol. 48:14
- Country of Publication:
- United States
- Language:
- English
Similar Records
Energy efficient fume and odor control equipment for coil coating line
Soil vapor extraction system design scale-up considerations
Related Subjects
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
54 ENVIRONMENTAL SCIENCES
COMBUSTORS
EFFICIENCY
ENERGY CONSUMPTION
ENERGY EFFICIENCY
PERFORMANCE
GASES
OXIDATION
ORGANIC COMPOUNDS
AIR POLLUTION ABATEMENT
CHEMICAL PLANTS
CHEMICAL REACTIONS
FLUIDS
INDUSTRIAL PLANTS
POLLUTION ABATEMENT
421000* - Engineering- Combustion Systems
320303 - Energy Conservation
Consumption
& Utilization- Industrial & Agricultural Processes- Equipment & Processes
500200 - Environment
Atmospheric- Chemicals Monitoring & Transport- (-1989)