Workshop GG

Green & Energy Efficient Approach to VOCs,

Hazardous Air Pollutants and Odor Abatement

Wednesday, March 25, 2015 11:15 a.m. to 12:30 p.m.

Biographical Information

Arnie T. Beringer, Owner & Managing Partner CEECO Equipment, Inc , Cincinnati, OH

513-709-8444 Fax: 513-672-0045 aberinger@ceecoequipment.com WWW.CEECOEQUIPMENT.COM

Arnie began his career as an intern for the Ohio EPA (RAPCA) while he was attending the University of Dayton pursuing a Degree in Environmental Engineering. After spending an additional year with Ohio EPA after graduation, Arnie worked as an environmental engineer for Navistar for approximately 3 years in both their Springfield and Columbus Operations. After Navistar, Arnie took the environmental manager position at Sun Chemical at their pigment plant operation in Cincinnati. For the next 16 years he had various plant and regional EHS management positions and last served as the Corporate EHS Compliance Assurance Manager for the North American operations for Sun Chemical. In May of 2011 he left Sun Chemical to take over the family business, CEECO Equipment, as a manufacturer’s sales representative specializing in air pollution control and process equipment solutions. Arnie is a longtime member of the Air & Waste Management Association where he has served as the President of the Southwest Ohio Chapter on two separate occasions, the last time having concluded in 2014.

Nathan D. Hess, Biological Oxidation Applications Engineer, Process Combustion Corp., 5460 Horning Rd., Pittsburgh, PA 15102

412-655-0955 ext. 3148 Fax: 412-650-5569 nhess@pcc-sterling.com Nathan has been a Biological Oxidation Applications Engineer for Process Combustion Corporation for a little over a year. The position entails designing biologically-based solutions for contaminated gas emissions in a number of different industries. Nathan is also responsible for development of the Biological Oxidation R&D initiative at PCC. Nathan graduated from the University of Delaware with a B.S. in Chemical Engineering.

Robert L. Miller Process Combustion Corp., 5460 Horning Rd., Pittsburgh, PA 5102

412-655-0955 ext. 3169 Fax: 412-650-5569 rmiller@pcc-sterling.com Bob has worked in the development and application of engineered products in the Chemical, Petrochemical and Refining industries for over 35 years. A major portion of his experience was with Saint-Gobain NorPro formerly known as Norton CPPC. Early on Bob was involved with mechanical design and development of metal, plastic and ceramic tower internals before migrating over to Sales/ Marketing responsibilities and new market development. He has also been involved in development of tower packing for heat and mass transfer applications holding several granted patents along with others in various stages of the patenting process. Bob joined Process Combustion Corp. in the fall of 2013 heading up PCC’s Bio-Oxidation technology product line.

• MANUFACTURER’S SALES REP AGENCY (SINCE 1961)

• HISTORY

• INTERN WITH OHIO EPA (RAPCA), THEN FULL TIME

• ENVIRONMENTAL ENGINEER – NAVISTAR (3 YEARS)

• EHS MANAGER, CORPORATE COMPLIANCE OFFICER – SUN CHEMICAL (16 YEARS)

• NORTH AMERICAN OPERATIONS

• CEECO EQUIPMENT – MAY 2011

• SPECIALIZE IN FANS AND AIR POLLUTION CONTROL EQUIPMENT, PROCESS EQUIP

PROCESS COMBUSTION CORPORATION

A World Leader of Integrated Solutions for Industrial Pollution

• Process Combustion Corporation Introduction• Air pollution control review• Biological Oxidation

• Overview• History• Development• Technology Comparison

• Environmental technology comparison

PRESENTATION OUTLINE

Formed Joint Venture in 1969 Bloom Engineering Company (USA) Urquhart Engineering Company (UK)

History

1989 PCC Wholly Owned by Bloom Bloom & Urquhart Acquired by Sterling

Industries (UK)

Thermal Oxidation

• Thermal Oxidizer• Recuperative Thermal Oxidizer• Regenerative Thermal Oxidizer (RTO)

VERTICAL FIRED THERMAL OXIDIZER

UP-FIRED THERMAL OXIDIZER

TO / HEAT RECOVERY SYSTEM

TAIL GAS INCINERATOR

GAS & LIQUID INCINERATION

Absorber Off Gas Thermal Oxidizer Wastewater Incinerat

Technology Expansion

2013 Added Dual-BioPhase™ BioOxidation

Technology

+

PCC BIO-OXIDATION

Established 1996

HN1

Slide 10

HN1 Hess, Nathan, 3/4/2015

Principal Publications (selected): 1. Goncalves JJ, Govind, R. “Enhanced biofiltration using cell attachment promoters.” Environmental Science

& Technology. Volume 43 (2009) 1049-1054.2. Gonalves JJ, Govind, R. “Analysis of biofilters using synthetic macroporous foam media.” AWMA Journal.

Volume 59 (2009) 834-844.3. Goncalves JJ, Govind, R. “Rapid evaluation of biofilm attachment promoters and biofilm growth orientation

using a micro-impedimetric device” Sensors and Actuators B: Chemical. Volume 143 (2009) 341-348.4. Govind, R, Ferguson, D. “Reducing generation of biogenic hydrogen sulfide in sugar wastewaters”

International Sugar Journal. Vol. 111, No. 1325 (2009) 278-284.5. Goncalves JJ, Govind, R. “H2S abatement in a bioreactor packed with iron (III) foam media.” Chemosphere.

Volume 73 (2008) 1478-1483.6. Anim-Mensah, A.R., Krantz, W.B., Govind, R. “Studies on polymeric nanofiltration based water softening

and the effect of anion properties on the softening process” (2008) European Polymer Journal Vol. 44, Issue7, 2244-2252.

7. Roe, A., Govind, R. “Biofiltration for waste gas – Employing Nature’s way for cleaner air” ChemicalIndustry Digest (2008) 104-108.

Who is PRD Tech?

Dr. Rakesh GovindPhD Chemical Engineering, Carnegie Mellon University, Pittsburgh, PA MS Chemical Engineering, Carnegie Mellon University, Pittsburgh, PA BTech Indian Institute of Technology, Kanpur, India

THE NEED FOR AIR POLLUTION CONTROL

ATMOSPHERIC CHEMISTRY

EFFECTS OF ATMOSPHERIC CHEMISTRY

World Resources Institute: August 2008 Monthly Update: Air Pollution's Causes, Consequences and Solutions

DESTRUCTION BY OXIDATION

TREATMENT OF POLLUTANTS

Chemical Oxidation

Thermal Oxidation

Biological Oxidation

CHEMICAL OXIDATIONChemical Oxidation converts hazardous contaminants to non-hazardous or less toxic compounds that are more stable, less mobile, and/or inert.

The oxidizing agents most commonly used are:• ozone • hydrogen peroxide• hypochlorite• chlorine• chlorine dioxide

Clean Air

Contaminated Air

Dilution Air

VOC LadenAir

ReactionZone

MixingZone

THERMAL OXIDATION

High Destruction Efficiency

Requires High Temperature (~1600F)

High Operating Cost • Consumes Natural Gas

Produces CO CO2 NOX

Catalytic Oxidation• Periodic Replacement of Catalyst is Required

Biological oxidation (Bio-filtration): Process whereby contaminants transfer from air phase to biofilm Biodegraded by microorganisms.

BIOLOGICAL OXIDATION

The Biofilm is the primary element of the Bio-Oxidizer involved in the destruction of the contaminants.

BIOLOGICAL OXIDATIONBiofilm is a living community of fungi and bacteria that utilize Carbon as their primary food source.

“GREEN TECHNOLOGY”• Does Not Consume Natural Gas• Does Not Generate NOx SOx CO• Produces ~90% Less CO2 vs. Thermal Oxidation• Operates at Ambient Temperature and Low Pressure.

Pollutant + Bacteria + Oxygen + Nutrients CO2 + H2O + More Bacteria

“Microorganism” refers to a wide variety of single cell, live bacteria.

Given sufficient time and quantities, bacteria can biodegrade nearly anything.

e.g. sugar, starch, sulfur, and iron….

MICROBES a.k.a Bacteria or Bugs

FAQ>>>“What happens if the Bugs get out of the bio-oxidizer unit?”

MICROBES

Nothing…………….

a.k.a Bacteria or Bugs

We simply harness the bacteria and contain it in an atmosphere which allows it to work significantly more efficient than in nature.

Bacteria is Everywhere in Nature…………….

MICROBES

On Contact Lens In Dental Plaque

Any guesses where these typical forms of bacteria are found ?

Bacteria is Everywhere in Nature…………….

a.k.a Bacteria or Bugs

A HISTORY LESSON

The first applications to treat odorous compounds were as early as 1923.

Primarily to control emissions of H2S from waste water treatment plants.

Europe: Applied to treat odorous emissions in low concentrations.

First soil bed bio-filter was installed in a European sewage treatment plant.

1923 1955 - 1959

EVOLUTION OF BIO-FILTRATION

Used to treat gaseous pollutants: Europe and US; Research intensified.

Became widespread in Europe.

Treatment of some (VOCs) in industrial applications.

1990’s

More than 1,000 bio-filters operating in Europe, and spreading throughout the US.

PRD Tech founded in 1996First Dual-Phase type design installed in 1999

1960’s 1980’s

EVOLUTION OF BIO-FILTRATION

R&D undertaken to address system configurations, media life, overall system performance.

2000 2003 -2009

Several new design treatment systems are installed within broad industrial sectors.

2014

Continued R&D aimed at industrial applications; Focused on high removal efficiencies in diverse temperature and loading mixes.

EVOLUTION OF BIO-FILTRATION

TECHNICAL JOURNALS

1994

2006

2009 2004

TECHNICAL BOOKS

2000:DevinnyDeshussesWebster

2005:Z. ShareefdeenA. Singh

BIO-OXIDATION MEDIA

Types• Natural Bio-active Media

• Original Technology

• Synthetic Media• Technology Advancement

NATURAL BIO-ACTIVE MEDIA

Microorganisms and Nutrients are Captive within the Media Structure

Biomass Cannot be Separated from Media

Biomass Growth Causes Media Settling• Continually Increasing ∆P

Media Replacement is Required to Replenish Nutrients

Media needs Fluffed to Obtain Porosity

NATURAL BIOACTIVE MEDIA Maintaining Optimal Moisture Content within the Media is Crucial

Media Height is Limited Due to Maintaining Proper Moisture Content• Results in Short & Large Cross-Sectional Media Bed Areas

Limited Capacity for Contaminants• Handles <50 ppmv in Gas Phase

Has Limitation to Neutralize Acids

• Bed Compaction • Media Replacement Cycle• Proper moisture control is critical

• Difficult to monitor for removal efficiencies• Limited Surge Loading Capability/Efficiency• Limited Upper VOC Concentration Capability

A principle drawback to the early designs was the large footprint required. A large biofilter (~200,000 acfm ) may occupy an area the size of a football field

EARLY BIO-FILTER DESIGN

EARLY BIO-FILTER DESIGN

Bed Compaction

Channeling Channeling

EARLY BIO-FILTER DESIGN

DUAL-BIOPHASE™

MEDIAMicroorganisms and Nutrients are not Captive Within the Media but

Immobilized On a Treated Synthetic Media Surface.

Biomass Can be Continually Separated from Media

Biomass Growth does not Cause Media Settling• Stable ∆P

Media Replacement is not Required to Replenish Nutrients

Media Height is Not Limited to Maintain Proper Moisture Content

Higher Capacity for Contaminants• Handles <5000 ppmv in Gas Phase

DUAL-BIOPHASE™

MEDIA

MEDIA COMPARISONEvaluation Category Organic

MediaDual-BioPhase™

Synthetic MediaMicroorganisms and Nutrients are Restrained within Media Yes No

Media Replacement is Required to Replenish Nutrients Yes No

Media needs Continually Fluffed to Obtain Porosity Yes No

Biomass Growth Causes Media Settling Yes No

Continually Increasing ∆P Yes No

Maintaining Optimal Water Content is Crucial Yes No

Media Height Limited to Maintaining Proper Moisture Content Yes No

Capacity for Contaminants - ppmv <50 <5000

Limited Capacity to Neutralize Acids Yes No

Biofilm – Biomass - Slough off

BIOFILM

Water Soluble Pollutants are Treated in the Liquid Phase.

Less Soluble Pollutants are Treated in the Gas Phase

Nutrient feed

WHAT IS A DUAL-BIOPHASE™ SYSTEM ?

Contaminant

Ambient Air

Mixer

Recirculating Loop to Aeration Mixer

Clean Exhaust

Soluble

Less Soluble

ADVANCED “BIO-OXIDATION”

Overall Foot Print56’ dia.

Overall Foot Print100’ x170’

TECHNOLOGY COMPARISON

Bio-Filter

Traditional Bio-Filter

TECHNOLOGY COMPARISONFOOTPRINT

Dual-BioPhase™

Technology

DUAL-BIOPHASE™ VS. TRADITIONAL BIOFILTRATION

Dual-BioPhase™ System:• Greater oxidation efficiency• Higher capacity for contaminants (100 times )• Lower operating cost, increases flow capacity• Has a smaller footprint (3 - 6 times)• Essentially no maintenance• No media change out required• Easily maintains pH neutrality• Self contained biomass growth

• Mesophilic microbes for 60o – 110oF, wet bulb.

OPTIMAL EFFLUENT FACTORS BIO-OXIDIZER

• Thermophilic microbes for 125o - 165oF wet bulb.

BIODEGRADABILITY OF COMPOUNDS

1 = Some, 2 = Moderate, 3 = Good

Contaminant Biodegradability Index

Aliphatic Hydrocarbons (Methane, Propane, Butane….) 1

Aromatic Hydrocarbons (Benzene, Toluene, Xylene) 2-3

Chlorinated Compounds 1

Nitrogen-containing carbon compounds (Amines) 1-3

Sulfur-containing carbon compounds (Dimethyl sulfide ) 1-2

ContaminantOxygenated Carbon Compounds

Biodegradability Index

Alcohols 3

Aldehydes 3

Esters 3

Ethers 1-3

Ketones 3

Inorganic compounds (ammonia, hydrogen sulfide) 3

1 = Some, 2 = Moderate, 3 = Good

BIODEGRADABILITY OF COMPOUNDS

BIO-OXIDIZER – ODOR CONTROL

Industrial Wastewater Treatment• Simultaneous VOC & Odor removal

Paint Manufacturing Animal & Pet Feed Production Food Processing Plastics Industry

COST COMPARE – ODOR SOLUTIONS

0.0

0.2

0.4

0.6

0.8

1.0

1.2

Carbon Absorption Chemical Scrubbing PCC Bio-Oxidizer

Rela

tive

Ope

ratin

g C

ost

ADVANCEDBIO-OXIDIZER – ODOR

DUAL-BIOPHASE™

HAP & VOC CONTROL

RTO Displacement• Wood Industry• Paint Industry• Industrial Wastewater• Food Industry• Pharmaceuticals• Tank Vent Gases

VOC – RTO DISPLACEMENTRTO/RCO… Well Known and Widely Used Technology….

However: Does Not Tolerate Particulates – ESP/Scrubbers Req’d Uses Fuel ($$$) – CO2 NOX Emissions Strict Thermal Safety Requirements Post Treatment of Gases Required to Remove SO2 NOX etc.

RTO VS. DUAL-BIOPHASE™

TECHNOLOGYRTO

Burns Natural Gas – Additional operating costValve maintenance/wear & tearPotential fouling of ceramic mediaStrict Thermal Safety requirements (1600F)Emits COEmits CO2

Emits NOx

Potential Post Treatment of Waste Gases

Bio-Oxidizer No Natural Gas No Major Moving Parts Anti Fouling Design Ambient Temperature Zero CO Emissions ~90% Less CO2

Zero NOx Emission No Post Treatment of Waste Gasses

0.0

0.2

0.4

0.6

0.8

1.0

1.2

RTO PCC Bio-Filter

Rela

tive

Ann

ualiz

ed C

ost

Capital cost/yr

Electrical Cost/yr

Gas Cost/yr

Nutrient Cost/yr

RTO VS. DUAL-BIOPHASE™

BIO-OXIDIZER

Electrical Cost/yr

Capital cost/yr

CO2 OUTPUT

Regenerative Thermal Oxidizer Natural Gas Consumed - 289 scfm 99.9% available to Carbon content CO2 Produced – 9,320 Tons/yr

Dual-BioPhase™

Inlet Gas - 43,160 scfm Inlet Carbon Content – 210 ppmv CO2 Produced – 1752 Tons/yr

Dual-BioPhase™ System - 81% Less CO2

TECHNOLOGY CONSIDERATION

VOC TREATMENT

Evaluation Category RTO Dual-BioPhase™Burns Natural Gas – Additional Operating Cost Yes No

Valve Maintenance – Wear & Tear Yes No

Potential Fouling of Ceramic Media Yes No

Strict Thermal Safety Requirements - (~1600F) Yes No

CO Emission Yes No

CO2 Emission Yes ~90% Less

NOx Emission Yes No

SOx Emission Potential No

Particulate Removal Required with Wet-ESP Yes No

Potential Post Treatment of Waste Gases Yes No

RTO vs. Dual-BioPhase™ System

• Process Combustion Corporation Introduction• Air pollution control review• Biological Oxidation

• Overview• History• Development• Technology Comparison

• RTO vs. PCC Biofiltration Technology

RECAP

Thank You

CC Process Combustion Corporation

“Green Technology”                           

PCC Dual‐BioPhase™ System