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PRE2MIER PROTEINS Poolboy, Ballinasloe, Co. Galway, Ireland. Tel.: 090-9642305. Fax: 090-9642738.

Mr Liam 0 Suilleabhain Environmental Protection Agency Regional Inspectorate John Moore Road Castlebar Co. Mayo.

Date Our Ref Your Ref 19/09/2005 M 5921 190905REGIl

IPC License Reg.No. M592

RE: Regenerative Thermal Oxidiser.

Dear Mr 0 Suilleabhain, In reference to proposed installation of Regenerative Thermal Oxidiser at thid site please find attached a process overview for same. If required, we will meet with yourselves to discuss the installation and its implications.

/ I ~

Yours Sincerely

6

Noel Ryan ( Rendering Director)

2 I SEP 2005 I I

Directors: N. Ryan, T. Tynan. Registered Office: 39/40 Upper Mount St., Dublin 2

Premier Protam is a regitered &ness name of Premier Proteins (2000) Ltd. (

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.. . .

PROCESS OVERVIEW

THREE TOWER

REGENERATIVE THERMAL OXIDISER

PREMIER PROTEINS

PROCESS OVERVIEW ISSUE 1 i

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BACKGROUND

The rendering industry is coming under increasing public and legislative pressure to prevent the release of vapours, foul air and volatile organic and inorganic compounds to the environment. The control of odour emissions from the site is also a pressing issue that must be addressed to ensure best practice is applied to the operation of the plant, conducive with its ongoing operation.

In many instances the treatment of off-gas fiom the rendering process in the form of vapour and foul air can be economically achieved by recuperative thermal oxidation, providing always that the thermal balance and physical layout of the process is such that this type of technology can be applied.

Where there is no (or limited) requirement for external heat recovery from the oxidation process a proven solution is available using Regenerative Oxidation technology.

The Regenerative Thermal Oxidation process (often referred to as RIGE Oxidation) is widely recognised as an effective VOC and odour control solution, allowing operators to comply with operational licences and approvals. The process involves taking the odour laden emuent gas stream and oxidising the volatile components at high temperature.

A wide range of effluent components may be treated at varying concentrations. Each plant being specifically designed to match the process flow, effluent type and concentration to ensure the most efficient solution is found.

In this type of plant, highly efficient internal heat recovery is employed to provide an economical solution requiring minimal fuel input, low operational costs and maximum environmental benefit. Thermal efficiency can be greater than 90% with secondary fuel consumption being limited to a pilot flame if the calorific value of the effluent is sufficient to maintain the combustion chamber.at the required temperature for oxidation of the pollutants. In all cases a fully modulating burner ensures sadequate temperatures are maintained throughout the plant operation.

The RIGE Regenerative Thermal Oxidiser from Babcock Wanson can be considered as a stand alone machine, which should be located as close as practicable to the source of the odour problem. The RIGE is usually mounted externally. All that is required is a flat, non-combustible surface and that all fuel, compressed air, steam and effluent and exhaust services can be brought to the appropriate connection points.

PROCESS DESCRIPTION

A typical system comprises vapour extraction from continuous or batch cookers, sterilisers plus foul air from presses, grinders, decanters and meal storage/treatment areas.

A specially designed induced draught fan, constructed from stainless steel and mounted on the outlet of the Oxidiser to prevent corrosion and avoid leakage, draws the wet gaseous effluent stream into a stainless steel collector vessel forming part of the ductwork system. The foul air from point

the risk of condensation when mixed with the wet effluent stream, before being drawn into the collector vessel by the effluent fan.

r extraction sources is passed through a steam filterheater battery to raise the temperature and reduce

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The collector vessel is maintained at a constant depression (typically in the order of 50-1 00 mm wg) by means of a pressure control loop and variable speed drive on the effluent fan motor. This system allows accurate control of the cooker depression and reduces the possibility of interference with the cooking process. Electrical energy consumption is also optimised at periods of low production where peak effluent destruction is not required. In addition to providing a common point for pressure control, the collector vessel also acts as a trap to help remove debris and/or liquid effluent from the process stream prior to entry to the Oxidiser. -.

To reduce the possibility of leakage of the wet effluent, welded duct connections are utilised wherever possible with a minimum of flanged connections. All hot ductwork is insulated to reduce condensation on internal surfaces.

Where dictated by the effluent conditions an effluent filter may be fitted in order to remove any large particulate carry-over from the rendering process. Where any filter is fitted, a differential pressure switch and alarm are provided to indicate the need for filter cleaning;

GENERAL PLANT OPERATION

The Regenerative Thermal Oxidiser consists of ceramic lined steel towers connected at the top by an oxidation chamber. The ceramic lining serves to protect the steel shell from the temperatures found in the process. Each tower contains a mass of ceramic media to provide heat transfer and storage. A burner is provided in each section of the combustion chamber to both pre-heat the plant and to ensure the set operating oxidation temperature is achieved under all normally anticipated conditions.

At start-up the plant is pre-heated by burner input and the addition of ambient air through an automatic damper. The plant is isolated from the effluent stream by an automatic damper at this stage. This allows the Oxidiser to reach its set operating temperature prior to the input of effluent gases.

When the Oxidiser has reached its preset temperature and the process is ready, the odour laden gas is passed, via purpose made dampers, up through the fmt tower, gaining heat from the pre-heated ceramic mass in that tower thereby starting the Oxidation process. The preheated effluent gas then passes into the combustion chamber and through the burner section causing the total flow to be raised to the full oxidation temperature thereby releasing any energy from the pollutants to the process. The cleaned gas then passes down through the second tower, giving up energy to the ceramic mass in that tower.

After a preset period of time (typically 90 - 120 seconds) when the ceramic mass in tower 1 has been cooled and the-outgoing tower 2 has been heated, the gas flow is swapped such that the effluent enters the newly heated tower (in this case tower 2). Further energy as required from the burner is added as per the first cycle and the cleaned gas exits via tower 3, thereby recovering heat.

After leaving the exit tower the cleaned exhaust passes through purpose made dampers to the chimney.

This process continues; the gas flow periodically swapping its route through the oxidiser controlled by a pre-set programme. This ensures that all effluent passes through an inlet and outlet tower plus the combustion chamber and is maintained at the required temperature for the correct time for thorough oxidation of the odorous compounds.

f i

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An illustration of the process is shown below:- &

4 . ' (/I .\. Q r X

U U

INLET FROM PROCESS

Three Tower RIGE - Cycle 1

, I. >

Three Tower RIGE - Cycle 2 I

INLET FROM PROCESS

INLET FROM PROCESS

Three Tower RIGE - Cycle 3

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One very important aspect of Regenerative Oxidiser design when applied to odorous processes is to ensure that the oxidiser makes adequate provision to "purge" each tower, in turn, during the cycle change over period.

The reason for this requirement is that during the tower inversion cycle (e.g. when the inlet flow swaps from tower 1 to tower 2) a portion of the incoming effluent will only have passed part way through the incoming tower and is, therefore, not fully treated. To overcome this situation a bleed of exhaust from the chimney is purged through the dormant tower to clean it in time for the next inversion cycle.

The net result of this design is to provide a stable emission output when compared with the transient peaks that will occur on two tower or two tower plus compensating designs, which are often applied to less critical processes.

A typical emission profile for two tower, two tower plus compensating tower and three tower oxidisers is shown below.

VOC Exhaust emission Twin Tower RlGE

Time base

VOC Exhaust emission 2 Tower + Compensating RlGE vs 2

Tower RlGE

Time base

A TYPICAL TWIN TOWER EMISSION

I I

A TYPICAL TWIN TOWER PLUS

COMPENSATING TOWER EMISSION PROFILE

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VOC Exhaust emission 3 Tower RIGE vs 2 Tower + Compensating

Tower vs 2 Tower % .

Time base

: A TYPICAL THREE TOWER EMISSION

PROFILE

..

FOR THIS APPLICATION A RIGE THREE TOWER DESIGN WILL BE INSTALLED.

THERMAL DESIGN

Critical to the success of the thermal design is the selection of the heat transfer media. Babcock Wanson Regenerative Thermal Oxidisers for the rendering industry utilise ceramic saddles to provide excellent heat transfer and storage characteristics whilst providing minimal pressure drop through the ceramic bed to reduce the required fan power.

The selection of this material provides a number of benefits.

b

0 Resistance to thermal shock

b Fatigue resistance 0

High temperature resistance (lOOO°C and over)

b Resistance to erosion

Very high surface area to mass ratio for efficient heat transfer

The oxidation zone includes a specialist burner, specifically designed by Babcock Wanson for this application. The design provides a stable flame fiont to achieve high oxidation efficiencies by providing an homogenous temperature in the combustion chamber zone.

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EXAMPLE INSTALLATIONS

Below we detail outline information on two operational meat rendering plants that have very successfully utilised three tower Regenerative Oxidisers (RIGE) for a number .of years.

EXAMPLE 1

Installed at a meat rendering plant in 1994 this three tower RIGE Regenerative Oxidiser treats up to 7500kgh of cooker vapour plus 6500kgk of foul and make up air. The machine is of an older design, which has subsequently been updated to improve inspection and cleaning access.

EXAMPLE 2

This photograph shows a three tower RIGE Regenerative Oxidiser installed at a mixed meat and fish rendering process (all dry rendering). It treats up to 7,OOOkgk of vapour from a single continuous cooker plus up to 21,OOOkgh of foul and room air.

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BABCOCK WANSON DESIGN EXPERTISE AND SERVICE

As a group Babcock Wanson have nearly 250 Thermal Oxidiser reference installations of varying types world-wide and are able to demonstrate a wide experience Lnd'process knowledge, combined with an excellent understanding of many industries.

*q-< ,_

Our continuous programme of research and development with our design teams based in the UK, France and Italy ensures that we are able to offer the best solution to any process problem; we have also worked closely with various equipment manufacturers in this respect. The Service Organisation and After Sales Care of the Babcock Wanson Group back all our installations in order to ensure the plant is maintained in an optimum condition and availability is maximised.

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Poolboy, Ballinasloe, Co. Galway, Ireland. Tel.: 090-9642305. ., - ._..- _. .- ~ --- Fax: 090-9642738. .- : . Pr-$,": : ; . ; i , ..,. I. $pncy '

. .+ , .

I .

' L- '3 r ' . Mr Liam 0 Suilleabhain

Environmental Protection Agency Regional Inspectorate ?L>ALlc 2005

* John Moore Road Castlebar Co. Mayo.

Date Our Ref Your Ref 08/08/05 M 59U180805CcResp M592/cc071oslcc081odc/cd)9los

IPC License Reg.No. M592

! RE: Letter of odour complaint

Dear Mr 0 Suilleabhain We are in receipt of three copies of complaint forwarded by your office dated 22/06/05, 23/06/05 and 24/06/05. We have taken the following measures as a results o f these complaints.

1. The arrival of raw material to this site is being managed to avoid ,as far is practicable, the queuing o f lorriedtrailers in our yard. However this has been made more difficult due to a recent D O N requirement on all rendering plants that deliveries of fallen stock &e made during the hour of 09:OO to 18:OO Monday to Friday and 1000 to 12:OO on Saturdays.

2. As a precaution we have temporarily suspended the processing of blood at this facility.

The above measures appear to have had a positive effect on the number of complaints received at this facility. In addition to the above there are a number of other measures which will be taken in the medium to long term future.

1. A new intake building with airlocks is to be constructed. This will greatly reduce the potential for hgitive emission. The new intake building will be able to simultaneously accommodate two deliveries which will fiuther help to prevent any queuing in the yard.

2. A regenerative thermal oxidiser is to be installed on site. The RTO will treat highly odorous streatns'thereby reducing the load on our bio filters.

3. An odour audits is behg conducted with particular emphasis o f fugitive emissions and the integrity of all buildings on site is being assessed to highlight any areas where there may be fugitive emissions. Measures will be taken to eliminate or minimise emissions for any highlighted sources details of findings will be submitted to the agency

Should you require further information please contact this office.

Yours Sincerely,

Directors: N. Ryan, T. Tynm. Registered Office: 39/40 Upper Mount St. Dublin 2

Prmum Aoteinr is a registad business name of fi& ProtGinr (2000) Ltd.

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