About the Client
A manufacturing site in eastern Europe producing Consumer Goods (FMCG) with a process that emits ammonia as a byproduct. The facility faced odor-related challenges due to ammonia emissions. Their requirement included an efficient and sustainable solution to ensure regulatory compliance and a safer working environment for their operators.
Challenge
The client needed an effective system to mitigate odor issues caused by ammonia emissions. Additionally, the facility sought a solution that could enhance air quality within the factory. Their goal was to remove airborne pollutants such as acetic and butyric acid, as well as particulate matter.
Approach
To address these challenges, JOA Air Solutions followed a 4-step process:
Pre-engineering study: An initial assessment to dive deep and define the full project scope and requirements. This phase included:
- Inspection & measurements on-site (temperature, relative humidity, flow, pressure drop, etc.) of the current process setup.
- Interviews with operators, process engineers.
- Odor tests with residents from surrounding neighborhoods.
- Detailed report that includes findings, actionable recommendations, and a budget quotation for the best possible solution direction.
Design & Engineering: Development of a tailored solution ensuring maximum efficiency and compliance.
- Creation of an air-technical model for system balancing and condensation risk calculations.
- Mechanical engineering designed a system that effectively addresses the challenge while ensuring seamless integration with existing infrastructure.
- Electrical Engineering & Software Engineering, making sure the system operates and communicates with existing equipment.
System Realization: Implementation and commissioning of a 3-stage Chemical Scrubber system.
- Manufacturing: Our Dutch manufacturing site produces all necessary parts for the 3-stage chemical scrubber.
- Logistics: Making all manufactured components ready for shipment and sending it to the client for installation.
- Installation: On-site project manager installs tailor-made system and ensures that everything is operational.
Service & Spare Parts: Maintenance and providing spare parts for the system in place.
Due to the complexity of the various challenges, a thorough approach lead to the design of a tailor-made 3-stage Chemical Scrubber System.
Outcome
Based on the Pre-Engineering study, JOA was able to provide Process Guarantees in advance of building and implementing the system.
- Effective removal efficiency of more than 80% of ammonia emissions and other odor-causing compounds, ensuring compliance with air quality regulations.
- Dust removal efficiency of 95%, with <5 mg/m3 and a 8-hour Time-Weighted Average (TWA). Highly improving Healthy Work Environment and preventing Dust Explosions.
- Enhanced process stability at both the STEM dryer for moisture removal and DCC stages.
- Removal efficiency of more than 80% for Acetic and Butyric acids.
- As the project evolved, a heat exchanger was integrated, resulting in improved energy efficiency, reducing operational costs and increasing sustainability.
Conclusion
By implementing a customized multi-stage chemical scrubber system through a structured 4-step approach, JOA Air Solutions successfully assisted the consumer goods manufacturer to achieve odor control, dust mitigation, and energy efficiency through heat recovery.
The integration of Heat Recovery in combination with a Chemical Scrubber further enhanced sustainability efforts, providing long-term benefits for both the production facility, its operators and the environment.
