Reducing Energy Consumption on Process Ovens & Oxidation Systems

Abstract

With the uncertain cost of energy, optimizing the use of air in process dryers, ovens and air pollution control systems is critical to your bottom line. The revived emphasis on air management through the entire process, from plant make-up air heating systems to pollution control system exhaust, provides many opportunities to save energy and cut operating costs. This presentation includes an overview of good air management practices used to optimize energy use in your process and plant. One of the most important benefits of the more stringent air pollution control regulations throughout the world is the focus on better use and conservation of our natural resources. Through the efforts of many of the world's finest engineers and scientists the world is now realizing the benefits of an environmentally friendly approach to manufacturing. These benefits, which include more efficient process operation, less waste generation and reduced emissions, have produced the unforeseen benefit of reduced production costs and higher quality products. Process dryers and ovens are used in the manufacture of a wide variety of products produced by the companies represented at the Industrial Energy Technology Conference. This equipment is installed and operating in facilities that produce printed materials, packaging materials, adhesive tapes, pharmaceutical diagnostic materials, coated papers & films, foil laminations, electronic media, and photographic & x-ray films. They are also used extensively in the food industry. The products manufactured include baked goods, cereals, pet food, tobacco, and many other products. Ovens are used to bake and cure surface coated materials. Such as building siding, window frames, window blinds, automotive parts, wood products, and miscellaneous metal parts. More stringent environmental regulations are also impacting the design and operation of coating and food processes. Today air pollution control devices are used on many of the above applications to control the emissions of volatile organic compounds (VOC's) and odors. As emission limits have decreased, the use of permanent total enclosures PTE's are becoming a standard part of the process line design. These enclosures are used to obtain 100% capture of the solvents used in the process. In addition, concerns over solvent concentrations in ovens along with concerns over exposure limits to employees have combined to drive process exhaust flows ever higher. Increasing process exhaust flows has been the common approach to addressing process and environmental issues. This increase in exhaust flows has resulted in significant increases in energy use and operating costs.