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PRESS RELEASE

Going Solar with Epcon Industrial Systems

American company announces plans to involve itself in solar energy.

Epcon Industrial Systems, LP, already an industry leader in air pollution control, is proud to announce their first venture into the field of solar energy production. This move is in line with Epcon’s stated business
mission: “Protecting the environment through technology.”

Solar energy is a nationally and globally valuable enterprise, with the potential to eliminate, or at least reduce, our economy’s dependence on non-renewable forms of energy, such as oil.

As cutting-edge science continually increases our ability to harness ever-larger amounts of the sun’s energy, solar panels could contribute to more than America’s financial health; the development of solar energy systems sufficient to reduce dependence on overseas oil may actually contribute to easing global political unrest.

Since 1976, Epcon has been actively engaged in creating and providing environmentally friendly, cost-effective solutions for industries ranging from food processing to metal finishing. This dedication to protecting our natural resources has resulted in the development of a full line of industrial products and processes, from heating and finishing systems to thermal/catalytic oxidizers and heat recovery systems.

As part of their ongoing mission to provide solutions that balance the energy needs of American industry with the environmental needs of humanity, Epcon’s design team has developed a process to use their already existing systems in the curing and baking processes of solar panel development and manufacture.

The benefit of improved solar efficiency goes much deeper than easing American industry’s dependency on oil. Although the initial cost for solar cells can be high, they quickly pay for themselves, since—unlike oil—the sun comes up every morning. And, perhaps most importantly, there are no waste products associated with converting sunlight into energy.
That means no greenhouse gas emissions, no foul-smelling exhaust, and no lung-smothering pollutants emerge from this technology.

With the smell of profitability growing ever-stronger, solar energy is on its way to becoming a player in the American energy contest. And the versatility of solar panels certainly doesn’t hurt—they can be placed anywhere, so long as the sun hits them. This fact is causing companies that produce things not traditionally associated with solar energy, such as thermal oxidizers and pollution control systems, to get involved in the game as well.


To learn more about this forward-thinking, environmentally-conscious company and the products offered, visit http://www.epconlp.com.
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Recuperative Thermal Oxidizer

Recuperative Thermal Oxidizers are designed to be highly energy efficient systems that achieve high levels of VOC destruction to keep processes well below required DRE emission levels. A RTO System is based upon the principle of thermal oxidation, which utilizes the process of regeneration for internal heat recovery.

The recuperative principle operates around multiple energy recovery chambers in use on the system, which are the housings for the ceramic heat recovery media. The ceramic heat recovery media acts as a heat exchanger for the system.

The multiple chambers operate under a "swing bed" absorption principle: which is the principle of transfer through multiple beds by the use of flow reversal. In the use of this principle with ceramic stoneware, the process is called regeneration.

As the dirty exhaust stream travels through the first bed of ceramic media, the exhaust stream adsorbs the heat energy stored in the ceramic media mass, which pre-heats the exhaust stream. The exhaust stream then enters the burner reactor chamber, where heat energy is added from the burner to reach the system operating temperature. After the temperature has been elevated, the clean exhaust stream then passes through the second energy recovery chamber. As the exhaust stream passes through the chamber, the cold ceramic media mass absorbs the heat energy of the exhaust stream, and stores the heat energy for the reverse flow of the system. Once the heat energy of the first chamber has been depleted through the absorption of the incoming air stream, the flow through the system is rotated, so the incoming dirty air stream is then directed through the previous absorption chamber, with the clean waste gas now going through the previously purged chamber.

By using the reversal of exhaust flow through the ceramic beds, a minimal amount of heat energy needs to be added to the incoming exhaust stream to maintain the systems minimum operating temperature. The sizing of the ceramic media beds is such that a 95%+ heat recovery efficiency is possible through the regenerating, reversal flow process.
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A VOC Abatement System relies upon the concept of a chemical reaction – when involving organic hydrocarbons the process is called oxidation. In an oxidation process, the compounds within the air stream – VOC pollutants – are broken down from their original composition and reformed into new compounds. In the VOC Oxidation Process, enough heat and oxygen are added to the hydrocarbons to create the oxidation reaction – this process is called Thermal Oxidation.By breaking the original composition of the VOC Hydrocarbons – carbon and hydrogen – we allow the two constituents to reform naturally into carbon dioxide and water vapor while releasing heat energy. The heat energy is then recuperated into the system by use of a heat exchange device, while the now clean air stream of carbon dioxide and water is discharged to atmosphere

In order to determine the most appropriate VOC Abatement technology available to best suit the application, the process exhaust stream must be characterized. The first step in characterizing the exhaust stream is to establish the current operating parameters of the plant – i.e. volumetric flow, volatile organic compound loading, and any other inorganic contaminants that might exist. By determining the existing operating conditions for the plant, a technology can then be selected based upon the major criteria associated with the equipment:


* Initial Capital Cost for VOC Plant

* Annual Operating Cost for VOC Plant (natural gas and electricity)

* Annual Maintenance Cost for VOC Plant

* Reliability of Plant Equipment vs. Plants Requirements for Process Run Time

* Required Destruction Rate Efficiency for Compliance with Regulations

* Flexibility for Future Operation of the Plant’s Process
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Epcon News update


Today, Epcon announces the manufacture and supply of a curing oven in Suzhou China to dry Flux Paint on one stand of aluminum tube in a continuous process, quench to cool the aluminum tubing, dryer to dry the water from the tubing and thermal oxidizer for VOC destruction. The curing oven exhaust shall be connected to a thermal oxidizer via ductwork supplied by others. We will supply a push/pull type system with curing oven exhaust fan and oxidizer induced draft exhaust fan. Epcon’s scope of supply includes:

a) (1) One curing oven
b) (1) One quench
c) (1) One dryer
d) (1) One thermal oxidizer

The aluminum tubing shall be coated and cured during the process. There shall be one (1) tubing strand passing through the oven. The maximum pass through rate shall be 60 m/min (197 ft/min). The loading for the maximum pass through rate shall be 200 Kg/hr (440 lbs/hr) for single tubing strand.

The process parameters are as following:

• Height: 1 mm to 5 mm (0.04” to 0.2”)
• Width: 10 mm to 30 mm (0.4” to 1.2”)
• Weight: .02 lbs/ft to .06 lbs/ft
• Line Speed: 60 m/min (197 ft/min)
• Solvent Removal: 4 Kg/hr (8.8 lbs/hr)
• Tubing Type: Aluminum 1000, 3000 alloy
• Number of Strands: One
• Curing Temperature: 120°C (248°F) PMT
• Style: Catenary
• Cooling Temperature: 120°C to 50°C (248°F to 122F), Water cooling depends on line speed and temperature.
• Product A-non-zinc coated, Product B-zinc coated



SYSTEM DESCRIPTION AND DESIGN BASIS

In the oven system hot air is used to dry the paint (coating) on the aluminum tubing and to vaporize all residual process coming of the coating during the drying of the tubing. The VOC’s coming out of the painted metal are destroyed in an oxidizer, there is no emission of hazardous substances in the atmosphere. Air recirculation system is designed to produce uniform heating in the oven. The VOC’s are carried to the oxidizer for oxidation and heat release.

In the oven system the oxidizer serves as the pollution control device. Time, temperature and turbulence (known as three T’s) are the three necessary ingredients for successful oxidation. The design shall ensure that all of three are sufficiently present. Destruction Efficiency of 95% is achieved by using a residence time of 1 second at 1400ºF (1600ºF max.). The VOC’s coming of the coated metal act as fuel to the oxidizer reducing primary fuel cost to absolute minimum.

The oven shall operate at 315°C (600°F) maximum temperature to achieve 120°C (248°F) peak metal temperature at the maximum strip speed.

PROJECT SCOPE
Equipment

Curing oven:

• Oven heating chamber (single zone)
• Gas fired burner
• Recirculation fan
• Exhaust fan
• Top and bottom hot air supply plenums
• Gas train
• Water cooling system (spray type)
• Dryer

Recuperative Thermal Oxidizer:

• Combustion/Retention chamber
• Natural gas fired burner system
• I. D. Fan with VFD
• NFPA gas train

Heat Recovery Systems:

• Pre-heat exchanger for the oxidizer

Accessories:

• Control panel – NEMA 12 Rated
• PLC


Services

• Design and engineering.
• Materials procurement.
• Shop fabrication and assembly.]]> http://www.epconlp.com/blog/index.php?entry=entry080217-141149
Catalytic Oxidizers


The primary purpose of the Catalytic Oxidizer is to oxidize the hydrocarbons contained in the exhaust coming from the process. Basically, the hydrocarbons require fuel and oxygen to heat the catalytic cell to a specified temperature where an exothermic reaction will destroy the hydrocarbons.

Catalytic Oxidizers convert process exhaust stream Volatile Organic Compounds into harmless amounts of carbon dioxide, water, and thermal energy - which are then safely discharged to the atmosphere. This process is known as oxidation. Catalytic Oxidation occurs through a chemical reaction between the VOC hydrocarbon molecules and a precious-metal catalyst bed that is internal to the oxidizer system. A catalyst is a substance that is used to accelerate the rate of a chemical reaction, allowing the reaction to occur in a normal temperature range of 275ºC to 350ºC. This operating temperature is substantially less than straight Thermal Oxidation, and when combined with a low VOC loading level from the process stream, the system becomes self-sustaining (requiring minimal natural gas to support operation).

Catalytic Oxidizers are an ideal control option in applications that have consistent Volatile Organic Compounds (VOC's). By using a catalyst bed in the air treatment equipment, oxidation is accomplished at much lower temperatures compared to thermal oxidation. A catalytic oxidizer operating 370 to 480 °C (700 to 900 °F) range can achieve the same efficiency as a thermal oxidizer operating between 700 and 820 °C (1300 and 1500 °F) which can result in fuel savings of 40 - 60% .

As explained above, normal units are designed to achieve 95% destruction efficiency when operated according to the design specifications.



• Advantages

* Lowest Operating Cost
* Effective with High VOC Concentrations
* Low Exit Temperature


• Disadvantages

* Process May Poison Catalyst
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Soil Remediation System


The purpose of the Soil Remediation system is to destroy the contaminants in the exhaust coming out of a process based on the principle of combustion. The process of combustion is the most commonly used method to control emissions of organic compounds. Soil Remediation units are simple systems capable of having very high destruction efficiency using combustion: a chemical process arising from the rapid combination of oxygen with various elements or chemical compounds resulting in release of heat The process of combustion has also been referred to as oxidation or incineration. Its primary functions are to extract VOC’s from contaminated soil related to Oil Drilling Rigs and/or Chemical Storage Sites A mobile unit is self sufficient and can be transported to remote sites. These units can acheieve DRE in excess of 99%


Advantages

* High DRE
* Lowest Capital Cost
* Low Installation Costs
* No Moving Parts = Lower Maintenance Costs
* Effective For High VOC Concentrations

Disadvantages

* High Operating Costs with Low VOC Concentrations
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PRINCIPLES OF COMBUSTION

Thermal oxidation technology has proven to be industry choice for destroying Volatile Organic Compounds (VOCs). The process of combustion is the most commonly used method to control emission of organic compounds. Combustion type systems are always simple systems capable of having very high destruction efficiency.

Combustion is a chemical process arising from the rapid combination of oxygen with various elements or chemical compounds resulting in release of heat. The process of combustion has also been referred to as oxidation or incineration. It is required to achieve complete combustion of the fuel gas so that no further air pollutants are added.

To achieve complete combustion once the air waste, and fuel have been brought into contact, the following conditions must be provided:

• a temperature high enough to ignite the waste-fuel mixture,
• turbulent mixing of the air and waste-fuel mixture, and
• sufficient residence time for the reaction to occur.

These three conditions are referred to as "three T's of combustion." The rate at which a combustible product is oxidized is greatly affected by temperature. The higher the temperature the faster the oxidation reaction will proceed. The process of ignition depends on the following factors:

1. Concentration of combustibles in the waste stream.
2. Inlet temperature of the waste stream.
3. Rate of heat loss from the combustion chamber.
4. Residence time and flow pattern of the waste stream.
5. Combustion chamber geometry and materials of construction.


Thermal destruction of most organic compounds occurs between 900°F and 1,300°F. The time for which the pollutants stay in the incinerator is called residence time. The higher the residence time the lower temperature can be used for the combustion chamber. The residence time of gases in the combustion chamber may be calculated by

t = V / Q

where, t = residence time, seconds
V = chamber volume, ft3
Q = gas volumetric flow rate at combustion ft3/s.

Adjustments to flow rate must add the extra combustion air added. For complete combustion to occur every particle of waste and fuel must come in contact with air (oxygen). If this does not happen, unreacted waste and fuel will be exhausted from the stack. Second, not all of the fuel or waste stream is able to be in direct contact with the burner flame.

In most incinerators, a portion of the waste stream may bypass the flame and be mixed at some point downstream of the burner with the hot products of combustion. A number of methods are used to improve mixing the air and waste streams, including the use of refractory baffles, swirl-fired burners, and baffle plates. Unless properly designed many of these mixing devices may create "dead spots" and reduce operating temperatures. The process of mixing flame and waste stream to obtain a uniform temperature for the decomposition of wastes is the most difficult part in the design of an incinerator. There are three types in which the combustion type of systems can be divided, which are as follows:

1. Thermal Recuperative Oxidizer
2. Catalytic Oxidizer
3. Regenerative Thermal Oxidizer.

All these types of Oxidizers are manufactured at Epcon. Catalytic Oxidizers use a catalyst to carry out destruction of VOCs at lower temperatures. Catalytic Oxidizers may or may not be provided with recuperative Heat Exchangers depending on the application requirements. The primary difference between the Regenerative Thermal Oxidizers and Thermal Recuperative Oxidizers is the principle of heat recovery.

TYPES OF HEAT RECOVERY

As energy costs become important, addition of heat recovery becomes essential. In both systems, hot clean combustion gases are used to preheat the incoming process exhausts. Heat Recovery takes two basic forms:

(A) Recuperative (B) Regenerative


OPERATION SEQUENCE (TWO CHAMBER RTO)

Continued preheating of the process gas causes the ceramic media canister to cool down, at the same time the ceramic media in the next chamber is heated. The inherent nature of the Regenerative Systems involves discontinuous or cyclic operation.

CYCLE –1

CANISTER 1- PREHEAT CYCLE
Cold process gases are preheated by the media in Canister 1.

CANISTER 2 - HEAT RECOVERY CYCLE
Hot air exiting the residence chamber heats up the media in Canister


CYCLE –2

CANISTER 2- PREHEAT CYCLE
Cold process gases are preheated by the media in Canister 2.

CANISTER 1 - HEAT RECOVERY CYCLE
Hot air exiting the residence chamber heats up the media in Canister


HEAT RECOVERY EFFICIENCY

Selection of the correct heat recovery efficiency in an RTO is a function of the following parameters:

• VOC loading in the exhaust stream.
• Presence of corrosive gases in the exhaust stream.
• Plant operation cycle for the RTO.

Heat Recovery Efficiency is defined by the following equation:

Eff. = (Preheat Temperature - Process Gas Inlet Temperature)
(Oxidizer Residence Chamber Temp. - Process Gas Inlet Temp.)

For Example:
A RTO with a Preheat Temperature of 1335°F (724°C) at an Oxidizer Residence Chamber Temperature of 1400°F (760°C) assuming an inlet temperature of 100°F (38°C), will have Heat Recovery Efficiency as follows:

Eff = (1335 - 70)
(1400 - 70)

= 0.951 or approximately 95%


Valves

In Epcon’s Two Canister RTO, there are two 30” poppet valves that control the airflow. The dampers are located in a position for easy maintenance. Access doors have been provided on each damper in the event access inside the poppet box is needed. The valve shaft can be disconnected and slid apart to allow replacement of the valve plate when it becomes worn out.

Insulation

The Thermal Oxidizer is constructed of material, which can withstand high temperatures and the walls of the equipment are insulated to avoid overheating of the outside walls of the unit. The typical width of insulation is 6 inches in the heat recovery chambers and 7 inches in the combustion chamber consisting of ceramic block.


Controls and Electrical Design

This Thermal Oxidizer is designed to simplify maintenance and service. The control panel contains Honeywell Flame Management System, relays, timers, and switches. This system is responsible for the complete control of the burner start-up, from pre-purge to the ignition trial and the final flame. Another control point is the High Temperature Limit, which monitors the operating temperature. A Variable Frequency Drive (VFD) controls the main exhaust fan. This allows for variable speed control of the fan to match the desired volume through the oxidizer. Other items in the control panel are the indicating lights and push/pull buttons. The control panel should be checked and monitored periodically to ensure safe and correct operation.


Other Features

Like the control panel, the gas train contains components that require little maintenance. Adjustments to the gas train have been made at the factory. Components have been set for proper operation and control. Many components are totally enclosed to protect them from damage by dust and dirt. Should any minor adjustments for the pilot or main gas regulator be required, refer to the literature on the specific component.

In the unlikely event that the ceramic media must be removed, there is an access doors on the top of the unit to allow access. .

The Thermal Oxidizer should perform satisfactorily and give many years of trouble free service. It however, like any high quality equipment, deserves proper maintenance and care.
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INDUSTRIAL GAS FIRED OVEN



CONSTRUCTION

An industrial Gas Fired Oven is typically of steel construction, comprised of inner and outer shells of sheet steel panels, separated by 4” thick, 6 lb/ft3 density mineral wool insulation. The panels are constructed as to minimize metal-to-metal contact between inner and outer shells and reduce heat flow from oven chamber to the exterior surface. The structures are self-supporting, rigid, and of adequate strength to support all auxiliary equipment. Interior surfaces can be made of 16 or 18 gauge aluminized steel and outer surfaces are made of 16 or 18 gauge aluminized steel as well.


OVEN BURNERS & HEATERS

The Oven is heated by one or more gas fired burners. Burners are usually located in the combustion chamber, separated from work chamber. Typical burner capacity is 1.0 x 106 BTUH designed in such a way that the Oven shall reach the appropriate operating temperature in sufficient time. Electric heaters that may be used are located on the walls of the Entry and Exit ends of the Oven. Recirculation air in the Oven is heated by means of the gas fired burners in the combustion chambers and the electric heaters on the walls. The design of the combustion chamber is to satisfy the specification for gas fired heating.

RECIRCULATION SYSTEM

An Oven at approximately 25,000 CFM capacity for example would be provided with one (1) Air Kit Type Recirculation Fan with. The recirculation fan is complete with belt guard, belt drive, airflow switch, pillow block bearings, and keys. The recirculation fans are driven by a 5 - 50HP motor mounted on an adjustable base.


EXHAUST SYSTEM

The Preheat Oven is provided with one or more General Purpose Exhaust Fans with 1,500 CFM capacity (each) on average. The exhaust fan is complete with belt guard, belt drive, airflow switch, pillow block bearings, and keys. The exhaust fan is driven by a motor mounted on an adjustable base.


SUPPLY AND RETURN PLENUMS

The Supply and Return Plenums are should include nozzles are made of 18 gauge aluminized steel that are adjustable to balance the flow. The hot air is delivered in the Ovens from the supply plenum located on the floor and is returned through the top opening in the Combustion Chamber.


ELECTRICAL CONTROLS

One large NEMA-12 Control Panel typically is used to house the controls. The panel can be attached to the Oven sidewall. A controller, switches, and indicating lights are mounted on the face of the Control Panel. In addition, the Oven has the following controls incorporated into the system:

• Control Power Selector switch.

• High Temperature Limit to assure high temperature safety.

• Temperature Controller to control burner.

• Combustion Air Blower is integrated to the burner as a heat source and for complete combustion of the fuel gas.

• Fan Interlock: All fans are interlocked by airflow switches to prevent overheating of the Oven if fan is either off or inoperative.

• Power supply ]]> http://www.epconlp.com/blog/index.php?entry=entry070614-164636

PRINCIPLE OF COMBUSTION

The primary function of the Thermal Oxidizer is to destroy the contaminants in the exhaust coming out of a process. The operation of the Thermal Oxidizer is based on the principle of combustion. The process of combustion is the most commonly used method to control emissions of organic compounds.

Combustion based systems are always simple systems capable of having very high destruction efficiency. These systems typically consist of burners, which ignite the fuel and pollutants, and a chamber, which provides the appropriate residence time for the combustion to take place. Combustion is a chemical process arising from the rapid combination of oxygen with various elements or chemical compounds resulting in release of heat. The process of combustion has also been referred to as oxidation or incineration.

It is required to achieve complete combustion of the fuel gas so that no further air pollutants are added. To achieve complete combustion once the contaminated air and fuel have been brought into contact, the following conditions must be provided: a temperature high enough to ignite the waste-fuel mixture, turbulent mixing of the air and waste-fuel mixture, and sufficient residence time for the reaction to occur. These three conditions are referred to as the "three T's of combustion". The rate at which a combustible product is oxidized is greatly affected by temperature. The higher the temperature, the faster the oxidation reaction will proceed.

The process of ignition depends on the following factors:

1. Concentration of combustibles in the waste stream.
2. Inlet temperature of the waste stream.
3. Rate of heat loss from the combustion chamber.
4. Residence time and flow pattern of the waste stream.
5. Combustion chamber geometry and materials of construction.


RETENTION CHAMBER DESIGN

Thermal destruction of most organic compounds occurs between 590°F and 650°F. However, most hazardous waste incinerators are operated at 1400°F. The time for which the pollutants stay in the incinerator is called residence time. The higher the residence time, the lower the temperature can be for the combustion chamber.

The residence time of gases in the combustion chamber is calculated by
t = V / Q
where,
t = residence time, seconds
V = chamber volume, ft3
Q = gas volumetric flow rate at combustion ft3/s.

Adjustments to flow rates must be made for the extra combustion air added. For complete combustion to occur, every particle of waste and fuel must come in contact with air (oxygen). If this does not happen, unreacted waste and fuel will be exhausted from the stack. Second, not the entire fuel or waste stream is able to be in direct contact with the burner flame.

In most incinerators, a portion of the waste stream may bypass the flame and be mixed at some point downstream of the burner with the hot products of combustion. A number of methods are used to improve mixing the air and waste streams, including the use of refractory baffles, swirl-fired burners, and baffle plates. Unless properly designed, many of these mixing devices may create "dead spots" and reduce operating temperatures.

The process of mixing flame and waste stream to obtain a uniform temperature for the decomposition of wastes is the most difficult part in the design of an incinerator. A Thermal Oxidizer must be designed very carefully and with proven methods to achieve maximum mixing of airflows and to avoid dead spots.


THERMAL OXIDIZER OPERATION

A Thermal Oxidizer consists of a combustion chamber, a burner, and a blower to draw air through the complete oxidizer. Along with the contaminant-laden gas stream, air and fuel are continuously delivered to the combustion chamber where the fuel is combusted.
The products of combustion and the unreacted feed stream enter the reaction zone of the unit. The pollutants in the process air are then reacted at elevated temperature. The average gas velocity can range from 10 fps to 50 fps. These high velocities are useful in preventing the particulates from settling down. The energy liberated by the reaction may be directly recovered from process or indirectly recovered by using a heat exchanger.


INSULATION

The Thermal Oxidizer should be constructed of material which can withstand high temperatures and the walls of the equipment are insulated to avoid overheating of the outside walls of the unit. These units are usually provided with sophisticated flame detection devices. The layer of insulation exposed in the Combustion Chamber is typically ceramic block that is 7” thick and a density of 10 lbs./ft3.
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