We have been busy lately delivering custom industrial ovens, direct fired thermal oxidizers, but we’ve recently delivered several custom thermal deoilers based on our patented method of coupling heat processing systems and air pollution control systems to deliver these results.
One of the thermal deoilers was delivered to a company providing stamping oil cleaning services for HVAC furnace and A/C coil and automotive heater core industries, is based on an Oxidizer/Oven patented-Epcon® system and features a burner-less deoiler, a cooling zone, multiple conveyors and platforms. The unit has a built-in secondary heat recovery system that uses a shell and tube heat exchanger design, to recycle the heat from the oxidizer back into the burner-less oven.
The Result: This system’s efficiency has significantly reduced cost by more than 30% when comparing the old method of aqueous cleaning to the thermal deoiling process. This deoiler also eliminated toxic waste water and reduced water consumption as well.
Another system recently delivered by the Epcon engineering team is an integral thermal deoiler design, based on one of Epcon’s patents utilizing a thermal oxidizer and thermal deoiler for the oven. This thermal deoiler is also burner-less and utilizes the secondary heat from the oxidizer. The thermal oxidizer a shell and tube heat exchanger design that reduced the fuel consumption of the oxidizer. In addition, a secondary heat recovery system, that incorporated a plate and shell heat which supplies the heat necessary to operate the burner-less oven.
The Result: This system’s efficiency has significantly reduced fuel consumption and operating cost by over 30%, as well as reduced the amount of water usage and eliminated the production of toxic waste water.
Epcon Industrial Systems also delivered a thermal deoiler to a major HVAC equipment supplier. This integrated system consisted of a processing oven to clean the residual oil present in the HVAC coils, combined with an air pollution control system thermal oxidizer to destroy the solvents evaporated during thermal cleaning process. This processing oven features a dual lane conveyor system with a precision lane adjustment mechanism, and unique air distribution nozzles arrangement to offer high and low-pressure air impingement over specific areas of the HVAC coil. The combination of a higher recirculation rate and turbulence in the Oven processing chamber allowed the end user to achieve proper cleaning of parts in 20% less time.
The unique design of the integrated oven-oxidizer system offered a highly energy efficient solution by using air pollution control equipment as a heat source to the processing oven. The recuperative-style thermal oxidizer with primary and secondary heat recovery arrangements were used to design a “burner-less” oven configuration to recover waste heat generated in the oxidizer.
The Result: This new, optimized system configuration resulted into energy savings of 5.5 MMBTU per hour, which saved the company about $125,000 per year, a much higher ROI than anticipated. Epcon’s patented method of coupling heat processing systems and air pollution control systems is a prime example of how Epcon’s thermal engineering can create significant cost savings by making the process more efficient.