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Direct Cold Plasma The innovative answer to odour control in the food and feed industry (PDF)


Increasingly, feed manufacturers are being required to address the issue of release of odour and harmful contaminants into the surrounding community.

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									               Digital Re-print - September | October 2011
Direct Cold Plasma: The innovative answer to odour control in the food and feed industry

                       Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.
                       All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies,
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                       ©Copyright 2010 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form
                       or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872

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     FEATURE                                                                                                                                                                                                                                                                                         FEATURE

                                                                                                                                                                                                                        In most cases in the feed
                                                                                                                                                                                                                    industry, the emission tem-
                                                                                                                                                                                                                    perature from dryers will be
                                                                                                                                                                                                                    less than this temperature limi-
                                                                                                                                                                                                                        Maintenance is minimal, if
                                                                                                                                                                                                                    the unit is used as a dust
                                                                                                                                                                                                                    collector as well as odour
                                                                                                                                                                                                                    abatement system, then the
                                                                                                                                                                                                                    unit would have a ‘wash-down’
                                                                                                                                                                                                                    maybe once per week and
                                                                                                                                                                                                                    an internal inspection once
                                                                                                                                                                                                                    a month would be recom-
                                                                                                                                                                                                                    mended. Operating costs are
                                                                                                                                                          and charge carriers. This is actually identi-             very low and mostly associated with the          handle 1600m³/h and tests were repeated
                                                                                                                                                          cal to what happens with pollution in the                 cost of electricity; 10-20kW for a standard      to check validity. Independent Olfactometry
                                                                                                                                                          atmosphere. Reactions occur with the odour                20,000m³/h cold plasma unit.                     testing was used as a means of determining
                                                                                                                                                          bearing compounds in the gas to be treated.                   A costing exercise produced by one of        odour reduction efficiency.
                                                                                                                                                          Ambient air may be injected just prior to the             APP’s customers, is shown below. This is             Test results indicate that odour removal
                                                                                                                                                          reaction chamber to optimise humidity and                 based on a 10-year period, including both        efficiencies of up to 90 percent are achiev-
                                                                                                                                                          temperature as well as adding ions to the                 investment and operating cost for a volume       able within the food and feed industry and
                                                                                                                                                          gas stream.                                               of 20,000m³/h. The operating costs for the       that the standard colds plasma module will

  Direct Cold Plasma:
                                                                                                                                                              In essence the cold plasma process                    scrubber alone or scrubber biofilter do not      handle around 20.000Am³/h.
                                                                                                                                                          encourages ‘oxidation’ of the odour bearing               include cost of water.                               Higher efficiencies may be achieved by
                                                                                                                                                          compounds at low temperature by creating                                                                   using a final polishing module. During testing,
                                                                                                                                                          discharge (cold plasma).                                  Testing in the petfood and fish                  both high and low odour concentrations
                                                                                                                                                              A closed-loop cooling unit ensures that               feed industries                                  were experienced; nonetheless cold plasma
    The innovative answer to odour control in the food and feed industry                                                                                  operating conditions within the high voltage
                                                                                                                                                          generator are maintained within controlled
                                                                                                                                                                                                                       Since 2003, extensive testing with a pilot
                                                                                                                                                                                                                    system both on extrusion flash-off, driers and
                                                                                                                                                                                                                                                                     achieved real odour reductions even on
                                                                                                                                                                                                                                                                     very low inlet concentrations, something
                                                                                                                                                          limits. A proprietary control system moni-                coolers has been carried out. All possible       that is not always the case on alternative
                     by Havard vetrhus, Director Sales & Marketing, Applied Plasma Physics AS,                                                            tors the high voltage passed to each of the               variables have been reviewed to determine        technologies.
                                    Norway Tel: + 47 5160 2220, Email:                                                              corona wires in the reaction chamber, and                 the optimum operating conditions for the             Overall the tests indicated that the cold
                                                                                                                                                          controls the voltage modulation that gener-               cold plasma system.                              plasma unit operated most effectively with-
                                                                                                                                                          ates the cold plasma.                                                                                      out a scrubber either at the inlet or outlet.

   ncreasingly, feed manufacturers are being      •   End of pipe solution                         with APP (Applied Plasma Physics AS).                      The system also detects arcs between the              Variables tested:                                Dust removal was very effective (99% reduc-
   required to address the issue of release       •   Low running cost                                APP is both an R&D and equipment sup-               corona wire and the cell wall, automatically               • Residence time (determines volume to          tion).
   of odour and harmful contaminants              •   Minimal maintenance                          ply company, specialising in the application           shutting down electrical supply for a fraction               be handled by a standard module)                  As a result of these tests, several petfood
into the surrounding community.                   •   Ability to operate at normal feed            of high voltage technology and non-thermal             of a second before power is reinstated.                    • Effects of water scrubber at inlet or         sites have now installed cold plasma technol-
                                                      manufacturing temperatures, to avoid         plasma systems for industrial processes. APP               The reaction chamber may be oper-                        outlet of cold plasma                         ogy for their processes. As per today, 50
    Local communities, special interest groups        cooling costs                                has now delivered more than 200 systems,               ated with the gas flow passing upwards or                  • Cold plasma unit operating alone              units are in operation in the petfood industry,
and government legislation all bring pressure     •   High odour removal efficiency                most running on difficult applications.                downwards depending on site layout. The                    • Adding water to humidify inlet or outlet      a figure that will increase substantially in the
to bear on factories to minimise real or          •   No chemical additions and need to               APP has experience on ultra high odour              unit is capable of operating on emissions with               gas                                           years to come.
perceived risks of contamination.                     maintain chemistry                           applications – where odour levels can be               relative humidity close to 100%, although                  • Air infiltration volume (ion enrichment)          The experience of the environmen-
    There are no universally applied standards    •   No liquid effluent waste                     over 200,000 odour units per m³ - and the              the closer to 100% RH the unit operates,                   • Intensity of cold plasma generation           tal needs of the feed industry, and APP’s
for odour or Volatile Organic Compounds           •   Instant on/off – no warm up time             company achieved odour removal efficien-               the higher the possibility of arcs and conse-              • Geometry and arrangement of reaction          approach to innovative design is combined
(VOC) emissions, and to provide solutions         •   Modular construction, ease of relocation     cies of up to 97 percent. Another advantage            quently risks of reduced efficiency.                         cells                                         to offer a competitive alternative solution to
that fit specific factory needs can be com-           if change of production location and         that is unique for this specific technology is             The unit can be operated with emission                                                                 a problem that is of increasing significance to
plex. There is no single solution but under-          ease the ability to add on modules           that both odour and dust are removed from              temperatures up to 70°C.                                     The pilot plant (test unit) is designed to    the food and feed industry.
                                                                                                                                                    symaga_quarter page_IAFD2011              13/5/11       10:09    Page 1
standing the feed manufacturers problems              according to required capacity               the production emissions.
certainly helps a great deal.                     •   Competitive capital cost
    In recent years, there have been numer-                                                        Cold plasma technology – Nature
ous changes regarding where production              This is a tall order but there is a technol-   in a box                                                                                                                                                
facilities are situated. Factory closures and    ogy can answer most of these needs: Cold              Odour bearing gases enter the cold
relocation of manufacturing units has become     Plasma.                                           plasma module, where care is taken to dis-
commonplace.                                                                                       tribute gases evenly as it enters the reaction
                       At the same time          A high tech, high voltage                         chamber. The reaction chamber comprises a
                    urban sprawl has resulted    solution                                          cluster of hexagonal cells. Running centrally
                    in residential areas being      In 2003 a global petfood manufacturer          through each cell is a corona wire, which is          "Over 20 years of experience in the design, construction
                    built closer to previously   tested a new technology for odour removal,        isolated from the rest of the chamber.                      and supply of storage solutions, worldwide"
                    remote industrial areas.     referred to as Direct Cold Plasma, on drier           The high voltage generator distributes
Another pressure companies face is meeting       and extruder flash-off exhausts.                  a modulating high voltage supply to each                                                         ALL TYPES OF SILOS INSTALLATIONS TO COVER THE MARKET NEEDS
local environmental needs.                          The technology had obvious advantages          corona wire, and this process results in a
    So what does the industry need from          over more conventional solutions. As a result     discharge between the corona wire and the                                                    Silos for seeds, cereals, malts, oil seeds (soya, sunflower, rape, ...), pellets, meals, rices, and in
its odour abatement equipment? This is a         the petfood manufacturer looked for a suit-       cell wall.                                                                                        general, products for agriculture, agrifood industry, biofuels, and biomass (wood pellets, ...)
complex question and the answer needs to         able technology partner for collaboration on          The discharge promotes the emission
include:                                         the application of cold plasma on petfood         with high-speed electrons, which collide                                                                     Ctra. De Arenas, km 2,300, 13210 Villarta de San Juan. Cludad Real - Espana
  • A compact design minimising space            applications.                                     with background gas molecules creating                                                                                     
     requirements                                   In 2003 they formed such an agreement          chemically active species known as radicals                                                     Phone: +34 91 726 43 04/ +34 926 64 04 75       Fax: +34 91 361 15 94/ +34 926 64 02 94

26 | September - october 2011                                                                                Grain &feed millinG technoloGy               Grain  &feed millinG technoloGy                                                                                             September - october 2011 | 27
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Innovations for a better world.
This	digital	Re-print	is	part	of	the	September	|	October	2011	edition	of	Grain	&	Feed	Milling	Technology	magazine.		
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             October                    2011
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                                                                                            folic acid prevents
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                                                                                            defects annually
                                    •    Direct Cold Plasma:

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                                         The innovative answer to odour               •     Global Feed
                                         control in the food and feed                       Markets:
                                         industry                                           Wheat supply
                                                                                            grows and grows
                                                                                            as corn crop

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