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Carbon Reactivation Systems

EnviroAir Carbon Reactivation Systems are used to reactivate spent activated carbon that has absorbed moisture and organic compounds. EnviroAir will also provide the required air quality control equipment to ensure compliance with EPA and local air quality control standards.

EnviroAir Carbon Reactivation Systems Feature:

  • Indirectly heated – no flame impingement on the carbon to cause oxidation and loss of carbon material
  • Exhausts are collected and discharged directly into air quality system – reducing pollutants
  • Fully automatic system – simple to operate

Carbon Reactivation Process Diagram

Our Locations

Spent carbon is fed into the input hopper.

Sealed screw feeder feeds the spent carbon into the rotary retort at a constant rate.

Spent carbon is heated to 1,400 to 1,650°F inside the rotary retort, evaporating moisture and oxidizing volatile organic compounds absorbed in the carbon micropores.

Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the carbon that could cause oxidation and loss of the carbon material.

Retort exhaust gases are collected in the retort exhaust hood and discharged to an air quality control system.

Transfer Chute

Cooling air is collected in the cooling drum exhaust hood and discharged to an air quality control system.

Heat from the reactivated carbon is transferred to the cooling air, in the rotary cooling drum. The reactivated carbon leaves the cooling drum at no more than 30°F above ambient temperature.

Fines in the reactivated carbon are filtered through screened openings in the rotary cooling drum.

Reactivated carbon is discharged from the cooling drum.

  • Spent carbon is fed into the input hopper.
  • Sealed screw feeder feeds the spent carbon into the rotary retort at a constant rate.
  • Spent carbon is heated to 1,400 to 1,650°F inside the rotary retort, evaporating moisture and oxidizing volatile organic compounds absorbed in the carbon micropores.
  • Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the carbon that could cause oxidation and loss of the carbon material.
  • Retort exhaust gases are collected in the retort exhaust hood and discharged to an air quality control system.
  • Transfer Chute
  • Cooling air is collected in the cooling drum exhaust hood and discharged to an air quality control system.
  • Heat from the reactivated carbon is transferred to the cooling air, in the rotary cooling drum. The reactivated carbon leaves the cooling drum at no more than 30°F above ambient temperature.
  • Fines in the reactivated carbon are filtered through screened openings in the rotary cooling drum.
  • Reactivated carbon is discharged from the cooling drum.

AVAILABLE COMPLEMENTARY SYSTEMS

Air Quality Control System

EnviroAir can furnish a complete air quality control system for your carbon reactivation furnace to ensure compliance with all EPA and local air quality control standards.

A typical pollution control system will include:

  • Cyclone for removing large particulate
  • High temperature baghouse for removing fine particulate
  • Packed bed scrubber for acid gas removal, if halogenated or sulfur bearing compounds are expected in the spent carbon
  • Water quench for cooling the exhaust gases prior to the packed bed scrubber

The organic compounds adsorbed in the carbon are normally destroyed in the rotary retort furnace. An external thermal oxidizer is not required to achieve air quality compliance in most applications. EnviroAir may provide an external thermal oxidizer to ensure compliance depending on the expected contaminants on the spent activated carbon.

Material Handling Equipment

EnviroAir can furnish the material handling equipment needed to transport the carbon material to and from your rotary retort furnace including hoppers, conveyors, bucket elevators, vibratory screen separators, barrel dumping stations, etc.

Catalyst Reclamation Systems

EnviroAir Catalyst Reclamation Systems are used to remove moisture, carbon, and volatile organic compounds from spent catalyst material before the process of separating precious metals from the carrier material takes place. EnviroAir will also provide the required air quality control equipment to ensure compliance with EPA and local air quality control standards.

EnviroAir Catalyst Reclamations Systems Feature:

  • Indirectly heated – no flame impingement on spent catalyst to cause oxidation of the precious metals
  • Exhausts are collected and discharged directly into air quality system – reducing pollutants
  • Fully automatic system – simple to operate

Catalyst Reclamation Process Diagram

Our Locations

Spent catalyst is fed into the input hopper.

Sealed screw feeder feeds the spent catalyst into the rotary retort at a constant rate.

Spent catalyst is heated to 1,600 to 1,700°F inside the rotary retort evaporating moisture, oxidizing carbon and volatile organic compounds from the spent catalyst.

Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the spent catalyst that could cause oxidation of the precious metals being reclaimed.

Retort exhaust gases are collected in the retort exhaust hood and discharged to an air quality control system.

Transfer Chute

Cooling air is collected in the cooling drum exhaust hood and discharged to an air quality control system.

Heat from the reclaimed catalyst is transferred to the cooling air in the rotary cooling drum. The reclaimed catalyst leaves the cooling drum at no more than 30°F above ambient temperature.

Fines in the reclaimed catalyst are filtered through screened openings in the rotary cooling drum.

Reclaimed catalyst is discharged from the cooling drum and collected for further processing.

  • Spent catalyst is fed into the input hopper.
  • Sealed screw feeder feeds the spent catalyst into the rotary retort at a constant rate.
  • Spent catalyst is heated to 1,600 to 1,700°F inside the rotary retort evaporating moisture, oxidizing carbon and volatile organic compounds from the spent catalyst.
  • Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the spent catalyst that could cause oxidation of the precious metals being reclaimed.
  • Retort exhaust gases are collected in the retort exhaust hood and discharged to an air quality control system.
  • Transfer Chute
  • Cooling air is collected in the cooling drum exhaust hood and discharged to an air quality control system.
  • Heat from the reclaimed catalyst is transferred to the cooling air in the rotary cooling drum. The reclaimed catalyst leaves the cooling drum at no more than 30°F above ambient temperature.
  • Fines in the reclaimed catalyst are filtered through screened openings in the rotary cooling drum.
  • Reclaimed catalyst is discharged from the cooling drum and collected for further processing.

AVAILABLE COMPLEMENTARY SYSTEMS

Air Quality Control System

EnviroAir can furnish a complete air quality control system for your catalyst reclamation furnace to ensure compliance with all EPA and local air quality control standards.

A typical pollution control system will include:

  • Cyclone for removing large particulate
  • High temperature baghouse for removing fine particulate
  • Packed bed scrubber for acid gas removal if halogenated or sulfur bearing compounds are expected in the spent catalyst
  • Water quench for cooling the exhaust gases prior to the packed bed scrubber

Carbon and volatile organic compounds found in the spent catalyst are normally destroyed in the rotary retort furnace. An external thermal oxidizer is not required to achieve air quality compliance in most applications. EnviroAir may provide an external thermal oxidizer to ensure compliance depending on the expected contaminants on the spent catalyst.

Material Handling Equipment

EnviroAir can furnish the material handling equipment needed to transport the catalyst material to and from the rotary retort furnace, including hoppers, conveyors, bucket elevators, vibratory screen separators, barrel dumping stations, etc.

Rotary Borings Dryers

EnviroAir Rotary Borings Dryers are used to dry and de-oil wet, contaminated chips from machining operations for improved safety in remelting operations and to reduce contamination in the recycled material. EnviroAir offers nine standard models ranging from 5 to 300 cubic feet of chips per hour.

Advantages of EnviroAir Rotary Borings Dryers:

  • Indirectly heated – no flame impingement on chips that could cause surface oxidation
  • Fully automatic system – simple to operate
  • Robust, simple design – low maintenance

Download Case Study (PDF)

Rotary Borings Dryer Process Diagram

Our Locations

Chips from machining operations are fed into the input hopper.

Screw feeder feeds the chips into the rotary retort.

Exhaust gases, smoke and dust particles are collected in the smoke hood and then discharged to the air quality control system.

Chips are heated to 800 to 900°F inside the rotary retort evaporating the water and oil on the chips.

Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the chips that could cause surface oxidation.

Dried chips exit the rotary retort and enter the rotary cooling section where the chips are cooled to approximately 300 to 400°F using room air.

  • Chips from machining operations are fed into the input hopper.
  • Screw feeder feeds the chips into the rotary retort.
  • Exhaust gases, smoke and dust particles are collected in the smoke hood and then discharged to the air quality control system.
  • Chips are heated to 800 to 900°F inside the rotary retort evaporating the water and oil on the chips.
  • Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the chips that could cause surface oxidation.
  • Dried chips exit the rotary retort and enter the rotary cooling section where the chips are cooled to approximately 300 to 400°F using room air.

Air Quality Control System

EnviroAir will furnish a complete air pollution control system for your rotary borings dryer that will meet EPA and local air quality control standards.

A typical pollution control system includes:

  • Cyclone for removing large particulate
  • Thermal oxidizer for destroying oil vapor and smoke
  • Heat recuperator (shell and tube heat exchanger) for preheating the exhaust gases entering the thermal oxidizer to reduce fuel costs
  • Baghouse for removing fine particulate

Auxiliary Equipment

EnviroAir will design and furnish a complete chip processing system to meet your chip drying requirements.

Typical dryer infeed equipment may include:

  • Infeed chip hopper
  • Chip wringer to provide uniform moisture content
  • Chip storage silo
  • Screw conveyors, bucket elevators and belt conveyors

Typical equipment at the dryer discharge includes:

  • Bucket elevator for lifting and cooling the chips
  • Vibratory pan feeder to distribute chip
  • Double drum magnetic separator
  • Vibratory screen separator to remove fines

Thermal Sand Reclamation

EnviroAir Thermal Sand Reclamation Systems reduce the amount of new sand purchased, the amount of waste sand going to landfills, and the associated transportation costs. EnviroAir offers six standard models ranging from ¼ to 6 tons per hour.
EnviroAir Thermal Sand Reclamation Systems feature:

  • Low operating cost – less than $7.00 per ton
  • Stronger molds and cores
  • Improved casting quality
  • Fully automatic system – minimal manpower to operate
  • Robust, simple design – low maintenance
  • No cooling tower to maintain

Download Case Study (PDF)

Thermal Sand Reclamation Process Diagram

Our Locations

Waste foundry sand is fed into the input hopper by a conveyor, elevator or pneumatic transporter.

Sealed screw feeder feeds the sand at a constant rate into the rotary retort.

The waste sand is heated to 1,200 to 1,500°F inside the rotary retort evaporating moisture and oxidizing organic binders.

Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the sand grains.

Retort exhaust gases are collected in the retort exhaust hood and discharged to a dust collector.

Transfer Chute

Cooling air is collected in the cooling drum exhaust hood and discharged to a dust collector.

Heat from the reclaimed sand is transferred to the cooling air in the rotary cooling drum. Sand leaves the cooling drum 10 to 30°F above ambient temperature.

Reclaimed sand is filtered through a 20-mesh screen on the end of the cooling drum.

Metal and other oversize materials flow over the filter screen and out the reject chute.

Reclaimed sand flows through the air classifier to remove fines.

  • Waste foundry sand is fed into the input hopper by a conveyor, elevator or pneumatic transporter.
  • Sealed screw feeder feeds the sand at a constant rate into the rotary retort.
  • The waste sand is heated to 1,200 to 1,500°F inside the rotary retort evaporating moisture and oxidizing organic binders.
  • Gas-fired burners heat the retort from the outside. This indirect heat prevents flame impingement on the sand grains.
  • Retort exhaust gases are collected in the retort exhaust hood and discharged to a dust collector.
  • Transfer Chute
  • Cooling air is collected in the cooling drum exhaust hood and discharged to a dust collector.
  • Heat from the reclaimed sand is transferred to the cooling air in the rotary cooling drum. Sand leaves the cooling drum 10 to 30°F above ambient temperature.
  • Reclaimed sand is filtered through a 20-mesh screen on the end of the cooling drum.
  • Metal and other oversize materials flow over the filter screen and out the reject chute.
  • Reclaimed sand flows through the air classifier to remove fines.

Air Classifier Process Diagram

Our Locations

Screened openings in the cooling drum filter reclaimed sand into the air classifier.

Adjustable slot in classifier infeed hopper to distribute the sand across the classifier.

Sand flows down inclined surface inside the classifier.

Room air enters the classifier through the cascading sand to remove unwanted fines from the reclaimed sand.

Reclaimed sand drops from classifier into a conveyor or pneumatic transporter.

Sand fines are captured in the upward moving airflow and are exhausted from the classifier.

Classifying air and fines are discharged to a dust collector. A damper is provided to adjust the classifying air flow rate to control the AFS fineness number of the reclaimed sand.

  • Screened openings in the cooling drum filter reclaimed sand into the air classifier.
  • Adjustable slot in classifier infeed hopper to distribute the sand across the classifier.
  • Sand flows down inclined surface inside the classifier.
  • Room air enters the classifier through the cascading sand to remove unwanted fines from the reclaimed sand.
  • Reclaimed sand drops from classifier into a conveyor or pneumatic transporter.
  • Sand fines are captured in the upward moving airflow and are exhausted from the classifier.
  • Classifying air and fines are discharged to a dust collector. A damper is provided to adjust the classifying air flow rate to control the AFS fineness number of the reclaimed sand.

Related:

Foundry Sand and Waste Foundry Sand (WFS) Management Challenges

Thermal Oxidizers

EnviroAir designs custom Thermal Oxidizer systems including direct fired, recuperative thermal or regenerative oxidizers. We specialize in turnkey installations of environmental air systems and can provide single source responsibility for the design, fabrication, installation and startup of your thermal oxidizer system.

Direct fired thermal oxidizers are a basic form of oxidizer with no heat exchanger capability. They have the lowest capital cost and are typically best suited for low volume, high solvent load applications.

Recuperative Thermal Oxidizers utilize heat exchangers to preheat incoming process air or combustion air in order to lower operating costs. Recuperative thermal oxidizers have a moderate initial capital cost with a significantly better operating cost than direct fired thermal oxidizers.

Regenerative Thermal Oxidizers (RTO) replace the heat exchangers utilized in the recuperative thermal oxidizers with ceramic media beds. The ceramic media beds offer the highest thermal efficiency and therefore the lowest operating costs. This type of oxidizer is best suited for higher volume lower solvent applications.

At EnviroAir, we will evaluate your entire application, to in order to offer the best customized solutions to fit your specific needs.

Wet Scrubbers

EnviroAir designs custom Wet Scrubber systems including venturi scrubbers and packed bed scrubbers. We specialize in turnkey installations of environmental air systems and can provide single source responsibility for the design, fabrication, installation and startup of your wet scrubber system

Venturi scrubbers are designed to remove particulate from exhaust air streams. They offer the advantages of being able to handle high temperature or moisture laden gases while reducing the dust problem resulting from disposing of collected dust. In venturi scrubbers, particulate laden air is passed through a venturi tube to which water is added at the throat. In spite of the relatively short contact time, the extreme turbulence in the venturi promotes impaction between the wetted dust particles and the flooding water. The wetted particles and droplets are then separated from the exhaust air in a cyclone. Recirculation of the water is possible with a custom designed recirculation tank.

Packed bed scrubbers are designed to neutralize gases and odors produced during the manufacturing process. Usually, the flow through a packed bed scrubber is countercurrent, with liquid introduced at the top to flow down through the packing, while gas is introduced at the bottom to flow upward through the packing. The packing is designed to produce a large surface area for the liquid to contact the solute gas. Chemicals can be metered into the recirculation water in order to aid in the neutralization process.

Venturi Scrubbers

EnviroAir provides venturi scrubbers to remove dust from exhaust air. Our venturi scrubber has a wetted wall venturi eliminating both the wet/dry interface region where buildup often occurs as well as the atomizing spray nozzles which can be susceptible to plugging. The dust-laden air and water are accelerated in the converging section of the venturi. The water is atomized in the venturi throat and the dust particles collide with and are absorbed by the water droplets.

In a normal profile scrubber, the exhaust air and dust-laden water droplets enter a cyclonic separator through a tangential inlet. This inlet causes the flow to spin through the separator towards the top discharge. The heavy dust-laden water droplets are thrown to the separator wall by centrifugal force where they collect and coalesce. This liquid slurry runs down the separator wall to the bottom drain or integral recirculation tank. The clean exhaust air is discharged out the top of the separator.
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Packed Bed Scrubbers

EnviroAir designs custom wet scrubber systems including packed bed scrubbers. Our specialty is turnkey installations of environmental air systems and can provide single source responsibility for the design, fabrication, installation and startup of your wet scrubber system. Packed towers or packed bed scrubbers are essentially contact beds through which gases and liquid pass counter currently or cross flow. They are used primarily for applications involving extreme pH gases, odors, vapors, and mist removal. While these collectors can capture solids, they are not normally used for this purpose because wet dust collecting in the beds would require unreasonable maintenance.

Packed bed scrubbers are designed to neutralize gases and odors produced during manufacturing processes. Usually, the flow through a packed bed scrubber is counter current, the liquid is introduced at the top and flows down through the packing, while gas is introduced at the bottom to flow upward through the packing. The packing is designed to produce a large surface area for the liquid to contact the solute gas. The countercurrent flow is highly efficient since, as the concentration of pollutant in the gas decreases while rising through the tower, there is a constantly fresher neutralization liquid available for contact.
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Rotary Retort Furnaces & Dryers

EnviroAir Inc. provides Rotary Retort Furnaces and Dryers for a variety of industrial markets. EnviroAir strives to set new standards of engineering innovation and to achieve the highest level of performance from our rotary retort furnaces and dryers. All required air quality control equipment to meet EPA and local air quality control standards are included with our systems. Our line of rotary retort furnaces and dryers include:

The EnviroAir facility in Southeast Wisconsin includes pilot equipment for developing new processes for our rotary retort furnaces and dryers. This pilot equipment is also available for Customer Demonstrations and Trials.

Tissue Dust Collection & Trim Collection Systems

At EnviroAir our Tissue Dust Collection and Trim Collection Systems, set new standards for innovation and engineering. We specialize in designing complete turnkey options for paper machines and tissue, towel, or napkin converting lines, to best fit our customer’s needs. Our systems feature the highest performance and reliability.

  • Improves the work environment for machine operators for greater efficiency
  • Reduces fire hazards for greater safety
  • Reduces blow downs and machine down time to increase machine productivity
  • Meets OSHA and NFPA requirements
  • Exceeds local air quality control standards

For additional information on the components that make up our Tissue Dust Collection and Trim Collection Systems, please select from the below links.