Advanced Cyclone Systems, S.A. (ACS) designed and installed, on a turnkey basis, a hurricane3 system and a Mechanical ReCyclone (ReCyclone MH) for Particulate Matter (PM) emission control of the flue gases from two biomass boilers. The installation took place in Nelspruit, South Africa, at the wood-based panels plant Sonae Novoboard, owned by Sonae Industria (SI).
Sonae Industria is one of the largest wood-based panels producers in the world. The product range includes particleboard, MDF (Medium Density Fibreboard), hardboard, OSB (Oriented Strand Board), production and sales of value added products and services - components, solutions and systems - for the furniture, building, decoration and DlY industries as well as production of high pressure decorative laminates and production of chemical products (formaldehyde and formaldehyde based resins).
On December 31st, 2011, Si's workforce numbered around 4,712 employees, on 27 production sites in 7 countries and sales locations in Portugal, Spain, France, Germany, United Kingdom, Canada, Netherlands, Switzerland and South Africa. Si's consolidated turnover totalled 1,364 million euros in 2011.
IDENTIFYING THE PROBLEM AND SOLUTION
The existing boilers (Konus thermal oil heater (KT) running mostly on wood chips and a John Thompson boiler (JT) running mostly on wood waste) had multicyclones (grit collectors) installed, whose efficiencies were not able to meet the newly legislated emission limits (100 mg/Nm3). At the time, emissions were 652 mg/Nm3 and 385 mg/NmJ, respectively, from KT and JT after the multicyclones.
ACS analyzed the case in its PACyc (Particle Agglomeration in Cyclones) model and confirmed that the emission limits could be achieved by installing a hurricane0 system (prepared with wear resistance features) to replace KT's existing multicyclone and a ReCyclone MH to be installed downstream of JT's existing multicyclone. With this arrangement, ACS models predicted emissions to be significantly below 100mg/Nm3 at the stack.