Super Dry Air Generator Odor Elimination In Intensive Feed Operations The Hygrex Super Dry Air Generator Hygrex Technologies Inc. Cleiton dos Santos Rosa 1307 Kamato Road South America Representative Mississauga, Ontario 55 (11) 9568-7521 Canada L4W 2M2 cleitonsr2000@yahoo.com (905) 290-0803 hygrex@aol.com
TABLE OF CONTENTS INTRODUCTORY LETTER P.1 SCOPE OF THE PROJECT P. 2 TECHNICAL PROPOSITION P. 2 Odors are carried by humid air Approaches to remove odors DISTILLING ODORS FROM THE AIR P. 3 Sealed or Closed Loop No Odours Escape to the Outside TECHNOLOGY P. 4 Maintenance Energy requirement Site Visit PROJECT MANAGEMENT P. 5 Construction SIGNIFICANT ATTRIBUTES OF THE PROPOSAL P. 6 CONCLUSION P. 6 APPENDICES HYGREX CLIENT LIST P. 8 HYGREX SPECIFICATIONS P. 9 2
HYGREX TECHNOLOGIES INC. South American Producers: Swine, Dairy, Poultry Operations Hygrex Technologies Inc. 1307 Kamato Road Mississauga, Ontario Canada L4W 2M2 Tel: (905) 290-0803 Fax: (514) 370-1295 e-mail: hygrex@aol.com Attention: General Manager and Engineering Re: Eliminating Odors from your Intensive Feed Operations Dear Sir or Madam: I am forwarding this overview of our approach to odor elimination from your operation. THE TECHNICAL PROPOSITION Odors are carried by humid air Odors are largely comprised of volatile organic compounds (v.o.c. s) and ammonia that are dissolved in the water vapor in the humid environment of your feed barns. When your barns are vented to the exterior these odors travel to neighbors and local communities Distilling the odours from the air About 40 years ago Hygrex first started tests to remove the moisture from pig barns in Germany. By removing the water we also removed ammonia and other volatile organic compounds that were bonded to the water molecules. We propose to remove the odors from your feed barns by installing Hygrex Super Dry Air Generators that will condense 94% of the water vapor from the air. Most of the super-dry air that is generated will then be recirculated into the interior of the barn to regulate the ambient relative humidity to around 60%. The remaining 20% volume of the super-dry (odor-free) air will be vented harmlessly to the exterior. Treating and eliminating earthern storage lagoons A sludge drying system for the treatment of manure into a dry odor free fuel would be the next step. The solids have a very high BTU content, while the treated water remains very high in nitrates and can still be utilized as an odor free fertilizer Please find some information below about Hygrex, as well as a list of client references. We sincerely hope that you find our proposal of interest, and remain available to answer any questions you may have. 1
SCOPE OF PROJECT There are two principal sources of odor from intensive feed operations: 1. The odors from feed barns that float to neighboring communities on prevailing winds on a constant basis 2. Odors from the storage and disposal of animal waste: a. The storage in lagoons provides a relatively constant source of odor pollution during summer months, which may abate during the winter freeze. b. Disposal of waste on agricultural land will cause severe odor issues - but these would be alleviated when the organic waste is used as an environmentally friendly fuel alternative. In this proposal we would like to address the odor problems arising directly from the intensive feed operations and earthen storage facilities. TECHNICAL PROPOSITION Odors are carried by humid air Odors are largely comprised of volatile organic compounds (v.o.c. s) and ammonia that are dissolved in the water vapor in the humid environment of your feed barns. When your barns are vented to the exterior these odors travel to neighbors and local communities Approaches to remove odors There are several approaches to removing v.o.c. s from the air that include using micron filters and chemical bonding agents, as well as masking applications. But the most effective technique of removing v.o.c. s is to distill them in a process that condenses water vapor from the air. In industrial wastewater treatment plants undesired materials such as heavy metals have to be removed from the wastewater by means of physical and chemical methods. Usually a thin sludge with a water content of approx. 95% results from this treatment. By using adequate systems for preliminary desiccation such as filter presses, a filter cake with a chunky consistency and water content of approx. 60% is attained. With the help of the Hygrex (TM) sludge drying systems the filter cake can be dried up to remaining water content of approx. 20% - 5%. Thus the weight of the sludge is reduced by 50%. The overall aim of sludge drying is to reduce the weight of the sludge to be taken to a landfill or to be recycled and thus to gain considerable cost savings. The Hygrex low-temperature drying principle operates on transporting warm and dry air through a defined volume of filter cake. The dry air now takes up the water stored in the filter cake. In the dehumidifying unit it is then cooled down at a heat exchanger to such an extent that the water can condensate. Right after this process another heat exchanger serves to reheat the air again. For this reason the air has an enormous water absorbing capacity. Both the heat exchangers, also called air cooler and air heater, are components of a refrigeration cycle. An advantage of this energy balance is that surplus heat arising to supply the air cooler with refrigerant is used in the air heater to constantly reheat the air. This air is then led through the container filled with sludge. Now 2
you can see another positive effect of the principle. The Hygrex sludge drying process takes place in a closed air cycle. From the system point of view there are no emissions, so no loss of energy occurs. DISTILLING ODORS FROM THE AIR The drying system operates on a special dehumidifying principle. Warm, dry and unsaturated air is led over the surface of the areas to be dried. Now the air takes up the water adhering to the surface areas well as airborne impurities. Afterwards the water condensates in the dryer with the help of a refrigeration cycle; the air is warmed again. A both ecologically and economically sensible cycle is closed. We propose to remove the odors from your feed barns by installing several Hygrex Super Dry Air Generators that will distill 94% of the humidity from the air. Most of the super-dry air that is generated will then be recirculated into the interior of the barn where it will combine with the balance of the atmosphere to regulate the relative humidity to around 65%.The remaining 20% volume of the super-dry (odor-free) air will be vented harmlessly to the exterior. Sealed or Closed Loop No Odors Escape to the Outside With the exception of the volume of cleaned air vented outside, this will be a closed loop system; the interior atmosphere will be continually recirculated and purged of water vapour. The 20% vented to the outside will be made up from deliberate air intake into the barn. Alternatively, a slightly lower air pressure can be maintained in the barn that will prevent ambient barn air from escaping and that will naturally aspirate air from the outside as the facility breathes normally. 3
TECHNOLOGY Hygrex Technologies Inc. has become today s' proven leader in dry air technology, by offering energy-cost effective, environmentally friendly, method of drying. HYGREX specializes in drying applications where water is basically the only element to be removed. Particularly suitable applications for dry-air generator include: drying food, filter cake sludge, water-based paints components, retrofit gas/heat ovens and the elimination of humidity in plant environments. HYGREX closed loop process 1/6 the energy cost of conventional drying methods. Buy using this closed-loop process the Hygrex dry-air generator does not require the installation of exhaust or air makeup, nor does it add heat to the material being dried, eliminated the risk of distortion, as well as cool-down zones and tunnels. No odors or gas emission are generated and the condensed water is reusable. Hygrex technology is currently in use worldwide in the following industries: food drying, automotive manufacturers, environmental companies, paint finishing systems, chemical companies, and water based undercoating, paint manufacturers, leather companies, drying toxic wastes, adhesives, agri-business. Applicable sectors include waste reductions, emission control and water recovery. The approach we propose is for an air-drying process manufactured for the past 12 years in Canada (and with a longer proven track record in Europe) by Hygrex Industries Inc. (Please see the Partial Client List in the Appendix). These air-drying systems have had particular market success to date in the municipal and automotive sector where some 2,000 units are in service around the world. We have reviewed the engineering studies originally commissioned by these clients which led to the recommendation of the Hygrex process against other dryers - and the conclusions support the same arguments we are using in support for our proposal here. The Hygrex drying process uses a heat pump (much like a refrigerator) to force the condensation of tremendous quantities of water vapour out of the air. This produces super-dry air - now free of odour that can be recirculated through the ambient atmosphere. The closed loop design means an extremely high drying efficiency in these applications. 4
Maintenance: The equipment design is proven, robust and comparable to household refrigerators in its simplicity and reliability. All maintenance and repairs can be completed by local refrigeration professionals. The only by-product is water. Energy requirement: The configuration we propose has been calculated from Hygrex experience with some 40 installations in Europe in pig barns and slaughterhouses. For waste management and the treating of manure, Hygrex has a long proven track record with toxic sludge drying for some of the largest industrial companies in the world. PROJECT MANAGEMENT Construction: The dryers and ducting we propose are not exceptionally complex in design, mechanized; or in need of sophisticated instrumentation. We supervise the installation of the dryers, ducts and accessories and commission the final installation as fully operational upon completion of our work. SIGNIFICANT ATTRIBUTES OF THE PROPOSAL Eliminate odors from intensive feed operations Qualify for Carbon Credits. Will comply with community odour standards Reduce livestock mortality and improve their living conditions Increase livestock reproductive rates Extend the life of facilities and equipment by reducing the humidity and metal corrosion. Much lower cost in the daily environmental control. Improve employee-working conditions. 5
CONCLUSION: We believe that this is the most progressive and effective approach to eliminating odor in agricultural operations. We also believe that the cost of odor elimination for the Hygrex Proposal is lower in both operating expenses and in capital investment than any other technology. We look forward to your comments. 6
APPENDICES HYGREX CLIENT LIST P. 8 HYGREX SPECIFICATIONS P. 9 7
PARTIAL HYGREX CLIENT LIST Stelfil Honda Alliston Honda F&P Tottenham Toyota Cambridge Ford St.Thomas Harz Wasserwerke Honda Alabama Canadian Mint Ballard Power Region of Peel Pilot project Hydro Quebec Magna International Magna International Honda Alliston Chile Egypt Thailand Ghana American Standard Lufthansa German Army Degussa Siemens A.G Daimler Chrysler Mercedes Benz Audi Audi Volkswagen Johnson Controls Adhesive Drexelmeyer Rehau Automotive Weku windows Thyssen Ford automotive supply Ford -Ingersoll Rand Ford-DuPont- BASF-Mercedes Benz- BASF Ford Automotive Rolls Royce SWE Eurodrive Grunfoss Sludge drying Lachine, Quebec 2- systems to dry sludge from wastewater Sludge drying 2-systems sludge drying Sludge drying Municipal sludge drying Sludge drying Sludge drying, Winnipeg Parts drying, Burnaby B.C. Energy from waste Test System in Shawinigan, Quebec Bumper drying at Polycon, Guelph Parts drying in Weston, Ont. Component drying- car bumpers Herbs drying Vegetables drying Pepper drying Drying vegetables Sludge Drying Sludge drying, Hamburg, Berlin, Cologne Sludge drying Sludge drying, Germany Sludge drying Sludge drying, Mexico Automotive paint drying Drying water based paint Drying protective coating for shipping Drying waterbase paint Drying Dekaware, Lueneburg Germany Automotive component drying, Munich, SC. Component drying, Alabama Paint drying Denmark Paint drying Hamburg Paint drying Berlin Special system for Ford R&D, Michigan Hygrex Paint test system, Wixom Mi. Hygrex Paint test on whole Mercedes cars, Mi Purchased test system Southfield, Mi Drying car undercoating, Kentucky Drying Parts in England Drying motors in UK Drying motors in Germany Numerous Hog and Slaughter operations in Europe. 8
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