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Appendix 10

Spread Sheet Showing Cost Per Ton

ofVOM Removed
Appendix 10 .

Spreadsheets Showing Cost

Per Ton of VOMRemoved

••••

Spreadsheets Show Estimated Cost Comparison.

Between·Two Types -of Controls

Based o'n Actual Bids

From Equipment Suppliers
,Cost Spreadsheet for the Rotary Concentrator with Oxidizer

Cost spreadsheet for the rotarY concentrator - based on the Durr Quote

UsinQ 654,000 cfm and 85% control efficiency

PARAMETER INPUT CALC.

Flowrate 1cfm) 654,000 654,000

Control deviCe input mass (tonslvear) 1 200 200

Concentration (ppm) 13

Facilitv operatinq schedule Ihourslvear) 3000

Thermal oxidizer temperature (F) 1450

Fuei cost, ($Imillion BTU) , ' 3,5 ,

Electricitv cosl, ($Ikwhr) 0,05

cosT CALCULATIONS

Heal recovery (%) 60

Electrical power (kW) " 467

Fuel usage (Btulhr) 37,565,699

Equipment cost (EC), (Durr 2001 quote) 2 9,210,500

Equipment Cost IECl, ICE equip, cost index, Julv 1995 doliar 9,189,035

Total Direct Cost (TDC), ($) 15,844,095

Total Capital Investment (TCIl, ($) 19,262,416

Direct ooeratino costs, minus utilities ($rvear) 563,622

Thermai incinerators fuei cost 1$lvearl 394,440 ,

Electrical cost ($Ivear) 108,491

Overhead, properly tax, insurance, administration I$""'ear\ ' 1,108,670

Capital recovery cost ($iYear 2,806,341

Styrene recovery cost ($Iyear) 0

Totai annualized cost ($Iyear 4,981,564

Cost per unil poliutanl removed ($/ton) J 29,303

Scaled to Year 2000 Doliars 38,973

~_~JI YOM _~~J~.~ionsJ!:1J!.!~J?!an!i!i~~_~.~Ug_J_~~__ C:9nt.~~L~_~_~i~~.: __~_ "_.___. ______________.._______"___,__________... --- ..__...._.- .

? Vnh 10 bused 011 bids received by AEA from equipment suppliers adjusted proporllollClfely 10 ClccQunl for capllal cosl of treating an airflow of

~54,OOO_~f!:fl

3 Value based on 85% control errlclencv I
--

Cost Spreadsheet for the Rotary Concentrator with Oxidizer

Cost spreadsheet for the rotary concenlralor - based on the MegTec Quote

UsinQ 654,000 cfm and 85% control efficiencv

PARAMETER INPUT CALC.

Flowrate (cfm)· 654,000 654,000

Conlrol device input mass (tons/year) 1

Concentration (ppm)

FacililY.operatinQ schedule (hours!Year)

Thermal oxidizer temperature (F)

Fuel cost, ($/million BTU)

Electricity cost, ($/kwhr)

200

3000

1450

'3.5

0.05

200

13, .

COST CAL CULAT/ONS

Heat recovery (%)

Electrical power (kWl

Fuel usaoe (Btu/hrl

60

467,·

37,565,699

. 'Eauipmenl cost (EC), (MegTec Systems, 2001 quote) 2 _ _ 1 7,761,890

Eauipm"iifCost (EC); (CE equip. cost index, July 1995 dolla~ 7,743,801

--- - I···

Tolal Direcl Cost (TDC)J!) ~89,5301 I I 1 I I ~~lal_Cnrllal.lnve~lrTlBnl (Tel),.($L . ._.. __.. __ .. 1... 16,470,224,.

Dli·oc,:I_OIJOn)ilnu-"Go~ISI._i-l_ilnlls_llillli'lo~_:($lyo~lr). .' .,-...,- . I _~)fj:\,G22 .-.

~\~:;:~~~~~1r-f$)3~~!tol .c.~sJ_($lY.oa~)--'---'-~.-~----_.._-- .---"~5ri:~~~1·-- --- --.----.~ ---1-- ---... '.-..... I-- . ---·1

-. _··,·----'1··--------I-e..-..-'--+-_..-

Overhead, properly tax, iiisurance, administration (s/year) 1 996,982,.

Capital recovery cost I$/year) I 2,399,547

slyrene recovery cost ($!yearl I 0

Tolal annualized cost ($/year) __ . I 4,463.082

Cost per unll pollutant removed ($Iton) 3

Scaled 10 Year 2000 Dollars

26,253

34,917

1 All VOM emissions in the plant are sent to the control device.

2 Value hased on bids received by AEA from equipment suppliers adjusted proportlonalely to account for capital cost of treallng an airflow of

654,000 efm

J Value based on 85% control efficiency r----i-
Cost Spreadsheet forthe Rotary Concentrator with Oxidizer

Cost spreadsheet for the rotary concentrator - based on the Frees Quote

Using 654,000 cfm and 85% control efficiency

PARAMETER

Flowrate (cfm)

Control device input mass (tons/vear) 1 .

Concentration (ppm)

Facility operatinQschedule (hours/vear)

Thermal oxidizer temperature (F)

Fuel cost, ($/million BTU)

Electricity cost, ($/kwhr) .

INPUT

654,000

200

·3000

1450

, 3,5

0,05

CALC,

654,000

200

13

cgSJ:.C2AL,fY.lAT!.(jN,S_, . •,_._._. -.::.::::.=::=I-=---===I.~_:::==__=I-"------I 1·----·11

Heat reCQvelV (%) .

Electrical power (kW)

Fuel usaQe (Btu/hr)

Equipment cost (EC), (MeQTec Systems, 2001 ouote) 2

Equipment Cost (EC), (CE equip, cost index, July 1995 dolla~1

Total Direct Cost (TDC), ($)

Total Capital Investment (TCI), ($)

60

467

37,565,699

8,970,572

8,949,666

15.470,679

18,799,955

Direct operatinq costs, minus utilities ($Tyeaif 1 563,622

Thermal incinerators fuel cost ($/year) , 1 394,440

Eiectrlcal cost ($/year) , 1,_~1",0",8,,,,49~1,+'---_e---_~---- -----1-------1

Overhead, property tax, insurance, administration ($/year) 1,090,171 1 1 I 1 I

Capital recovery cost ($/year) 1 2,738,965

Styrene recovery cost ($/vear) I 0

Total annualized cost ($lYear) . I 4,895,690

Cost per unit pollutant removed ($/ton) 3

Scaled to Year 2000 Dollars

1 All YOM emissions in the plant are sent 10 the control device.

28,798

38,302

2 Value based on bids received by AEA from equipment suppliers adjusted proportionately to account for capital cost of treating an airtlow of

654,000 cfm, This quote didn't include price'of installation and freight an additional cost of $500,000 was applied to account for these items,

based on the average from other vendors.

3 Value based on 85% control "efficiency
Cost Spreadsheet for Biofiltration Process

A B C 0 E F G

'I Cost spreadsheet for biofiltration processes - based on the BioRem quote

l Using 654,000 elm and 85% control efficiency

J

4 PARAMETER INPUT CALC,

0 Flowrate (cfm) 654,000 654,000

6 Control device input mass (tons/year) 1 200 200

I Concenlr.alion (ppm) 13

Facility operating schedule (hours/year) 3000

l; Electricity cost, ($/kwhr) 0,05

IV

1 COST CALCULA TlONS

1<:

1;j

'14 Electrical power (kW) 1,786

'10

16 Equipment cost (EC), (Blorem) 2 9,850,000 . I I Equipment Cost (EC), (CE equip, cost index, July 1995 dollars) 9,935,874

'ttl Total Direct Cost (TOC), ($) 17,009,164

l~ Total Capilallnvestment (TCi), ($) 20,705,309

LV

LI Direct operating costs, minus utilities ($/year) 1,049,932

;,:;,: Electrical cost ($Iyear) 267,888

l::l Overhead, property tax, insurance, administrallon ($/year) 1,458,172

Capilal recovery cost ($Iyear) 3,016,556

Tolal annualized cost ($Iyear) 5,792,548 .

<:0

II Cost per unit pollutant removed (:ti/ton) 34,074

Scaied to Year 2000 Dollars 45,318 .

30 1 All VOM emissions in the piant are sent to the controi d~vice,

31 2 Vaiue based on bids received by AEA from equipme~t suppiiers adj~sted proportionately to account for capital cost of treating an airflow of 654,000 cfm

32 3 Value based on 85% control efficiency
Cost Spreadsheet for Biafiltralian Process

A B C o E F G

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L

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Cost spreadsheet for biofiltration processe.s - based on the BacTee quote

Using 654,000 cfm and 85% control efficiency

4 PARAMETER INPUT CALC.

b Flowrate (elm) 654,000 654,000

6

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Control device input mass (tons/year) 1

ConcentraUon (ppm)

Facility operating schedule (hours/year)

ElectriCity cost, ($lkl'ihrj

200

3000

0.05

200

13

lTI COSTCACCU[J(T10NS

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14 IEleclrlcal power (kW) 1,71J6

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1-1~ 1;;;\UIPllIul\t cogl (EC)~(i;,;;:r;;~;;;_ I 14,31J1J,0001 1 I 1 1

Equipment Cosl (EC). (CE equip. cosllndex, July 1995 dollars) 14,513,437

18 ITolal Direct Cost(TDC), ($) 1 24,150,162

19 IToial Capilallnvestmenl (TCI), ($) 1 29,549,161

120

ILllDlrecfoperalingcosis: minus utilities ($/year) I 1,049,932

I22lEleclrical cosl ($/year) 1 267,888

Z~ IOverhead, propertylax;-rn-surancB,-administration lS/Yeiirj I 1,811,926 I ~~ ICaPi18ireooVery-cOSf($7Year) I 4,305,017 1

-I I 1 1

Tolal annualized cost ($Iyear) 7,434,763

126 I

~CosIPerunitPoliulantremOVed($/ton)' I 43,73~1 I I I I I 1-29i~.~aledJ.o Ye~L3.9.9-o.P--,,!I.f!~~ ._ 58~166 __ .

30 I' All VOM emissions in the pl"nJ "rA sAnt to the control device. 1 1 1

31 I' Value based on bids received by AEA from equipmenl suppliers adjusted proportionately to account fdr capital cosl of trealing an airflow of 654,000 cfm

32 I' Value based on-85% control efficiency
Appendix 11

Proposal from BioRem Technologies, Inc.

Appendix 12

Proposal from BacTee Systems, Inc.
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Proposal from

BacTee Systems, Inc.
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BacTee Systems, Inc.

~30 South 48th Street

Grandl!:0rks, North Dakota 58201

'Phone: 701.775.8775

Fax: 701.775.8117

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FAX COVER LETTER

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COMPANY: .4!?\{. ~v:eat"mfL'N'1'¥JL PHONE: t-3C,-'7/C, -f.{lJH)

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(INCLUDlNG COVE1l.I..E:'n'ER.)

FROM: ~..J (Vl REPLY REQUESTED? YIN

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COMMENTS:__-"'p,--'-6..::;·...;..c....:;~....:()"-"J...;..a....;..L>=- __r+"-'-r_.... e-"'(,--'-1<-.-='--'i!-"C""l.1''-''1z,"=-....:I2-=E-"(e'-=u.:...:c:.;:·s....:T'---.::-

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CONFIDEN1'IALITY STA1'E¥£'NT: Tbeinformatirm contained in this facsimile message

is confide1/Ji4J and iliuRdetJ tndy for the use ofeke indifJidJlal or entity 1U2med abO'CJe. Iftbe

reader oftlm message is 1Wt the i1Iteuded recipient, or the anpkJyee or agent re$pansibk to

delioerit to tbei1ilafkd recip~t..yau are 1Kreby notifkd tbat any dissemintrtiOR,.

distriJ»aion In' copying ofthis cornmllllication is strictly probibited. IfyoJl bave reCeived tbis

commlUlicatWa in error, please ifunediately notify.us by telepbone, and ret:uT7l the origintZl

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. !fyou do not receive all the pages, please call (701) 775-8775.

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BacTee Systems, Inc,

May 11,1001

Mr, John Gibbons

Advance Environmental Associates, Ltd.

300 S: Second Streel

,51. Charles, MO 6330 I

Phone 701.775.8775 Fax 701.775.8117

830 Soul!> 48th St., PO Box 5192. Gruncl Forb NO 58206-5192

Dear Mr. Gibbons:

BaeTee Systems is pleased to submit a Concept Proposal relative to a biotihcr application

for your boat manufacturing facility. We have outlined systems (hat correspond to you

request for sizes ranging from 50,000 - 300,000 efm of ventilation air from the pianl

Given' the presence of methyl methacrylate, we strongly recommend thaI a pilot,

demonstration test be conducted ofside stream air prior to completing urinal design for

the facility. BacTee would welcome the opportunity 10 work with you in conducting

such a test.

1would recommend that wc discuss this further upon your review of Our proposal.

Don Mathsen, PE

Chief.Engineer

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Sincerely

/ .-7

-pt/~
BacTee Systems, Inc, Phone 70/.775.8775 Fax 701.775.8117

&30 South 48rh Sr.. PO Box 5192, Grand Fork, NO 58206-5192

ConceptProposal

,

vac Control 'System - Boat Manufacturing Facility

Submitted to:

Mr. John Gibbons

Advance Environmental Associates

300 South Second Street

Sl Charles, MO 63301

636·916-4800 (p)

636-916-3717 (f)

Submitted by:

Mr. Don Mathsen. PE

. BacTee Systems, Inc.

830 S. 48th. Sl

Grand Forks, ND 58201

Phone: (701 )775.8775

Fax: (701) 775-8117

Date:

May 11,2001
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Scoping Proposal for Biofilter • vac Control AppHcocion .

. Boat M.rrofBcturing Faolity

May It, 200l

Table of Contents

1. SUMMARY

2. INTRODUCTION

3. SITE CHARACTERIZATION

4. TECHNICAL. PROPOSAL.

5. PRELIMINARY ESTIMATE OF OPERATING COSTS

6. SeOPING COSTS FOR INITIAL.INSTALl-ATION

7. PROJECT TIMETABLE

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a
Scupiug PlUpm,l!.IC'OI UiUlil{CI - VOC CU!ltlul Appli.l"lltlUIl

Boal Manufacturing Facility

M.y II. 2001

1. Summary

RaeTer: SySiems, Inc. (Au~T""1 munuiaelur"s lj hilllilia od"r or V()C diminlllilln .'y"lem Ihal is Ihe

most complt:te, mhll,t, anti env;ronmenlJill)' compalibk solulion 10 II1~ control of odors and VOC's

in the· biofiltrntion industry. Over the life of th~ sys\em, thl' f3a~T~c approach 10 hillliitralilln

typically yield$ Ihr: lowest ownero;hip cosL' 01" any availahk odor or VOC ,",lnlrol straleb')'.

'I"he low operating cost ol"th~ llacT(.~·biotilter (csul\s hom I} th~ low ,Illlic head ol"lh" aeral;"n and

substrate systcm, 2) the long life of the well-crginccrctl RatTc" ~qllipmcnl. and ~) Ihe low icv<:f of

w""r<llorull<:nl ion required by Ihe BacTee syslcm. .

I3aeTce On~(S a stand-alune system thai requircs the lowesl spac~ r"'iu1r"n1enl "ithin Ihe hiofilier

indll>try. BacTee works c1l1sely wilh ~nginL'ering firms. such as Ach;Jlleo'. 10 pnl\ ide a biofiller odor

and VOC eunlrol system wilh oplimal syslcm porfommn""

2. Introduction

l3iofilters were iniually de,'eloped for the odur control mar,ctr!a~" and h;"e pr(""n Ihen1,d"e, 10 be

Ihe mo~t c()sl-efr~Cliv~. environmenlally henign means of ('dor o( V()C control. for numerous

industrial, agricultural proc~ssing, and municipal waste trealment applicatiolls. Morc recently.

biofilt~rs designed by l3acTcc personnel havc dcmonslrated thaI hillfillralioll isu sound solulit>1l for

air slr~ams wilh bOlh h,W odor Cllnl;lminanl roncenlr;lIion, I:?-](I ppm II:?S) lwd Inoocrate to high

concentrdtion level> (100.300 ppm II:?S). .

Th~ 13acTee lJioJilter technology ciln addrcss a varicty lII" VOCcOlllrol appli~uliollS .Rased on an

analysis of the wa;;tc stream, BacTee will determine if a hiofilter ;, eilher 1) an appropriate

kchnt>lob'Y for the giv<:11 applicalioll, 2) reqllires a pilot tl'St I1n'gram prim \ll final siLing and

selection, or 3) thL' compounds or conccntrations in the air ~\ream do nol \cnd lhemselv~, ttl

hio filtralion.

l3aeTee providcs hio!iltcr s)'stclns [hat incorporate the lalesl in aeculion ~nd c"lnlrol lethnology ft>r

compl~lely au16malu; op~rali(lIl as well as aeralitln noors Ihal minimi,e dovmlime when the stlb~trate

media must be replaced. Professionals design OacTec unils fll(cachapplicatilln ,,,ith the ea[lacil}

and control ofthe .~ystem tailored to the source of emissions and Ih" level "fmonilOring r"ljuir"d.

3. Site Characterization

This Scoping Proposal is b1l,ed on Ihe conditions shown in Iahle /. rlle'e enndillon, arc bused on

the data provided \0 l3acTce as a reference point for Ihe ·si.l.es alld huLlgetary CllSi figures illcluded

herein. Actual conditinns fllr lhe sit< that Jill"r I"rnm Illese 1ISSUmpli(;n, may ;l1I<;r Ihe si/e and cosl

for this set of conditions. BacTee weleoID"S the opportunity to providl' a mor"d<:tailed proposal

based on actual sit~ Cllnditions as derived f"lIri either on-sik kSling or a nlllre Jdaikd ana'I)',i, or

the efflUent air stream

Th<: biodegradation levcl or ,tyrene makes It well sUlIl:d .for letrlU\a! or hiolihlilllon: Likewi5c,

melhyl melhaerylal~ is biodegr;dahlc hutto a lesser exl~nl Ihan slyrene Th~ presence oflhe mdhy!

methacrylate with the ,tyrene points 10 the need for ;I pi.lnl te,1 program III bc conducted on a

sl ipstream ofthc cmucnt air prior 10 final sizing ol"the systcm.

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Scoping Proposal fur Bioftlter - VOC Comrol Application

Boat MaJnJfumring FBCllity

May 11, 2001

Table 1: Site Desien Parameter.!:

Parameters o >erating Conditions

GelcoatOo Lamination 00 Units

Isite Air Flow 120,000 180,000 sefm

. Estimated Temp Range 65-15 65-75 of

Estimated Influent 30-50 30-50 %

Humiditv Ranae

Peak InfluenlConc. .

125 126 LbIhr

ITotaI Clroat1ie l.os<1)

Mjnj~~r':'t Cone. 40 24 I.hlhr

rrot>I 0< l.t>o

!Organics Present . . Styrene & Styrene Only

Methyl

MethacrvlaJc

4. Technica.1 Proposal

. 4.1, Introduction

BacTee is pleased to offer Advance a biological approach to VOC control for their client's boat

manufacturing facility. This propmal provides lin engineering and bndgetary estimate only and

is subject to further evaluatioll of the site,integration with' existiogfacilities aod services

located on site, and the re3ultli of a recommended pilot test program.

4.1.1. Application - GQal

To remove the organic load containing styrene and methyl methacrylate and other compounds

associated with the fabrication offiberglass bOat production from the ventilation air. The objective is

a reduction ofthe,e loads in the range of 85-95% ofthe raw wa,~te air stream.

4.1.2. BacTee Biofllter Design Philosophy.

Atypical BaeTee liiofilLer unit for VOCand Odor Control is shoWn in Figure\. The bacteria living

on the organic host material. or biosubstrate, digest the VOCs and/or odor. BacTee provides the

substrate media derived from materials available locally at the site of the installation. The final

products ofbiodigestion are carbon dioxide and water alOIlg with material suitable for disposal as a

soil conditioner.

The key elements to a successfully operating biofilter are:

• The proper mi.x of substrate materials assuring long life of the biological media while

nurturing a high level ofbacterial metabolic activity. .

• A uniform distnbution of air through the substrate while maintaining a low pressure

~~. .

• A cOntrol system that integrates the response of the biofilter with the operation of the

emission source. Likewise, the control system must anticipate and control me response

ofthe substrate media based on the incoming emissioncharacterislics.
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"'oj, ........, oj .... ....n.....>.. 'c ... , ....... " ... oj ........ ,

Seoping Propos31 for Biofilter - vac Conlrol Application

Boa:r Manof!cllJring Facility

May II, 2001

M~nu.al nampa10.11 mu1r..iple bay units)

W211."f Drain Line Conditiol'loe;r

PolableJf'lantw"""" --+:'-..l.--f-"---~-'

Satllbl'y l..aM ...... . -

'.1:' ••••' >•••••

Malo AirPlenum Treoch •

Op<ional Sprinkler !lV'''''''

Bemnnin.ofBiofiher

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Figure 1: Typical BaeTee Biofilter System and PrindpalComponenLI

The typical BacTee system consists ofthe following components or subsystems:

• A blow~rthst provides the negative pressure for the collection system and drives the air

through the beds ofbiomass."

• The biosubstrate'lilter' media that serves as host material for the active bacteria; this

material iSseleeted from locally available waste organic materials with an active lifetime

of nominally two to five years. . .

• BacTee's aeration floor system that provides, with negligible pressure drop, uniform

distribution of air throughout thc biosubstralc bed and also controls water from excessive

rainfall. With BacTee'saeration floor. the media substrate can be easily replaced without

interrupting the operation ofthe biofilter.

• A conditioner that conlrols the temperature and the humiditY level oflhe air entering the

biosubstrate bed. .The module contains all pumps, plumbing, and sensors necessary for

proper conditioning ofthe air stream. .

• Acomplele lie system, including power . switchgear, process. controller, and

instnnnentation hardware. Systems integration services are provided, as required, based

on a scope of work determined upon initiation of the project.

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.scoping Proposal for Biofiher - vac Control Application

Boat ManufacnlTing Faality

May I L 2001

Gll!eJt lhat BacTa Is worklngfrom only pr~l/mlnary Information relative to actual site descriptions, BacTu

will ~.lire the bctegratiotf ofth e proposed UryOUIS with furl}, a daailed site plan.< in an actual applicatlofL

5. Preliminary Estimate of Operating Costs

,BacTee proposes a biofI1ter system that wi1l:on a 16-hr/day, 160 daylyr operating basis, have an

eneri<.Y requirement attributable to the biofilter portion of the hiullller odor control system as per

Table 2.

Table 2: Operatiooal Requirements:

Air Flow projectltd Operational Requirements

cfm Annua' Eledrical ~nnual Gas Consumption Operator Attention Su~te Replacement

Energy (101 MEltu/yr) . (kWh/y)

50,000 150,000 . Requires Specific Site Info 2 hr/wI< every 2 - 3 yes (typical)

and P~ot Studv

100,000 300.000 . . 2 hrfwk. eve"! 2 _ 3 yes (typica~

200,000 600.000 . 2 hrlwk every 2 - 3 yes (typical)

300.000 900.000 . 2 hrlwe eve"! 2·3 yea", (typlcsl)

The BatTee biofilter requiresminimal operatingattentiolL A check on performance patameters and

a visual inspection of the facility once a week. is adequatcin most ca,e~. BacTee can provide a

maintenance service agreement on an annual, or multi-year, basis as per the needs ofthe OWNER.

.BacTee's biosubstrate media his experienced lifetimes of up to six years. A three-year replacement

cycle can be used for estimating purposes. BacTee can pr~vidt: a more detailed O&M projection

. upon further discussion with· Advance on the specific operating criteria and specification of the

system; '.

6. Seoping Costs for InitiallnstalJation

BacTee will work with Advance to provide lhecombination ofservices and hardware that offers the

most fully-integrated package within thebudgetaJ)' and emuent management rcquircmeng of a given

project specification. BacTee's seoping budget es(imale (+/-20%) lor (hese bioliller units are shown

in Table 1. The budget estimate includes the following'

1. Blower - Conditioner Module

Air blower with VFD-drive

Conditioner·unit

Recycle pump

2. Ductwork from the transition to the conditibncr inlel to the inle! llrthe main air plenum trench.

3. Aeration floor components

4. BiofiltCT media (substrate)

5. Auxiliary heating package

7
~~~--~ ~.~.---.

a e : Ite (O(lUlremen13

Site Alr Row - JOO,OOO 200,000 100.000 50,000 ,. Cf,n

Design Alr Flow 330,000 liO,oOO 110.000 55,000 Cfin

Max. H",at Capacity' 45.000,000 30,000,000 15,OllO,OOO 7,500,000 . BruJh

Max. Water Required 72 48 24 12 Gpm

Electrical S"",ice , 750 500 250 125 KW

Requirerrierlt ,

NO. of Bay Units - 36 24 12 6

, Bay Unit Size - '18,00 180O 1800 1800 FI2

- iotal Say hea 6-4.600 43,000 '11,600, 10,800 . Fl2

I Heatine capacity from .:boiJer or other,au,,-!liary belt source will likely be needed to achieve the

b.i!ltdt Jevd of VOC mort! JlOi!ible willi the biofilter. The values inlltis table are projecied to be

inuimom amounts; under the colden winter conditions. A pilollt&t will provide mort dctailed data

,00 the input he.altbal may be required to meet tbe periormJLnct requirements. The source for any

au:rlliaIy healing would be determined froaithe aetual slterequiremenlS and tlle availability of

exilting energy 10Ul'C,tS al the site,

Figure 2 outlines the general biofilter configuration for a 50,000 cfm biotllter. Additional bays and

additional blower conditioner modules can be added in a para1Ie] arrangement 10 accommodate

greater airflows. Two bays,each -1800 ft2 are located back-In-back surrounded by concrete walls of

nominally 9' height. This allows any set oftwo bays to be shul down for maintenance or substratereplacement without disabling lht: operalion or the biufiIler. The remaining bays will do a very

substanlial job of odor reduction during these periods. • Blower Condilioocr

Modulos

Scoping Proposal Ibr Biofiltcr • VOC Conuol Application

So.!! Manufacturing Facility

MAy II, 2001

• Utility requirements in 480 V AC. 60 llz. 3 phase electrical power or as per customer

specification,

Based on the Site Design Parameters ofTable .1, the sile requirements and utility suppon services for

the three different flow levels are sununarized in Table 2,' '

T bl 2 S' R

I

I '

l'

i

18~ 50'

Fijlure 2: General Arrangement and Footprint for a 50,000 dm bioftlrer.

60'

.ConTrol Buildina

Air 1--'------'---'-'---'. -----'-Fran

Pl>n,

60'

62'

ij" : '.

l ' ,

6
B

Scoping !'rapasal for Biolilter - VOC Control App~catian

Boar Manufacturing Facility

May 11,2001

6. Complete BacTee auwmaled control system with remote monitoring capability

7. An allowance for general site construction c·osts and 200' of piping/ductwork from the plant to the

control building of the bioli1ter. This allowance does not account for any special site

requirements such as any requirement for pilings., seismic ratings. and other local code

requirements.

All systems integration work on the system including all system control pands andjunetion boxes.

delivered to the site assembled and pre-tested. ,

Table 3 S· p' f B T B' 'fil . COPlUjI; nc~ or lie ee 10 I teTS

Site Air Flow Proiect Cost Cost per CFM ..

50,000 $1.975.000 $39

100,000 $3,115,000 .$31

200000 $5035000 $25

300,000 $6,630,000 $22

7. Project Timetable

The typical timetable offered by BacTee for installing the above system is providcd·in Table 4. Fasttrack projects can be undertaken with pr~subminal approval of the Engineer for all long-lead

.components.

TIIbl e 4 P . T b : rOlect imeta Ie

Ph.a•• Months 1 2 .3 4 56 7 8 9 10 11 .12 13 14

I. Pilot Test * * * 2. T~hnical Design * * Support

3. Construction & * * * • * • Implementation

4. lnitial Operation • •

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U~/.L~/U.L J.U:,J,J rA.J,. TI lUI /I~ O.L.LI

F<lX= 636-916-3717 Pages: 1

rt;"""- - , . - .. ._-- . Addre",,: Phone:

BacTee §Y§U~lDn§t PO Box 5192 701-775-8775

830 s. 48'" SI. Fax: ][He.

Grand Forks, NO 58201 701-775-8117

To: John Gibbons -Advance Env. From: Don Mathsen AV .•...

Phone. 636-916-4800 Date: 5/15/01

Re: Substrate Replacement

o Urgent 0 fCll'Review 0 I'\ease Comment 0 Ple",;e Reply 0 As per Your Request

John - This is in response to your telephone message of Friday aftemoon Telative to

substrate replacement costs. .

BacTee would procure the substrate media from the nearest available supplier of organic

materials that meets BacTee's specifications. 'Without the benefit of having identified that

source at this time, I can only give you a scoping price based on our prior jobs. Obviously.

the distance to the plant from the source of materials will determine freightcosts, which are

a significant portion of the substrate cost. .

For scoping purposes, I recommend using the following range of values:

As IlndlGated In our telephone conversation, we have seen substrates last from three to SIX

. years under highly loaded conditions, A key to long life of the substrate is proper

humidification, moisture and temperature control of the air entering the biofilter bays.

Please let me know if you have any additional questions,

._...- '1

·.AirFlow Substrate Volume Low Estimate

I

High Estimate _...-

50,000 cfm 3,500 cu. yd $70.000 $110.000

100,000 cfm .7,000 cu. yd $140,000 $~O~OOO -"1

r.---'-' --- .'---

$280,000 I 200,000 cfm .. 14,000 cu. yd $440,000

I

- 300,000 cfrn 21,000 cu. yd $420,000 $660.000

- .. , .. _..---

- ---_._,-----------
BioDigestor Technologies, Inc.

. November 20, 1996

Sverdrup Corp.

Attn: Mr. Robert Jorgen

13723 Riverport Drive

Maryland Heights, MO 63043

H. Peter Hombach

ChiefScientist

Roger AnderSen

.Don Mathsen

cc:

Dear Mr. Jorgen:

Thank you for your interest in biofilter applications. I am forwarding a technical description of

biofilters which currently is in draft form. Please note our "Facts and Rumors" about biofilters which

are included with the teclmical description. I also include our :ecent reference list.

BDT provides complete systems for municipal and industrial biological. waste management

applications in support of professional engineering firms. BDT, together with its German technology

team members, have been involved with over 140 biofilter systems worldwide. in more than 10 years of

operating experience, and the total air volume treated by. all installations of our team is 1,300,000 scfm

at this time.

BDT uses the BioAerThl aeration· system; a feature available in the US only through BDT. The

BioAerThi system offers the lowest operating and maintenance costs of any biofilter and composting

aenitlon method in the world. In addition, BDT designs its systems with bdtLogicThl process control

strategy that enables the BioDigestorThl to be used in high performance applications and high VOC

concentration ranges that are not within the capacity of biofilters designed by other companies.

Together with BDT's proprietary approach to the selection and adaptation of organic biosubstrates, the

BDT approach to biofiltration opens ne . or 10 trano.

Some of our current VOC or control projects include desigfis proviaed to HDR and MalcolmPimie. An installation by Metropolitan Sewer District Cinco been performing flawlessly

and successfully since early 1 . ne our pe ormance European systems operated six years

between biosubstrate changes under high temperature conditions with rapidly fluctuating input

concentrations at 99%+ odor destruction efficiency.

Together with BDT's ongoing operation and maintenanc.e support program whereby we monitor the·

operation of our installations from our home office, the BioDigestorThl design enables the customer to

be assured of a low-cost, long-life. biofilter in a system that has become the standard of the industry in

Europe..

We would welcome the opportunity to work with you on any current or future biofilter application.

Sincerely,

~~+r~u

BDT· A BiD-Environmental Company

P.O. Box 12015 . Grand Forks. North Dakota 58208·2015 . 701.775.8775 . Fax: 701.775.8117
Iii BioDig"'o, Technologi", Inc

BIOLOGICAL WASTE AIR PURIFICATION

THEORY AND FUNDAMENTALS

Dr. H. Peter Rombach and Don V. Mathsen, P.E.

:Copyright © 1994; 1996 by BioDigestor Technologies, Inc.

The ·information contained in this document is protected by copyright law.. Reproduction or translation of any·part of this

work beyond that permitied by Sections 107 or 108 of the 1976 US Copyright Act without the permission of the copyright

owner is a violation ofthe law. . .

This handbook may only be used for informational purposes, and is subject to change without notice. It has been prepared to

the best of the knowledge of the authors, however, neither the authors norBDT assume any responsibility or liability for

errors or inaccuracies that may appear in this book. .

This handbook may be quoted in the way commonly used iii the scientific and engineering community; in this case, BDT

expects to beinformed ofsuch reference.

. BIOFILTER. REL. 5, April 1996
Contents

1. General 3

2. Substrate , 3

·2.1 History : 3

2.2 Biological ConSiderations : 3

2.2.1 Type (Quality) of Microflora ..: 1 4

2.2.2 Active Cells (Quantity) ofMicr~f1ora : : 4

2.3 Substrate and Application 6

2.4 Carbon Balance 6

3. Mech'anical Design : 7

3.1 Open or Closed? ; 7

3.2 Components ofa Biofilter ; 7

3.3 Air Distribution System :.: : : :.~ 8

3.2.1 Air Volumes, Sizing : 8

3.2.2 Air Temperatures , : : : 8

3.2.3 Ductwork and Manifold 8

3.2.4 Air Flow through Biosubstrate : : : 8

3.3 Conditioner : : 9

3.4 Fan 10

3.5 Sprinkler..: : : 10

4. Electrical and Control Design , : 11

4.1 Control Cabinet, Enclosures, and Wiring : II

4.2 VFD II

4.3 Sensors , : I I

4.4 Electronic Controls, PLC I I

4.4 Remote Mo~itorini : , : : II

5. Engineering : 11

6. Applications: Odor and VOC Control : , 14

6.1 Pollutant : : 14

6.2 Concentration : 14

6.3 Destruction Effect, "Efficiency" : 14

6.4 Concluding Remarks 15

6.5 Biofilter and BioDigestorTM What is the Difference? : : 15

7. Operation and Maintenance : 16

7.1 Operational Safety 16

7.2 Compliance· Monitoring : : 16

7.3 Maintenance ; : : : , 16

8. Cost Comparison : 16
/-. ,

1. General

Biological purification ofwaste gases by means ofa BioDigestorTM can be used where a broad range of

volatile organic compounds (VOCs) and odor-intensive air pollutants are released. The decomposition

of the pollutants is carried out by micro-organisms settled on a solid carrier substance. Compost and

, other natural organic materials are used as carrier substances. Sometimes synthetic materials 'are used

as carriers. The substances carrying the mic'ro-organisms are commonly called substrates. The airpollutants in the waste gases get adsorbed on the sUrface ofthe substrate and are subsequently decomposed by micro-organisms. ' ,

In terms of the general categories of aerobic vs: anaerobic microbial action, biofilters fall into the

category of aerobic systems; however, if a biofilter is not properly designed and maintained, it may

well switch into anaerobic conditions. Since anaerobic conditions destroy the efficiency ofthe biofilter,

this is one of the most undesirable situations. The proper design is the best guarantee that anaerobic

conditions will not occur.

, Under aerobic ,conditions, incoming VOCs are biologically oxidized 'and about 80% to 90% of the

carbon will be found as carbon dioxide. The carbon balance is used within the microbes to enable

growth. This biological growth determines the lifetiine of the substrate. Over the lifetime, constantly

increasing effici~ncy is observed, however, the flow resistance als'o increases over the lifetime.

2. Substrate

2,1 History

The substrates used by various suppliers show a remarkable variety of mixtures. Substances such as

peat, heather, loam, compost, styrofoam, even activated carbon or zeolite in a mixture with organic

material have bee~ Used. Historically, the biofilters developed out of the German invention of a

Bodenfilter (soil filter) about 25 years ago; this is still the theoretical basis for the application ofloam.

The various biosubstrate materials have distinctly different properties. Table I also lists the BDT substrate which is a specially prepared material ofthi: compost type.

Amazingly, one can observe a trend in the USA where the 10 or20yearold findings in Germany and in

the Netherlands are repeated andreported as new, rather than adopting the experience of companies

likeBDT. '

2.2 Biological Considerations

For a general understanding of the operation ora biofilter, some microbiological understanding is

useful. It is important to know that an active biofilter is a rrticrocosm in its own right, containing

bacteria, fungi, algae, protozoa, and frequently wows: a complete miniaturized food chain. However,

the main responsibility for destroying gaseous pollutants is borne by the bacteria, and to a fesser extent

by fungi. The .applicability of a substrate for use in a biofilter depends on the quantity and,'even more, '

the quality of bacteria and fungi in the substrate.

Omitting the biological details, one can distinguish the microflora more generically by the temperature

range where their metabolism operates at an optimum; Table I provides a schematic of the optimum

ranges of metabolic activity. Omitting the exotic Archaebacteria, the rough classification is in terms of
psychrophilic (sometimes called cryophilic), mesophilic, and thermophilic bacteria: these terms are

derived from the ancient Greek words \jfUXPO~ (psychros) = cold, KPUO~ (kryos) = ice, «HAOe; (philos).

= friend, >JEcrOV (meson) = middle, 8EP>JO~ (thermos) = hot. One should bear in mind, however, that

there is a floating transition between these domains of predominant activity. An advanced control

system for biological systems, therefore, must take into account these tloating transitions. Consequently,

firm set points are not applicable in the control strategy of advanced biofilters.

100

-.;

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: -'.

...•j.•.

. '.

:"'.

"

;'-'.

"-7 _ . -',

'--;" . ....

:.. , -' .~. -.-.-

Figure I: Metabalic Ac'tlvity ofMicro-organisms

2.2.1 Type (Quality) of Microflora

From the above basics,one can easily conclude that thermophilic and mesophilic species are to' be

preferred because oftheir specific activity, i.e. higher throughput in biochemical conversion. However,

this strategy obviously cannot be applied ifone were to simply pass polluted air through some kind of

substrate.Under such simple

conditions,nocontrof is possible

ofthe environment in which the

microorganisms dwell. This is

the key reason that any efficient

biofilter operation reqwres an

electronic control system. One

should keep in mind, however, .

that for all practical purposes

only aerobic micro-organisms

are importa.J:lt for the function of

a biofilter. The anaerobic organisms are usually avoided, and

become a concern in poorly designed biofilters.

In BioDigestorTM systems,

mostly thermophilic ~acteria,

with some contribution ofmesophilic bacteria, are employed for

VOCcontrol in order to achieve maximum destruction efficiencies. In some odor control applications,

mainly psychrophilic and mesophilic bacteria are recommended.

2.2.2 Active Cells (Quantity) of Microflora

In the various substrates, the count of biologically active particles in the starting material can vary

quite significantly. Numbers can be as low as 10' to IDS cfu (colony forming unitS) in loam, peat, or

heather. Values as high as 10' cfu are found in some composts or in the BDT substrates; a deviation of

one order of magnitude is not ofmajor concern. It has been shown empirically that, in addition to the

absolute number of active material, a broad variety ofspecies is required; the preferred species are of

t.he Pseudomonas family. The presence of most members of the Aspergiilus family is not desirable

sinc~ they may emit airborne germs from the biofilter, and these Aspergillus germs are considered a

health hazard; especially A. fumigatiJs and A. aure:us. The count of all airborne germs emitted from a

biofilter is about 10,000 ml-', which is about the count in air-conditioned rooms, and one order of

magnitude less than in the vicinity of cattle.

After getting the fresh substrate into a biofilter, a decrease in cell count usually occurs while the activity increases. Since the specialists among the microbes survive and proliferate, the decrease in the
TaMe J: Properlies ojBiofiller Substrales

substrate

. loam, soil

peat

heather

compost

styrofoam

mixtures'

BioSubstrates

cost

low.'

low

low

low

high

high

medium

resistance .'

high

medium

low

medium

low

medium

low

lifetime

very long

. long

long

short to medium

long

. very short'

long to very long

efficiency

ven; low

low

low

medium

medium to high

medium'

very high

max. conc.

·Iow

.Iow

low

medium to high

medium

high

,very high

disposal

bio-clegradable

bio"degradable

bio-degradable

mostly bio-degradable

not bio-degradable

not bio-degradable

bio-degradable

I containing additives such as activated curbon, zeolite, or perlite

, inactivity of carbon or zeolite after surface or pores are .covered

The column "cost" shows "low" when the material price is determined by freight, i.e. the substrate ~s such has a typical cost of less

than $30 per ton (all prices plus freight). A price level of$30 up to $80 per ton is considered medium, and prices above $80 per ton are

considered high.

A flow "resistance" res\llting in a pressure drop across a I mhigh substrate at less than 250 Pa (one inch of water) is called "low",

between 250 Pa and 500 Pa "medium", and above 500 Pa "high".

A "lifetime" of less than.l year is "short", I to 2 year,s is"medium", more than2 years is "long".

The "efficiency" is rated "low" when the biological conversion is less than 20 g/m3h, "medium" in the range 20 g/m3h to 50 g/mJh,

"high" in the range 50 g/mJh to ISO g/m3h, and "very high" at conversion rates exceeding 150 g/m3h. .

A "maximum concentration" of 100 ppm is "low", up to 500 ppm ";nedium", up to 1,000 ppm "high", and above 1,000 ppm "very

h~". .'

The column "disposal" is intended as an indication whether the spent substrate may cause additional costs because it may be a

hazardous waste. .
coull! is not directly related to the performance of the biof1lter. These specialists among the microbes

need, for their optimum performance, certain humidity and temperature conditions. Most biofilters

operate in the ambient temperature range, and therefore the predominant category ofmicrobes is within

the mesophilic species. However, BDT operates biofilters at higher temperatures than commonly seen

on the market, and consequently the higher efficiency and better performance is attributed to an increased number ofthermophilic species.

For a steady operation of a biofilter; it is of prime importance that the optimum humidity and tempera-

, lure conditions for the biology are met. This has ttirned out to be a challenge for the control systems

since the set points are not constant (see below, Controls section).. '

Special experience is needed to condition the substrate with the right nutrients or to apply the right

amount of buffer capacity and intrinsic pH value. Most biofilter companies treat this knowledge as

proprietary information and so does BDT. '

2.3 Substrate and Application

Depending on the application, BDToffers different substrates. As can be concluded from the discus-

, sion above, the use of "some,kind of compost" that may be available is a safe way to failure. BDT has

developed certain standardized substrate mixtilles, generated locally in order to avoid excessive transportation cost. These are cured within the installed biofilter for between two to four weeks, to achieve'

optimum performance. Sometimes, BDT will use inoculati'on procedures to enhance the growth ofthe

desired species. It is important to know that there is no single "magic mixture" since the performance

depends largely on the geographical environment, owing to influences by climate and external species

that may settle on the substrate. Consequently, BDT has always followed the route of. using locally

available material, the selection of which is based on BDT' s vast knowledge of biological systems.

The general properties described in Table 2 hold for all typesofBDT BioSubstrates. It is noteworthy

that biofilter substrates have a particular smell. People usually do not find this smell offending. The

smell of BDT's substrate can best be described as the smell of damp woods in the summer. It is a

"natural", "biological" smell. This odor is not related to the amount,or chemical nature ofthe incoming

VOCs.

Table 2: Standardized BioSubstrates used in the BioDigestorTM

BioSubstrate

BioSubstrate Type I

BioSubstrate Type 2

Bio,Substrate Type 3

Predominant Biology

thermophilic with mesophilic

mesophilic with psycbrophilic

mesophilic with thermophilic

Preferred Application

VOC and odor control, soil vapor extraction

odor control in WWTP, rendering operations

odor control

2.4 Carbon Balance

Aerobic biological processes such as a biofilter operation are expected to use some carbon Tor their

own growth, i.e. they are not expected to have a perfect conversion of incoming carbon into carbon

dioxide. In biofilters, this measurement requires some experience because the time constants for VOC

reduction and carbon dioxide release differ significantly. In BioDigestorTM systems, BDT finds 85% to

90% of the incomingcarbon to be recovered as carbon dioxide with the'gas stream; the balance contributing to biological growth. The measured data are in agreement with literature data for bacterial

metabolism.
3. Mechanical Design

3.1 Open or Closed?

A biofilter can mechanically be set up in various ways. The least expensive solution is the open flat bed

filter. Closed systems are more expensive and special configurations like a stacked system (usually.

applied in systems with serious space constraints), a tower configuration, or a roof installation are all

common. BDT is able and willing to install any optimal system for a given problem. The commonly

quoted advantages and disadvantages of open vs. closed systems are shown in the table. Within the . . biofilter vendor community, this question has resuLted in a philosophical dispute with no end in sight.

BDT takes apragmatic approach. .

It turns out that most ofthese commonly heard claims cannot be substantiated. The question "Open or

Closed?" is truly philosophical in nature, however, incertain cases the biofilter is always a closed

system. For packing and transport reasons, this is the case with mobile biofilters.

Table 3: Advantages and Disadvantages ofOpenand Closed Design

Inexpensive because no housing structure is needed. The air from the biofilter is released at a height where

l. ' the dissipation in. the ambient air is easier.'

The rain water saves on the wateibill.

The external conditions for the biological system can SirJ)ple monitoring of even air distribution. easily be controlled. .

No system needed that resembles a stack.

Clea.nliness of biological system is obvious to all

visitors (pR effect). .

Sampling for monitoring is difficult. .

The biosubstrate is subject to weather influences.

The treated air coming out oflhe biofilter is

released at ground level and can stay there, depending on weather conditions.

Higher investment. Monitoring ofaverage values is

simple, but monitoring distribution ofvalues is very

difficult.

Closed system's.are frequently equipped with astack

(negative PR effect).

3.2 Components of a Biofilter

The essential components to a biofilter are the

air distribution system

• conditioner

• fan

• substrate

• sprinkler

• contrQlsystemwith sensors.

The mechanical components are discussed in this chapter.
3.3 Air Distribution System

3.2.1 Air Volumes, Sizing

Biofilters can be designed for virtually any air flow. Very small biofilters are used in soil extraction

(flow 1,000 mJ/h or below), while typical biofilters are tn the range of 5,000 to 50,000 m'/h. The

largest biofilters built to date are for air flows of over 250,000 m'fh.

It is important to note that despite the claims of most biofilte~ vendors no linear relationship exists

..between the flow rate and the size of a biofiller. The quantity and composition of the chemical

constituents ofthe waste stream strongly influence the size ofthe biofilter, independent ofthe gas flow

rate. Another misconception is that the depth and width of a filter bed are dependent parameters (i.e.

one can compensate for height with the width ofthe substrate bay). This is not the case. Sizing of the

beds requires specific knowledge of the interaction bet~een the organic waste constituents and

the microbial biologies. Consequently, BDT and other vendors typically keep their means ofsizing a

biofilter as proprietary knowledge. Neither air volume npr VOC concentnitioiI, alone, determine

the sizing ofa biofilter, despite the statements ofthi: VDI (Verein DeutscherIngenieute. Association

of German Engineers) repo.rt on biofilters which are commonly used as a quasi-standard.

Since there is no linear or otherwise simple relationship between the size of a biofilter and the air

volume, the frequently quoted residence time in a biofilter is useless in sizing. Experimentally observed dependencies of VOC destruction, allegedly on residence time, truly rely" on other governing

factors that also influence residence time, i.e. the residence time is not an independent variable.

3.2.2 Air Temperatures " , Incoming gas sfream temperatures have an acceptable range as diverse as the flow rate. The incoming

air may be anywhere from very cool (no limit) up to 300°C ifthe air is dry (i.e. an ambient air source).

At high temperatures (over 40°C), the amount of moisture included in the waste air stream at that

temperature is a !TI0st critical design factor. Becausegaseshave unlimited miscibility, a saturation

level for steam is not definable at these high temperatures. BDT will assist the customer iri defining

whether a "biofilter 'is a feasible solution in cases where high teo;peratures are associated with high

"moisture conterits.

3.2.3 Ductwork and Manifold

Obviously, good engineering design practice should be used in sizing the ductwork for a biofilter.

"Often, the layout of a good air-handling system determines the optimal configuration ofthe biofilter

bays for a given site; therefore, site and ductwork design should go hand-in-hand in the early stages of

a project. Likewise, the selection of ductwork materials is determined by the types and concentratiorl

of contaminants in the gas streain.-

3.2.4.1\ir Flow through Biosubstrate

All biofilter systems require that a high speed air flow in a duct dissipates evenly in the broad area ofa

biofilter. This has been the major challenge for biofilter designers for a long time. Historically, sandor

gravel beds have been used to support the substrate and to allow the air distribution. These simple

systems have neven'lorked welL The main disadvantages are the

• uneven air distribution, leading to "channeling" within the bed;

• high flow resistance, leading to increased energy cost;

". water seepage into the ground, leading potentially to pollution problems;

replacement of the bed required when biosubstrate is moved,

• increased operating cost.
:iI

Figure 2: BioAe",-rnAir Distribution System

Picture 'shows BioAer" C

Overthe past 10 years, mainly two systems ofa "stone"

support basis have been developed. In both systems,

developed independendy at about the same time, the

"stones" are laid out on a concrete slab thus allowing

heavy equipment to drive on the aeration floor. This is

important to allow easy access and quick loading or'

. unloading of a biofilter ~hen that becomes necessary.

Whereas one system can be described as a pipe built

ofsmall stone pieces. with air gaps, the other system

("1:iaseplates") contains a two dimensional channel

system. Common sense and experimental data teli that

a pipe system operates on higher pressure drop than a

.' . two dimensional channel system, and this means sub-

. stantially higher compression energy for the pipe-like

system. As a result, the baseplates have almost forced

the "stone" system out ofthe market:

THE FINAL VERSION OF THIS TECHNICAL HANDBOOK WILL INCLUDE.A GRAPH

OF PRESSURE DROP IN PIPE SYSTEM I GRAVEL BED YS. BIOAER

Figure 3: BioAer"AirDistribution System

Picture shows BioAer'" C

As mentioned above, the biology needs certain tempera-

·ture and humidity conditions. These are maintained by

the so-called "conditioner". The conditioner is an air

washer, common toindustrial or commercial air:.conditioDing. The intensewashing ofihe air removes dust that otherwise would clog the biofilter·and sets the

right temperature and humidity level.' . .

It is often overlooked that a spray mist does not adequately humidify the air to the extent required in

biofilter operation; the lack of moisture will sub"equently dry out the biosubstrate arid result in the

infamous "wall effect" and "channeling" which are irreversible conditions. Since conditioners operate

·as adiabatic units in humidifying the air; one must assure a sufficient heat transfer jointly with the

·humidification, as it is done with BDT conditioner units. Depending on .the application, the condi-.

tioner may be connected to an external heat source through a heat exchanger for the heating and I or

3.3 Conditioner

The baseplates are known in Europe (where they were

invenied) as RottAe(~, and they are sold in North

America under the brand BioAerTM. BDT exclusively

uses this system because of its technical advantages.

Typically, this air distribution system pays for itself

within 1Y, years, based on the savings in operating costs

(compression energy).

'. Depending on a given application, BDT will advise the

customer whether to use concrete baseplates or poly- '.

mer baseplates; BioAe(Thl is available in both varieties.

The BioAerThi baseplates can be ordered from BDT as

·components.
!

;I

cooling ofthe water in the internaJ circulation loop ofthe conditioner. This operation is also controlled

by the automatic control system (bdtLogicTM).

The amount of water used in the conditioning process, the associated energy balance, and the amount

of water evaporated from the conditioner can be calculated in a somewhat tedious process using stan-

. dard engineering tables. BDT has developed a computer program for this design step and for use in

general purpose air conditioning (see Technical Sheet of the WinHumTM program).

The nozzles used inside the BDT conditioner are a special clogging-free type that can let particles of

8 rom diameter pass through without negative effect. The BDT conditioners humidify the air to a

minimum of92% relative humidity. Conditioner units are shipped assembled or pre-assembled; they

are made in either stainless or FRP, depending on the application. Conditioner units can be ordered

from BDT separately as custom-made items,

It is important to know that the condItioner does not operate at one preset temperature; the temperaturefhumidity program is rather complex. .

3.4 Fan

Aside from the obvious task to move the waste air to the biofilter, the fan is also instrumental in

providing the oxygen supply to the BioSubstrate; even the "hibernating" organisms' are in need of

o;<)'gen when the bacteria cannot feed on VOCs. These two crucial functions require that the speed of

the fan is adjustable to the needs ofthe substrate and to the removal ofVOCs. This is accomplished by

,a variable frequency drive (VFD). . , Because ofthe crucial role of the fan in keeping the biological system aerated, BOT will oftenrecommend a small backup fan unit that is automatically triggered by the control logic (bdtLogicTM). The

need to do so is determined in the detail engineering process by BOT, or jointly with the engineering

firm chosen by the customer.

The fan status is constantly monitored for current, temperature, and phase by the bdtLogicTM control

system. In larger industrial appIi cations, this includes the monitoring ofvibration and bearing temperature in order to avoid uRscheduled maintenance events and undesirable downtime.

3.5 Sprinkler

TO BE INSERTED
4. Electrical and Control Design

4.1 Control Cabinet, Enclosures, and Wiring

TO BE INSERTED

4.2 VFD

TO BE INSERTED

4.3 Sensors

TO BE INSERTED

4.4 Electronic Controls, PLC

Obviously, a biofilter must take whatever comes out of a given production or ventilation process. Some

biofilters designed by our competitors require uniform emission constituentswith uniform gas flow

rates and constant VOC loads. Since this is not the real world of a production process, BDT follows a

different line ofthought.

Through the "smart controls" concept ofBDT, the biofilter is capable of adapting itself-to a wide range

of input temperatures, humidity levels, and contaminants in the waste gas stream. It is BDT's experience that a biofilter can stay in "hibernation", i.e. at reduced' temperatures and without a gaseous

carbon source, for several weeks, provided that the proprietary algorithms ofbdtLogicThl control system are implemented. The 'operation cycle of a process/production line can remain unaffected by the

environmental control technologies when the bdtLogicTM system is used. Typically, a BioDigesto{rM is

operating at 90% efficiency or more within less than one hour after an extended "hibernation" period

- unlike common biofilters where several hours, and sometimes several days, are needed to restore

efficiencies.

The proprietary bdtLogicTM control algorithms also contain a program block for data acquisition and

data recording. As part ofthe software system, data can optionally be recorded and archived on a PC

and/or by a strip-chart recorder. . . .

The operator interface is a touch-screen with a visualization of all pertinent process parameters. Ifhuman interaction withthe fully automated system becomes necessary, this interaction will be through

touch-screen commands.

The bdtLogicTM hardware typically interfaces with an existing PLC system .through a serial port, or

operates with a PLC provided by BDT as part of a complete control system. bdtLogicThl has the input

and output characteristics described in the Technical Specification Sheet.

4.4 Remote Monitoring

For safety of continuous operation, a remote log-on capability is implemented with bdtLogicThl. BDT

will regularly log into the system remotely"to provide a continuous quality assurance program.

5. Engineering

The design criteria involve parameters such as gas-stream humidification and associated water requirements, gas-stream temperature and heat requirements, fan size, and the geometrical dimensions

of the area containing the active biosubstrate. In the case of VOC emissions, these parameters are
,

,

:rt r:

. determined by measurements on a slip stream from the actual production process. For the removal of

odors, measurements can usually be omitted.

The measurements are performed on an actual biofilter in a mobile test laboratory called a Mobile

Engineering Parametrization Station (MEPS). The MEPS should not be confused with a demonstration unit and is not a feasibility test; the feasibility is determined before the MEPS is sent to a site.

Unlike a demonstration unit which simply is a down-sized version of a regUlar biofilter, the MEPS is

equipped with sophisticated data acquisition features that would not typically be found in a full-sized

unit. It is important to know that only with the proper determination ofthe design criteria can a performance guarantee be given.

One ofthe most important factors is the "sizing," i.e. the determination ofthe width and height ofthe

full size biofilter bay or tower unit. The width depends mostly, but not exclusively, on the toial air

volume, while the height depends mostly, but not exclusively, on the desired removal rate. Therefore,

the reduction of the total air volume at the emission source can be the most important cost saving .)_

factor. Despite the information obtained from many biofilter companies, the removal rate is almost

independent on the input concentration. This makes possible the opportunity to reduce air flow at the

source to reduce the overall cost of the system.

BDT is a systems provider and offers the design and installation of a complete odorfVOC control

facility. Where a biofilter is one subsystem in an odor control or VOC control installation, BDT works

closely with the enginee~ing firm(s) in developing the specifications and design criteria. Consequently,

BDT establishes and maintains relationships with engineering firms that allow the prompt delivery and

integration ofspecifications and drawings into complete design packages.
·.

Table 4. Biodegradability of common VOCs, as commonly accepted

Sources:

VIiI Report #3477 (VDI Handbuch Reillhallllllg der Lufl. yol. 6)

VDI Report #3478. quoted in Chemical Engineering, Dec. 1992

Remark: VDI ;s the Association of German Engineers (vereill Dell/scher [llgenieure)

Excellent Good Minimum Unknown

toluene 'benzene m<;thane acetylene

xylene styrene pentane methacrylate

alcohols acetone cyclohexane isocyanates

methanol ethylacetate diethylether trichloroethylene

butanol phenol dioxane perchloroethylene

tetrahydrofurane dimethylsulfide' dichloromethane

formaldehyde thiocyanates

a,etaldehyde thiophene Zero

butyric acid methylmercaptane

trimethylamine carbondisulfide I, I, I-trichloroethane

amides

pyridine IMPORTANT: This table does not reflect the viewpoint and

acetonitrile knowledge ofBDT, and is not endorsed by BDT

isonitrile PLEASE NOTE: VDI's view is detenmined by the low'

chlorophenols concentrations «500 oom) in common biofilter aoolic;.;,tions

Table 5. Biodegradability of common VOCs - BDT's point of view

Source: Eight years of biofilter experience.

Excellent Fair Minimum

aromatic hydrocarbons (toluene, xylene, benzene

meSitylene, styrene) aliphatic hydrocarbons (pentane to

aliph,atic hydrocarbons (octane and heptane, cyclohexane, cyclopentadiene)

higher) chlorinated hydrocarbons (chloroheterocyclic compounds (tetrahydro- form, methylene chloride, vinyl

furane, ethyiene oxide, pyridine, chloride, benzyl chloride)

thiophene, dioxane) diethylether

aliphatic and arlHllatic alcohols (methanol, ethanol, propanol, butanol, benzyl

alcohol. ethylene glycol)

aldehydes (formaldehyde, acetaldehyde,

benzaldehyde)

carhonic acids (fonmic acid, acetic acid,

propionic acid, butyric acid)

amines (trimethylamine, ammonia)

ketones (acetone, MBK, Cyclohexanone)

esters (ethylacetate, acrylate, methacrylate)

phenols, thiophenols, merc~ptane:s

thioethers

nitriles, isonitriles .

thiocyanates, isocyanates

carbon disullide, hydrogen suIlide

aliphatic hydrocarbons (propane

, and butane)

trichloroethane, percbloroethylene,

trichloroethylene
..

6. Applications: Odor andVOC Control

6.1 Po/Jutant

As stated in the introduction, biofilters are an efficient method ofremoving organic compounds from

gas streams. Specific questions about the effectiveness of biofilters should be addressed to BOT, although some general rules apply as "rules ofthumb":

• Organic compounds of high boiling point can be captured and destroyed by a biofilter more

easily than low boiling compounds (theoretical background: adsorption isotherm).

• . Organic compounds ofhigh symmetry cannot be removed by a biofilter, or at least it is difficult

(theoretical background: the enZymes orthe microbes need a preferred carbon-hydrogen bond to begin

the oxidation).

• Inorganic compounds commonly found in gases (such as NO , SO , NH) are efficiently de- )it

stroyed in a biofilter...· x , x. J .

Germany's VDI has issued a report providing design criteria for biofilters, and this report also lists a

table of compounds. Although BOT does not agree with the placement ofsome entries in this table, it

can be uSed asa good guideline. VDI's and BDT's point of view are shown in table 3.

6.2 Concentration

G

'g> 601-----j------::

BOT has truly expanded the scope of

biofilter applications.

w

§5 40

..~ 20))

.

6.3 Destruction Effect, "Effi- c.,. t-- co lffion bior!lt r

ciency" 0 o 2,000 4;000 . '6,000 8,000

The destruction effect, commonly but CONCENTRATION (ppm C3-equivalerits)

wrongly called' efficiency, in a Figure 4: Operating rallge ofbioft/ters and BioDigestors.The

BioDigestorTM biofilter is 90%+ de- light blue shaded area is covered by the common "bioft/ter"

struction of the incoming VOCs, and definition.

even a destruction of99%+ is not out ofquestion, depending onthe nature ofthe pollutari.t, the air flow,

and the design. For high input conce{1trations, the air released from the biofilter even at a 99%+ destruction level may contain levels ofVOCs that can be detected by the very sensitive instrument ofthe

human nose,depending onthechemical nature ofthe VOC. The sensitivity ofthe nose for concentration.levels v'3.ries over multiple orders of magnitude. Conseq\lently, compliance With envirOnmental'

standards does not always result in no odors, although in most cases the VOC destruction is down to a

level that one cannot-smell. Certainly any biofilter can be designed in a way that the air released from

the biofilt~r only has the natural smell ofthe biosubstrate; this is a question of design and sizing.

The chemicaJly unspecific "odors" from some processes are a typical phenomenon ofthe food indus-

.. Sometimes consulting engineers are misled by literature statements that biofilters can only be applied

at comparative.1y low concentrationsofbelow 1,000 ppm carbon. BDT has never shared this view, and

is successful in operating biofilters at 80 r--'-"---r----,-----,------,

much higher concentrations of up to

21,000 ppm (as carbon, 7,000 ppm as

propane) owing to thefact that BDT has

developed the' technology of applying

.thermophilic bacteria. This "operating

window" is shown:iri figure 4.
..,

tries. Chocolate production, coffee bean roasting, fish processing, and rendering operations are among

the most notorious. These odors are very often related to small amounts of compounds where the

human nose is particularly sensitive, and the concentrations of the "odors" in air are unusually low. In

these cases, biofilters are the method of choice because the smell can usually be removed by 99%.

6.4 Concluding Remarks

The general biofilter theory outlined above is not to be read as an instruction for a "Do it yourself'

biofilter- there is no universal "biofilter r-ecipe" or "biofilter design". Depending"on the specific application, BDT will design the BioDigestorTM accofding to the requirements of a particular task, and

although BDT has gained reputation for preferring'thermophilic bacteria, BDT will in certain applications prefer a mix ofpsychrophilic and mesophilic bacteria. For many industrial applications, Application Sheets are available from BDT upon request

6.5 Biofilter and BioDigestorTM - What is the Djfference?

As shown above, the highlights of~ BioDigestorTM include the application of advanced controlsysterns allowing a continuous recalculation ofset points, ofthe best currently available air distribution

system, and ofthe lowest possible O&M cost for a hiofilter application.

A typical BioDigestorTM design is shown in Figure 5.

Acces~ Aproll

Access,

Figure 5: TjpicaI BioDigestor Design
)

I

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7. Operation and Maintenance

7.1 Operational Safety

'Biofilters'have an unusual level of inherent safety and even more so with the modern BioDigestorTM

design. BDT will, upon request, provide assistance in a HAZOP evaluation,

7.2 Compliance Monitoring

It is important to know that in an intermittent operation cycle of a production process the biofilter , .

responds after a "swing-in" time interval and likewise responds with a "swing-out" when the VOC

concentration drops sharply. Consequently, the only way to. describe the performance of a biofilter is

through the integral ofthe concentration in the time interval t = t and,t = ti + A, with A as the "swingout" time. Unfortunately, this fact has not become widely knowrt and seems to be unpublished,

7.3 Maintenance

The BioDigestorTM is designed to operate unattended. The weekly maintenance check requires about

one hour. In addition, a more extensive quarterly ¢heck is requi~ed; the'quarterly maintenance check

requires about one day.

8. Cost Comparison

TO BE INSERTED
BioDigestor Technologies, Inc.

Site Evaluation Form

Waste Gas Treatment

.

PLEASE NOTE: ALL lNFORM:A:rION ON TfllS SHEET WILL BE TREATED CONFIDENTIALLY!

1YPE OF PlANT {INDUSTRY BRANCH

LOCATION, STATE

EXlSTING EMISSION CONTROL O..e. new instaDatlon, equipment being replaced)

CURRENT METHOD O.e. incineration, carbon adsorption, Qltect vent, etc.}

SCHEDULED START-t)P DATE OF NEW OR. REPLACEMENT EMISSION CONTROL SYSnEM

TARGET VALUE FOR EMISSION REDUCTiON

PREFERENCE OF ENGINEERING FIRM Qf any), NAME AND PHONE NUMBER OF CONTACTAIR FLOW (m'ih or efin)

CONTINUOUS FLOW { TYPICAL.INTERVALS

TEMPERATURE of waste' gas stream

MOISTURE of waste gas.stream

AlEROSOLS { DUST (particle size and amount)

Please attach your business card here· ?

or write down your name, company, address,

phone and fax number

ANALYTICAL DATA

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BioDigestor Teclinologies, Inc.

MOST COMMONLY ASKED QUESTIONS

ABOUT BIDFILTERS

Abbreviations used:

ppm . parts per million .

VOC Volatile Organic 'Compounds

Q: Is a biojilter system as simple as it appears to be?

A: No. "First generation" biofilters were little more than piles of dirt, wood chips or compost

through which an off-gas was blown. These systems were successful on a limited range ofapplications.. "Second generation" biofilters incorporated humidification of the gas stream. This enabled

biofilters to be used over a broader range of discharge gas moisture conditions. State-of·the-art, high

performance biofilters, the "third generation," cOlltrol the biological environment and off-gas parameters under all process conditions. "Third generation" biofilter systems constantly monitor and integrate control of both the biofilter (i.e. the biology) and the exhimststream (i.e. the process). The

conditioner unit modifies the air stream temperature and moisture accordingly. Since the control unit

has to deal with the living and subsequently changing body of a biological system and (in many cases)

changes in off-gas flow and .load, it cannot rely on fixed set points for temperature, humidity, VOC

load, etc. Consequently, the "third generation" units operate on algorithms that maintain the proper

conditions for the biology under all process operating modes.

A~vice: Ask your biofilter vendor to describe the control strategy ofhis system. Do not accept a

biofilter control strategy withfixed set points!

Q: Does a biojiiter need a constant airflow and a constant load of VOCs?

A: No. Measurements on third generation systems have demonstrated that well adapted microorganisms will "hibernate" (reduce their intensity of metabolism) after a couple of hours when VOC

. concentrations (nutrient levels) decline. It is important that a biofilter control logic adjusts the air

flow, temperature and humidity accordingly during these levels oflow concentration (stand-by operation). A "third generation" biofilter automatically performs this task. There is no necessity to "feed"

the biological systems during these periods.

Advice: Avoid any biofilter design that "demands" additional nutrients or 'fertilizers.":

Q:' Does a biojilter need several weeks to regain performance after a plant shut-dlJWn?

. A: No. After several days - even up to several weeks - ofappropriately induced "hibernation", the

biological system will regain full efficiency within two hours ofresuming normal process cOnditions in

most cases. This short recovery time is a feature ofa "third generation" biofilter that controls the entry

and exit from this induced "hibernation" state. A level of 90% efficiency is usually reached within 30

minutes ofresumed operations

Advice: Donot e;pectthis performance from a biofilter operating without proper control logic (first

or second generation system). Ask your biofilter vendorfor a performance guarantee.
Q: Doesn't a biofilter need a lot ofspace for high air volumes?

A: Not the football fields often imagined and quoted. It is true that biofilters require space for

housing the biosubstrate materiaL However, the design of the biofilter system has a major impact on

the biosubstrate volume and the subsequent footprint of the system. With poor design, the area required increases dramatically. A modem, "third generation" biofilterdesign with the appropriate controllogic dramatically reduces the footprint (up to 70%).

Advice: Seek info!mationfrom several vendors regarding their proposed space requirements. A "resid~nce time" calculation is typical of ''first and second generation" design which leads to largerfootprints. With "third generation" design, the resideuce time is not the dete;mining si::ingfactor.

Q: Can a biofilter handle a VOC concentration above 1,000 ppm?

A: Yes. Without an appropriate control strategy, early generation biofilters were limited to low

concentration applications,i.e. up to 500 ppm. Third generation biofilters using a "smart" control

system destroy concentrations of up to 6,000 ppm (18,000 ppm in carbon equivalents!) on most solvents or fugitive emissions.

Advice: Ask your biofilter vendor whether or not his "ppm values" are based on propane or carbon

equivalents. ·Then do your own computations and compare the efficiencies of different competing

biofilter systems. Do not anticipate first or second generation biofilters to perform at high removal

.rates on a COnsistent basis.

Q: Are VOC renwvallevels above 90% feasible with a biofilter?

A: Yes. Track records of modem biofilterapplications.show that destruction levels well above

90% can be consistently realized. Destruction levels of 99%+ have been demonstrated over many

years.

Advice: Ask your biofilter vendorfor reference applications.

Q: Are biofilterspracticalfor destroying inorganic gases such as hydrogen sulfide?

A: Yes. Inorganic gq.ses like hydrogen sulfide, ammonia, nitrous oxide; chlorine, or sulfur dioxide

will be destroyed in a biofilter under the appropriate conditions. Likewise, most VOCs containing

hetero-atoms are destroyed in a high efficiency biofilter. . .

Advice: Ask yourbiofilter vendor whether they are confident that their biofilter can remove a given

compound.

THE ULTIMATE QUESTION: What tnilkes biofilters so attractive compared to other air pollution control technologies?

THE ULTlJ.\1ATE ANSWER: Biofilters are inexpensive to operate, have a long service life, do not

generate hazardouS waste, and are highly reliable ifproperly designed.

THE ULTIMATE ADVICE: Compare othertechnology options with biofiltertechnology.. In tnilny

cases biofiltration will be the answer! Select the biofilter system that offers the highest value over

.the life ofthe system.. .'

Copyright © 1996 by BioDigestor Technologies, Inc.

The information contained in this document is protected by copyright law. Reproduction or translation of any part of this

work beyond that permitted by Sections 107 or 108 ofthe 1976 US Copyright Act without the permission ofthe copyright

owner is a violation ofthe law. This text may be quoted-in the way commonly used in the'scientific and engineering community; in this case, BDT e~pects to be informed ofsuch reference.
III BioDigestocTechnologie;, Inc

There was a Time of Rumors -

but now it's Time for Facts

10 Rumors and F~cts about Biofilters

Abbreviations used:

ppm . part per million

VOC- Volatile Organic Compounds

RUMOR #1: Biofilters need a constant air flow and a constant load ofVOCs.

FACT: It's just a rumor' Measurements on BioDigestorThl systems prove.that the well adapted micoorganisms will ;'hibernate" (reduce their intensity ofmetabolism) after a couple of hours when the VOC concentration diminishes. Within the

BioDigestorThl design, during these periods of non-emission ofVOes the air flow is cut down to a minimal level (stand-by

operation). There is no necessity to "feed" the biological systems during these time periods, although some technical papers

call for this practice.

RUMOR #2: After plant shut-downs, th~ biofilter needs weeks to get up to performance again.

FACT: It'sjust it rumor! After several days of hibernation, even aflera week or two, the biological system will run at full

efficiency again within at the most two hours ifthe BioDigestorThl design has been chosen. The level of90% offull efficiency

value is usually reached within 30 minutes.

RUMOR #3: A biofilter is always in danger of flipping into anaerobic conditions which tum the biomass into a smelly,

useless material.

FACT:

teams may

It's

face

just

dlfliculties

a rumor!

in

Any

designing

properly

a biofilter

designed

in

biofilter

the way

is

that

far

anaerobic

from an anaerobic

conditions

condition,

cannot occur.·Within·the

however, inexperienced

BioDigestorTM

design'*.

design, a worst-case protection is built into the system to safeguard the filter even if everything else fails. The BDT team has

in the past been called to rescue a "dead" (non-aerated) biofilter designed by a well known competitor, and within three days

the biofilter was fully active again without an exchange oftbe biological material..

RUMOR #4: Biofilters need a lot ofspace, up to several football fields in area for high air volumes. '?

FACT: It'sjust a rumor! It is true that biofilters need more space than competing tSc.~er, ~nly through poor

design is the .area dramatiCally larger. For a BioDigestorThl built by the BDT team i Missou~ the regular biofilter design as

commonly reported in the literature would have called for an area of 2,200 m', how., e BDT calculation demonstrated

that only 600 m' are required - a size reduction of 73% while maintaining a 94%+ destruction efficiency! -Upon customer

request, the filter was built at 1,050 m' to allow for plant expansion.

RUMOR #5: Biofilters can only be used at low·concentrations, well below 1,000 ppm.

FACT: It's just a I)lmor! Unfortunately, "ppm" is a very generic description of a concentration, and comparing ppm values.

given by different people very often means comparing apples and oranges. In biofilter applications, ppm commonly refers to

the volume ofthe gaseous voe (standard conditions) in air {standard conditions), with the voe amount calculated on the

basis of carbon .atoms. Because detectors are mostly calibrated against propane calibration gases, and because propane
fl·

contains 3 carbon atoms per molecule, the ppm values given by different people may differ by a faclOr of three. BDT uses

ppm values consistently as values based On propane, i.e. in a comparison with carbon or methane based values, our values

must be multiplied by three.

Ordinary biofilters perfonn well at low concentrations, i.e. up to 500 ppm. For higher concentrations. advanced design such

as the BioDigestorTM technology is necessary. With a BioDigestor'P', for most solvents or fugitive emissions, concentrations of up to 6,000 ppm (18,000 ppm in carbon equivalents!) will be destroyed efficiently.

RUMOR #6: VOC removal efficiencies ofbiofilters are poor and can hardly reach 90%.

FACT:'Ifsjust a rumor! The track record ofBioDigestorTM applications shows that regularly destruction efficiencies well . . above 90% can be reached. Within the BDT's tearn track record is one installation in Gennany where constantly over the past

8 years destruction efficiencies'of99%+ have been demonstrated.

RUMOR #7: Hydrocarbons cannot be destroyed efficiently in a biofilter because they are hydrophobic and cannot get

into the watery biofilm.

FACT: It's just a rumor! The rumor stems from experience with the ordinary biofilter design. Under the operating conditions of a BioDigestorTM, most hydrocarbons will be destroyed. However, the hydrocarbons With very low boiling point

(methane, ethane) do not have enough residence time to get biologically attacked while being adsorbed on the lipophilic

menibranes that are the skin ofthe bacteria.

RUMOR #8: Biofilters are not useful for inorganic gases; or VOCs containing hetero-atoms such as halogen, nitrogen, or

sulfur.

FACT: Ifs just a rumor! Inorganic gases like ammonia, nitrous oxide, chlorine, or sulfur. dioxide wi1I be destroyed in a

biofilter under the appropriate conditions. Likewise, most hetero-atom containing VOCs are destroyed in a BioDigestorTM.

BDT will advise the customer whether the BioDigestorTM can destroy a given compound.

RUMOR #9: There isno competent source ofinfonnation available regarding biofiltration as there fS on other methods .

and technologies for air pollution control.

FACT: It's just a rumor! The BDT team offers all the infonnation you need to determine if your specific problem can be

solved by a biofilter. This infonnarion is as close to you as your fax machine. All you have to do is fill out the site evaluation

sheet which facilitates rhi.s process and send it to one of our offices. In response w.e send, without any obligation to you, a

proposal for a BioDigestorTM system addressing your emission control needs.

RUMOR #10: Biofilters are inexpensive to operate, highly reliable if properly designed, have a long lifetime, and do not

generate hazardous .waste.

FACT: WelL all four statements are true for a biofilter with the BioDigestorTM design.

Copyright © 1994, 1996 by BioDigestorTechnologies, Inc.

The infonnation contained in this documeni is protected by copyright law. Reproduction or translation of any part of this

work beyond that permitted by Sections 107 or 108 ofthe 1976 US Copyright Act without the permission ofth" copyright

owner is a violation ofthe law. .

This text may be quoted in the way commonly used in the scientific and engineering community; in this case, BDT expects to

be informed ofsuch reference.
Site Evaluation Form

\Vaste Gas Treatment

BioDigestor Technologies, Inc.

PLEASE NOTE: ..>J.L rNFORlvlATrOCI ON TH1S SHEET WILL BE TREATED CONFillENTL.>J.LY'

TYPE OF PLANT {INDUSTRY BRANCH

LOCATION•.STATE .-----'---------"'------- _

EXISTING EMISSION CONTROL (i.e. new installation. equipment being replaced)

CURRENT METHOD 0.e~ incineration. carbon adsorption, direct vent, etc.)

SCHEDULED START-UP DATE OF NEW OR REPLACEMENT EMISSiON CONTROL SYSTEM

TARGET VALUE FOR EMISSiON REDUCTION

PREFERENCE OF ENGINEERING FIRM (if any). NAME AND PHONE NUMBER OF CONTACT

AIR FLOW (m'lh or elm)

C0r:!TlNUOUS FLOW { TYPICAL INTERVALS

TEMPERATURE of waste gas stream

MOISTURE of waste gas stream

AEROSOLS' OUST (particle size and amount)

Please attach yDur business card here ?

or write dow11 your name, company, address,.

phone and fax number

ANALYTICAL DATA

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Site Evaluation Form

Waste Gas Treatment

BioDigestor Technologies, Inc.

PLEASE NOTE: ALL fNFORMATION ONTHrs SHEET WE.~ BE TREATED CONFrDENTL.lJ.LY'

TYPE OF PLANT (INDUSTRY BRANCH

LOCATION, STATE

EXISTING EMISSION CONTROL a.e. new installation. equipment being ~=:.'3;:e:d)

CURRENT METHOD a.e. incineration, carbon adsorption, direct vent, e!\;.;

SCHEDULED START-UP DAtE OF NEW OR REPLACEMENT EMISSIC'; CONTROL SYSTEM

TARGET VALUE FOR EMISSION REDUCTION

PREFERENCE OF ENGINEERING FIRM 01 any). NAME AND PHONE ~,"-·!.I;;=R OF CONTACT

AIR FLOW (m'lh or elm)

. CONTINUOUS FLOW { TYPICAL INTERVALS

TEMPERATURE or waste gas stream

MOISTURE of waste gas stream

AEROSOLS { DUST (particle size and amount)

Please attach your business card here

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phone and fax number .

/-S":.,-YTICAL DATA

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BioDigestor Technologies, Inc.

U.S. and European Biofiltei Projects

BDT-GeoTec Partial Reference List

October 1996

.. This reference list contains 91 entries, of more than 140 installations worldwide. The

distribution of applications ofthe entries in this list is·as follows:

OTHER

23.1%

FOOD

PROCESSING

7.7%

WASTEWATER TREATMENT.

46.2%

BDT· A Bia-Environmental Company

P.O. Box 12015 . Grand forks, North Dakota 58208-2015 . 701.775.8775 . fax: 701.775.8117
PAGE 4

Customer I Company Project I Usage Flow RMe Flo"!,Rate Year

'·,:1'. m'lhr cfm (operuti..ng sincet

fa, Buter GmbH Waste Water Treatment 3,600 2,120 1994

Bahnhofstrasse 50 Plant (WWTP)

48607 Ochtrup City ofOchtrup

Germanv '

Scliaap GmbH Rendering Plant 5,000 2,940 1989

Averbeck 51

48619 Heek

Germa,ny ,

Sfadt Coesfeld Waste Water Treatment 4,000 2,350 1994

48653 Coesfeld Plant (WWTP)

Germany City ofCoesfeld

, ,

Heitkamp GmbH " Waste Water Treatment 15,000 ; 8,300

Rodenkirc!lener Strasse 200 Plant (WWTP)

50389 Wesseling City ofBergischGer:manv Gladbach,

Kessler & Luch GmbH Waste Water Treatment 30,000 17,650 ' 1995

MathiaS-Brueggen-Strasse 154 Plant (WWTP)

50829 Koln City ofBoilll-Duisdorf

Germanv

Johann Gergen GmbH Waste Water Treatment 24,000 14,120

Kaiser-friedrich-Ring 23 Plant (WWTP)

66740 Saarlouis City ofVolklingen

Germanv

BASF Soil Remediation 150 90

Carl~Bosch-Strasse38 Facility

67063 Ludwigshafen

Germany

, Phillip MOller GmbH Waste Water Treatment' 7,800 4,590 1992

Monschstrasse 11 Plant (WWTP)

70191 Stuttgart Hungary

Gennany

Stahl Ton AG Waste Water Treatment 7,800 4,590

Riesbachstrasse 57 , Plant (WWTP)

8034 lurich Bleachery

Switzerland ,

Phillip MOUer GmbH Waste Water Treatment 1,200 700 1994

HeiruichstraSse 11 Plant (WWTP) 500 290 1994

043 17 Leipzig lott KG

Germany two compact biofilters

Felgentreff Entsorgung GmbH Waste Disposal Plant ,12,000 7,060 1992

Molbisei Landstrasse

04579 Espenhain

Germany, ..... ..

PWA Potsdamer Viasser & WWTP 2,000 1,100 1993

Abwasser GmbH Pump Station

Potsdamer Strasse 32-34 City ofPotsdam

14612 Falkensee, Germany
PAGE 6

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!

Cus~olller ! Company Project/Usage Flow Rate Ii10w Rate .. ' Ye.ar

rri'lhr cfm (operating ,ince)

Berufsschule Gelserrkirchen Pilot Plant 300 176 , 1991

Heegestrasse 14

45897 Gelsenkirchen

Germanv

Teckenbrock GmbH Waste Water Treatment 3,600 2,120 1993

BoumalU1strasse 25 Plant (\VWTP)

46325 Borken City ofIsselburg

Genpanv .

Lineg Waste Water Treatmef\t 600 350

Friedrich-Heinrich-Strasse 74 Plant (wwrP)

47475 Kamp-Lintfort ..

Germanv

Wieninger GmbH .. Yeast Processing Plant 12,000 7,060

Postfach 26 05

94016 Passau

Ginnanv '..

Schaap GmbH Rendering Plant . 60,000 35,300 .. -. 1988

Averbech 51

48619 Heek - ; . . Germanv . .

CincilU1ati Metro Sewer Waste Water Treatment 3,600 2,120

District, City ofCincilU1ati . Plant (\VWTP)

1600 Gest Street Polk Run Unit

CincilU1ati, OH 05203 Loveland, Ohio

Cincinnati MSD Waste Water Treatment • 14,600' 8,100 1997

City ofCincilU1ati Plant (\VWTP)

1600 Gest Street Mill Creek

Cincinnat~ OH 05203 Cinci!U1ati, Orjo

Abwasserzweckverband Sludge Drying Facility 2,500 . 1,390 1995

Kliirwerk Breisgauer Bucht

79362 Forchheirn

Gennany

Kompostierungsanlage Composting facility 6,000 3,300 1996

Bischofsheim

Industriestr. 24

65474 Bischofsheirn, Gennanv

Stadt Abwasseraufbereitung Sludge drying facility 17,000 9,400 1996

Klarwerk

Rheinuferstr. 2

79713 Bad Sackingen,Gennanv

Stadt. Abwasse.mufbereitung Sludge Drying facility 21,000 11,700 1996

Klilrwerk

RheinuferStr, 2

79713 Bad Sackingen,Gennanv

GER GrevesmUhlen SlUdge Drying Facility 1,000 600 1995

Langer Steinschlag 2

23939 Grevesmiihlen

Gennany
PAGES

Customer / Company Project / Usage Flow Rate Flow,Rate .Year.

m'/hr cfm (operadng slnce)

Kompostwerk Bentheim Composting Facility 42,000 23,300 . ·1996

Kiesstralle

49849 Wilsum

Germanv

Kompostwerk Liineburg Composting Facility 50,000 27,800 1995

Zentraldeponie Luneburg

Adendorfer Weg

21357 Bardowick.Gennany ,

Stadt Koln Composting Facility , 70,000 38,900

GroBkHlrwerk Starnmheim

50667Koln

Germany

Weiss Bio-AnIagei1lVogteier Composting Facility 34,000 18,900. ·1995

Kompost GmbH

An der Oberrothe

99986 Niederorla, Germany

MERA DUren-Horin ·Solid Waste Treatment 62,000 34,400 1994

DUrener Deponie GmbH Plant

Pfarrer Peuss-Str. 46

52393 Hurtgenwald-Horm

MEV Liineburg SolidWaste Treatment 70,000 38,900 1995

Zentraldeponie Plant

Adendorfer Weg

21357 Bardowick.Germany

Abfallwinschaftsbetriebe MSW Treatment Plant 50,000 27,800 1996

Munster City ofMunster

Eulerstr. 12

48155 Miinster, Germany

MAT Mull- und Abfalltechnik Waste Water Treatment . 12,000 6,700 1995

GmbH Plant (WWTP)

Monchstr. II City ofHogel

70191 Stutt<W1, Germany

Annuss Slaughterhouse 6,000 3,300 1994

cIermany .

.

Reemtsma GmbH & Co Tobacco Processing 50,000 27,800 1996

Imhoffslr. 44

30853 Langenhagen .

Germany·

Pumpwerk Bochum Waste Waler Trealment 4;500 2,500

Germany Plant (WWTP)

Pump Station

City of Bochum

KJilranJage Lohmeri Waste Water Treatment 3,000 1,700 1996

18176 Lohmen Plant (WWTP)

c;ermany City ofLohmen
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·&Advance

Environmental

Associates, LLC

MEMO

May 11,2001

To: AEA File

cc's: Andy Polcyn

Dave McKenzie, Crownline .Boats

.From:· John R. Gibbons, P.E.

... Subject: Proposal fram BioRem

BioRem decided not to subrriit a written prop.osal and therefore, this memo summarizes a phone

call that I had with Richard Puntis, Director of Sales..

They are proposing to use their Synergytm system to treat the styrene and MMA. They strongly

suggest doing a pilot study before designing a full-scale system. Also, they will not provide a

. performance guarantee without a pilot study. As a side-note, their pilot plant may not be

available until September, 200 I since there is a company that is close to issuing a purchase order

for a system. To do a pilot study will cost $40,000 (3-nionth study). The data from the pilot.

study will be used to determine the humidity/temperature, loading and flow rate requirements.

Also, the data will determine ifthe desired control efficiency can be achieved. .

Richard saidthat for a 300,000 cfrn system, the cost ofthe full-scale system will be

approximately $15/cfm. I asked him ifit would vary for a flow rate as low as 50,000 cfm and he

said no. The size of a unit treating 300,000 cfrn would be 37,500 if. He said that they could

make tiers for the unitto reduce the size. The cost goes up tb$25/cfrn iftiers are necessary. The··

unit would require air pr~treatrnent using spray humidification.

He said that the media Jrilliast approximately 10 years and that it costs $21/ft' to replace the

media. The air temperature coming out ofthe biofilter will be approximately 50-60 F and heat

recovery for sending air back into ih·e plant is possible using air to air heat exchangers.·. The· .

eXhaust from the biofilter can not be directly recycled to the plant due to some natural toxins in...

the eXhaust. .

C:\JRG DOCUMENTSIPROJECTS\COOCOO4\BIOREMTELECON.DOC
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Fan

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• low operalitlg and maintenance costs

• guarallleed reliobilily and-performance

• proven resulls Gtld outstanding service

Re'i!eneratlon Une

"~'\ffl~,Pi-'--'''-'1

I

Scrubber I

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BIOFILTRATION ... ADVANCED TECHNOLOGY

(UmpliLIlHJs rVOC",I dlld r!>~l

manufacturing rmcll\rlli..t'_"''''lll~

iacililies ;"'lore relidble rh,1n

chemical scrubbers dlld nh.'re.

dffnrdable than itH..:int:'f-:ir~·'r:;

biofiltration use<; ndturdlly L'/",al",J.",,,, .._<:::.c===

occurring microbe's to biolugically break down odors. solvents and other VOCs present in

waste air streams, in.'o corlx)n dioxide and ~'ater It's a completely natural process 'thai

doesn't use chemicois "r prcoduce wastes ,-\vatldble exclusively from BIOREM. a leadin~

North ,~merican biotechIlDlog:,' company. SYNERGY' is the' most advanced biofilter 011

the market

Low OPERATING & MAINTENANCE COSTS

Biofiltratibn is d reliC'lble and·

"Jist-effective way tll elilnilidte

1 '. ~,""'0 _

BIOFILTER

Why are so many plants.replacing their scrubbers thermal incinerators or carbon

sy'stems with SYNERGY? Three simple r~a'il'ln"

The SYNERGY''' process u.s. Palent No. 5,869.323 .

SYNERGY'~ . elimirratesyour VOC emissions and gives you more time to

~oncentrate on wnat tlOU do best. - manufacture and process flottr products.

With their new SYNERGY systems, up al1..

running man~: plant Dw.ne.rs are "now' savinl;(

h,!ndreds of thousands of dollars each year'

They no longer have to buy expensive chemicals like sodium hypochlorite or

chlorine dioxide that most scrubbers need Or they are eliminating high energy

costs typically seen with thermal sys'tems SYNERGY· has minimal operating

requirements. There dre no un~ecessary or complicated controls ~nd 'no

expensive hazardous waste t9 take away,

Carbon System

• Thermal~xld [;tier

~-, I

'nllld- ~1

• Blofllter

Catalytic o.xldl;ter"

Tolal FiveYearCosl of

Blofillralion '5. AIlemalive Technologies

'SIll"''' -

BIORIM

SYN ERG Y" REMOVES AND'

DESTROYS ODORS AND VOLATILE

AND ORGANIC COMPOUNDS .

(VOCsj AT A LOWER COST FOR

BOTH INSTALLATION AND

OPERATION WHEN COMPARED TO

ANY OTHER DESTRUCTION OR

TREATMEN' TECHNOLOGY.

INSTALLATION COSTS FOR

SYNERGY" CAN BE AS MUCHAS

15% ·LOWER. MORE IMPORTANT,

THE ANNUAL OPERATING COSTS

FOR SYNERGY'" ARE 60% TO

75% LESS. AT EVERY POINT IN

THE ANALYSIS SYN ERGY"

'IS YOUR MOST EFFICIENT AND

COST EFFECTIVE .CHOICE FOR

VOC CONTROL.

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The SYNERGY'" hiofilter system

is setting new standards in the

biological treatment of waste air

contaminated with VOCs and odors.
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BIORQM

ONGOING SUPPORT

- BIOREM offers the most comprehensive ongoing moniJoring and support program in the industry. For the first

year after your new SYNERGY'· system installation. BIOREM will monitor its performance at no additional cost

to you. Every three months, you simply collect and sena us a sample of your biofilter media. In our

lab, we'll examine:

• pH

• moisture content

• particle size analysis

• nuirient'availa6ility

• mlcro6ial enumeration

Our industrial microbiologists can' determine if any trends ar~ oc~urring that could cause problems down the

road if left unmonitored. In this way. we can develop a unique preventative maintenance program. It's these

small but important details that demonstrate our commitment to you.

WHY CHOOSEBIOREM?

Satisfied clients all over the world ~re using the SYNERGy,,'system from BIOREM. The reasons are simple. First

andforemost, we're biotechnologists with the scientific expertise to devel()p the latest breakthroughs in the

biologic~1 treatment of waste air streams. But we don't stop there. We use this knowledge to bring you leading

edge biofiltration systems that are customized to your needs. With pilot plants available to gather site specific

data, we can fine tune the design of your SYNERGY'· system and guarantee its performance.' "

Our resources include experienced engineers, chemists, industrial microbiologists and state-of-the-art

laboratory and research facilities. It all adds up to the most complete service' in the biofiltration in<;!ustry. From.

start to finish, BIOREM brings you a low cost, low maintenance, reliable solution to your odor, VOC and H1S

control needs. We know you'll be impressed with the SYi'JERGY"biofilter.

For a price quote, a detailed proposal, or for more information on our SYNERGY:·, BASYS'·, or BIOFILTAIR'·

systems visit our website at www.bioremtech.com or contact us today at 1-800·353-2087.

Biorem Technologies Inc. 7496 Wellington Road 34, RR#3 Guelph, Ontario, Canada NIH 6H9

Telephone >19.767·.9100 • Fax >19.767.1824 • Email info@&ioremtech.com • www.&ioremtech.com
,..,., ~~

BIOREM

HOW TO ELIMINATE PLANT ODOR COMPLAINTS

Andrew J. Polcyn RECEIVED SEP

Advance Environmental Associates

300 South Second Street

St. Charles, MO 6330 I

Dear Andrew:

VVednesday;August23,2000

.I have ~nC1osed the i,nfomiation you requested about the Biorem Technologies Inc. (Biorem) Biofilter systems for

the control ofplant odors. I hope you'n fmd this infomiation useful and thank you for your interest. '

If you've ever thought "I wish I knew of a technology that would eliminate my plant odors without using

hazardous chemicals, that was maintenance free and that didn't cost a .fortune to operate?" then the enclosed

information describes a technology that can help. ' .

As abiotechnology company specializing in the design and installation ofbiomters since 1994, we've developed

three distinct biofilter systems for the removal of odors, VOCs and H,S at wastewater treatment plants, composting,

rendering, chemical, food and ingredient manufacturing and pet food manufacturing plants all over the country.

Biofiltration is a proven technology that involves the biological breakdown of odorous compounds to water and

carbon dioxide.' Plant air streams are collected and passed through a speciaily prepared media where the

biodegredation takes place.. Biofiltration is more reliable than chemical scrubbers and more cost-effective than

incineration!

Biorem has been on the lea.ding edge of the development ofbiofilter technology in North America. VVe can work

with you to eliminate odor or VOCs at your site by designIng, building and goaranteeing one of our:

•

•

•

BioultAIRTM - custom low cost highly effective odour controlBiofilterfor large flow rates,

BASYSTM - modular biofilters infoursizes manufacturedfrom mild steel orFRP, OR, NEWFOR 7000 our,

.SY1:lERGTI,;\'~;spai:e-saving combi'l(jJiq~:ofalllghly effective biofilter with an efficient after adsorber!

. - r~~1tt~~~.>i ;·~/~.;i Jl~~ .'. . r systems are defining a','iieW<'staHi:lard ill degj'iidation rates of odor compounds, H,S and VOCs from

'4:;~;m,i'"'"-Ca!11 me today at (5(~f7§J~91b9:~d:'i;if~ff~~ an appointment or to receive a proposal. ·11, '"~l'1'

~~~n~~~;:.{f'\"· , Director, Sales & Marketing

PS Vonlt ~th;;.;.-opportu.n.a;y ro- yed.«ce"yO1M'" odor"/Vc:JC contYol- CcUJ.,

meo{or lA/q~ yLffht" Nc:JW!

Blorem Tee'nn%gles Inc. 7496 Wellington Road 34, RR #3, Guelpli, Ontario, Canada. NIH 6H9

Teleplione: (5191 767·9100· Fax: (519) 767-1824· E' mail: hiorem@intrnear.com owww.bioremtecli.com
Zarook Shareefdeen} Ph.D.

Director ofResearch

I

Experience Summary

Dr. Zarook Shareefdeen has extensive experience in

bioflltp research During his PhD program. he

developed pilot and laboratory scale biofllters at

Hazardous Substance Management Research Center t

(HSMRC) at New Jersey Institute Tech.. for treating

Volatile Organic Compound (VOC) emissions. As an .

assistant Professor in the department ofChemical

Engineering at King Fahd University ofPilroleum &

Minerals, Saudi Arabia he supervised several graduate

theses and carried outfunded research projects related

to bioflltration, Prior tojoining Biorem. he has worked

at University ofCalifornia as apostgraduate researcher

in a National Science Foundation (NSF) funded project.

He has published extensively in high quality refereed

journals and presented papers in national and

international conferences. He has received afunded

research projectfrom National Research Council (NRCCanada) for developing novel sampling techniquesfor

biofilter air streams characterization. .

Primary ResponsiblIities

+ R&D project proposal preparation

+ Implementing R&D Projects

+ Management ofR&D Lab.

+ Research and Engineering Services

Education

Ph.D.. in Chemical Engineering, New Jersey Institute of

Technology (NJIT), NJ, (1994)

Dissertation: "Engineering Alialysis of a Packed-Bed

Biofilter for Removal ofVOC (Volatile Organic

Compound) Emissions"

Post Graduate Research, Department ofChemical and'

Environmental Engineering, University ofCalifornia,

CA (1999)

BIOREM

Sample

Project: Blolilter DesIgner

Biofilters for emission control have received

considerable attention from industries as an

alternative method to corrventional air pollution

control technologies. Solutions of biofllter

models involve highly sophisticated numerical

. methods. R&D division ofBiorem has developed

a user-friendly software BIOFILTERdesigner.

which enables users of various disciplines to

design bioflltersfor VOC emission control easily

.without having to go into complex math~matics.

Journal Publlcalions

Zarook S. M., and A. A. Shaikh, 1997, "Analysis

and comparison ofbiofllter models", Chemical

Engineering Journal, 65,.55-61.

Zarook S. M., A. A. Shaikh and Z. Ansar, 1997,

"Bioftltration ofVolatile Organic Compound.

(VaC) mixtures under transient conditions",

Chemical Engineering Science, 52, No. 21/22,

pp4135-4142.

Zarook S. M., A. A. Shaikh and S. M. Azam, 1998.

"Axial dispersion.in bloft/leTs", Biochemical

Engineering Journal, 1,77-84.

Conference Presentations

Zarook S. M. and B. C. Baltzis "Bioflltration of

voc mixtures: Modeling andpilotscale

experimental verification", Air & Waste

Management Association, Ciricinnati, OH, (June

19-24, 1994).

Zarook S. M., A. A. Shaikh "Oxygen Limitations

in Biofilters", Chemical Reaction Engineering VI"

Engineering Foundation Conferences, Banff,

Alberta, Canada, (June 8-13,1997).

Zarook S. M., A. A. Shaikh, A. Adeeb "Effect of

Feed and Surrounding Temperatures on the

Toluene Remaval in a Biofllter", First international

Symposium on Issues in Environmental Pollution,

Denver, Colorado, USA (August 23-27, 1998).

ProfessIonal Affillations

American Chemical Society (ACS)

American Institute ofChemical Engineers

(AIChE)

Air & Waste Management Association (AWMA).