Is Landfill Gas a Renewable Energy Source?

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Click to Expand Landfill gas, or LFG, comes from decomposing solid waste. Often considered a foul-smelling hazard and source of air pollution, it can also be captured, refined, and reused for energy production. Shell and tube heat exchangers are critical throughout the processing stages that convert LFG to fuels and other energy sources. Keep reading to learn more about landfill gas, how it can be reused to benefit the environment, and the role shell and tube heat exchangers play in the process. What Is Landfill Gas? When trash is added to a landfill, it decomposes over time. Initially, decomposition is aerobic (i.e., in the presence of oxygen); however, after several months, the decomposition becomes anaerobic (i.e., without oxygen). This anaerobic decomposition results in LFG. LFG is composed of many different gases, but primarily methane and carbon dioxide, approximately 45-60% and 40-60% respectively. It also contains small amounts of carbon monoxide, hydrogen, sulfides, ammonia, oxygen, nitrogen, and nonmethane organic compounds, including vinyl chloride, benzene, and trichloroethylene. Is Landfill Gas a Renewable Energy Source? As a byproduct of decomposition, LFG is naturally released into the surrounding environment, generating odors and air pollution. Instead of allowing the gas to escape, many landfills recapture or extract it for processing. This converts it into fuel that can be used directly for medium-BTU applications or used to power turbines to generate electricity. It can also be further processed for use as vehicle fuel or added to gas pipelines. LFG also stands out among renewable resources like wind and solar because it is constantly being produced. While wind speeds vary and the sun sets each night, trash never stops decomposing and generating LFG. According to the EPA, landfill gas offers many environmental benefits: It is a renewable and safe energy resource. It reduces reliance on using other polluting forms of energy. It reduces air pollution and other risks to health and the community. The EPA also notes several economic advantages of LFG: LFG is a ubiquitous and consistent local resource and recycling it is cost-effective. Reusing LFG can generate economic advantages for the local community. LFG energy projects can create local jobs. Landfill energy sources have the potential to attract businesses to the area. Landfill Gas Coolers, Heat Exchangers, from Enerquip  How Shell and Tube Heat Exchangers Assist in Recycling and Recovering LFG LFG recovery and processing involves many steps. Shell and tube heat exchangers are an important part of the process. LFG Collection and Processing Collection. Escaping LFG is collected through a network of pipes and wells. Processing. Moisture is removed from the LFG so that siloxane and sulfur can be removed to create fuel for electricity production or medium-BTU applications. Advanced processing. Removing carbon dioxide, nitrogen, oxygen, and VOCs creates fuel for vehicles or to be added to gas pipelines. The Role of Shell and Tube Heat Exchangers Cooling and Condensation. Shell and tube heat exchangers help cool raw LFG, condensing the moisture to separate it. This prevents corrosion of equipment due to moisture. Heating for Siloxane Removal. Shell and tube heat exchangers heat LFG to separate siloxanes. This protects downstream equipment and improves gas quality. Heat Recovery. Shell and tube heat exchangers help recover heat from combusting purified LFG. The recovered heat can be reused in other processes to improve efficiency. Energy Production Fuel for Engines or Turbines. Purified LFG can be used to power turbines or reciprocating engines to generate electricity. Heat exchangers assist in maintaining ideal operating temperatures. Environmental Benefits Reduced Emissions. Heat exchangers assist in efficient cooling and purification of landfill gas, reducing harmful emissions. Energy Efficiency. Incorporating heat exchangers allows for the recovery and use of waste heat. Challenges and Considerations Corrosion and Fouling. Heat exchangers require protection from corrosion and fouling from gas impurities. Maintenance. Regular maintenance is required for efficiency and optimal performance in extreme operating conditions. Heat Exchangers From Enerquip for Landfill Gas Applications As the world moves towards renewable energy sources, biofuels like LFG are an ideal solution for powering equipment that generates electricity and in other applications. Shell and tube heat exchangers are a critical part of the LFG capture and refining process. Enerquip’s high-quality equipment helps you meet landfill gas renewable energy demands. Contact us or request a quote to get started.   More from the Enerquip Blog Plastic Pyrolysis: Transforming Waste into Resources How Economizers Enhance Thermal Oxidizers Five Ways to Increase Terminal Efficiency Biofuel Blending Solutions from Enerquip [Video] Waste Heat Economizer FAQs

Plastic Pyrolysis: Transforming Waste into Resources

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Click to Expand As the world faces growing challenges from plastic waste, innovative technologies like plastic pyrolysis offer promising solutions. Plastic pyrolysis transforms discarded plastic into useful fuels, chemicals, and materials, helping to reduce landfill waste and support a circular economy. Enerquip is providing thermal solutions to serve the emerging plastic pyrolysis industry. What is Plastic Pyrolysis?  Plastic pyrolysis is an advanced recycling process that heats plastic waste in the absence of oxygen, breaking it down into valuable liquid and gas products without burning it. This process, known as thermal decomposition, takes place at high temperatures—around 932 °F (500 °C)—and produces fuels like pyrolysis oil and gas. These fuels can be used in a variety of applications, including energy production and chemical manufacturing. Unlike traditional incineration, pyrolysis reforms plastic into useful substances instead of turning it into ash or releasing harmful emissions into the atmosphere. This makes it a more sustainable option for recycling plastic waste. The Plastic Pyrolysis Process The plastic pyrolysis process involves several key steps: Shredding and Drying: Plastic waste is shredded and dried to prepare it for the pyrolysis reactor. Feedstock Separation: Non-plastic materials are removed to ensure pure feedstock for efficient processing. Thermal Decomposition: The plastic is heated in a reactor, where it vaporizes and breaks down into pyrolysis oil and gases. Oil Distillation and Purification: The liquid fuel produced is distilled and purified for further use. Storage and Dispatch: The final product is stored for distribution or immediate use. Catalysts for Improved Efficiency Certain catalysts can enhance the efficiency of the plastic pyrolysis process by speeding up chemical reactions and improving fuel quality. Common catalysts include: ZSM-5 FCC MCM-41 Zeolite Benefits of Plastic Pyrolysis Plastic pyrolysis offers several advantages that make it an attractive option for plastic recycling: Relatively Eco-Friendly: Studies show pyrolysis is more environmentally sustainable than landfilling or incinerating mixed plastic waste. The oil produced through pyrolysis replaces the need for new commercial diesel, reducing environmental impact. Combustion-Free: Since oxygen is absent in the pyrolysis process, no greenhouse gases are emitted from combustion. The only emissions come from the fossil fuels used to heat the reactor, which can be reduced by using the fuel produced during pyrolysis. Cost-Effective: The gas produced can be reused to heat the reactor, saving significant costs on external fuel. Importance of Plastic Waste Recycling in the Chemical Industry Plastics are not a renewable fuel source. Producing plastics and converting them into fuel releases a considerable amount of pollution that can put the health of nearby residents at risk and accelerate climate change. However, plastic recycling reuses processed plastics, reducing the need to extract raw, new materials from the earth and preserving natural resources. In recycling applications, plastic pyrolysis can also help minimize the emission of heat-trapping gases into the atmosphere. Properly recycling plastic waste can help prevent it from entering rivers, oceans, and ecosystems, where it can contribute to the degradation of the environment and harm wildlife. Recycling gives plastics a second purpose, preventing it from becoming a recurring pollutant. Types of Equipment Used in the Plastic Pyrolysis Process Shell and Tube Heat Exchangers A shell and tube heat exchanger plays a crucial role in the pyrolysis process by managing the heat transfer between different fluids or gases. Here’s how it fits into the plastic pyrolysis system: Preheating the feedstock to reduce energy consumption in the reactor. Cooling pyrolysis vapors to condense them into liquid products like pyrolysis oil. Recovering heat to increase energy efficiency. Stabilizing reactor temperature for optimal performance. Enerquip Heat Exchangers for a Pyrolysis Application Pyrolysis Oil Burners While an industrial pyrolysis oil burner is considered optional, the equipment is typically necessary since the pyrolysis oil can be used as fuel to heat the pyrolysis reactor. This eliminates the need to purchase fuel from other sources, resulting in convenience and cost-saving benefits. Carbon Black Screw Conveyors Following discharge from the pyrolysis reactor, carbon black must be carried away by screw conveyors. These specialized conveyors help save time and labor. Environmental Protection Devices A tail gas purification system is used to purify the tail gas produced during the pyrolysis process. Most pyrolysis plants also maintain a flue gas desulfurization tower as part of their standard flue gas purification system. If there is a greater need for environmental protection, custom configurations are available to meet those needs. Auto-Feeders An auto-feeder improves the efficiency of feeding plastic into a pyrolysis reactor. By automatically pressing the plastics into the reactor at high pressures, auto-feeders can significantly reduce the amount of time and effort needed for feeding compared to manual labor. Vacuum Systems Once the plastic pyrolysis process is complete, a vacuum system extracts the remaining oil from the reactor to prevent the oil from causing a fire when the reactor door opens. Plastic Pyrolysis vs. Mechanical Recycling Chemical Recycling Chemical recycling encompasses reprocessing technologies, such as industrial pyrolysis, that directly affect the formulation of the polymer or the polymeric waste. Chemical recycling converts the polymer into chemical substances or products for either its original purpose or other purposes, except for energy recovery. Mechanical Recycling Also known as physical recycling, mechanical recycling involves processing plastic materials without altering their original chemical structure. The plastics are subject to various processes, such as melting and grinding, that alter the materials’ physical form. Without breaking any polymeric chains, these steps aim to purify the material for reuse. Enerquip: Your Partner in Plastic Pyrolysis Solutions Since 1985, Enerquip has been a leader in providing industrial heating and cooling solutions. All of our products are manufactured in the U.S. from our carbon-neutral facilities in Wisconsin and Oklahoma. We continuously explore new and emerging technologies to enhance sustainability, from biofuel blending to landfill gas recycling—and now, plastic pyrolysis. Request a quote today to see how our equipment can serve your process application.   More from the Enerquip Blog 7 Ways Shell & Tube Heat Exchangers Outperform Plate & Frame 5 Ways Shell & Tube Heat Exchangers Help Recover Waste Heat Enerquip’s Environmental Commitment How

Exploring Electrolysis as a Leading Hydrogen Production Process

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Electrolysis is a method that produces carbon-free hydrogen from nuclear and renewable resources. The process uses electricity to split water into oxygen and hydrogen molecules in the electrolyzer unit. Electrolyzers come in a range of sizes, from small appliance-sized units for small-scale hydrogen production to large-scale units for production facilities in the renewable energy production sector. Learn more about the main types of electrolysis and how Enerquip’s solutions serve this market. Types of Electrolysis Processes for Hydrogen Production Click to Expand Electrolyzers are made of a cathode and anode with an electrolyte separating them, similar to a fuel cell. There are several types of electrolyzers, each with different functions based on the material of the electrolyte and the ionic species it conducts. Polymer Electrolyte Membrane Electrolyzers A polymer electrolyte membrane (PEM) electrolyzer has an electrolyte made of a specialty plastic. When water is introduced to the anode, it reacts to form oxygen and hydrogen ions with a positive charge. The electrons move through an external circuit system, and the hydrogen ions are drawn across the PEM to the cathode. There, the hydrogen ions and electrons combine to form hydrogen gas. The reactions are as follows: Anode: 2H2O → O2 + 4H+ + 4e- Cathode: 4H+ + 4e- → 2H2 Alkaline Electrolyzers In alkaline electrolyzers, hydroxide ions (OH-) in the cathode move through the electrolyte to the anode, and hydrogen gas is generated in the cathode. Alkaline electrolyzers typically use a liquid alkaline electrolyte solution of potassium or sodium hydroxide. However, newer alkaline electrolyzers that use electrolytes made of solid alkaline exchange membranes (AEMs) are being developed and show promising results in lab environments. Solid Oxide Electrolyzers A solid oxide electrolyzer uses a solid ceramic electrolyte to conduct oxygen ions (O2-) selectively under elevated temperatures to produce hydrogen. Steam in the cathode and electrons from the external circuit combine to create hydrogen gas and oxygen ions with a negative charge. These oxygen ions transfer through the ceramic membrane, reacting at the anode to generate oxygen gas and electrons for the external circuit. The Role of Thermal Process Equipment in Electrolysis Electrolysis offers a unique opportunity to align hydrogen production with renewable energy sources, like wind power, by using excess electricity for hydrogen generation when energy supply exceeds demand. This process provides operational flexibility that enhances the overall efficiency of renewable energy systems. Enerquip supports hydrogen production by designing and fabricating industrial heating and cooling equipment essential for electrolysis processes. All our products are made in the U.S. and play a crucial role in hydrogen generation. Our heat exchangers and heaters—such as shell and tube heat exchangers, waste heat economizers, and thermal fluid heaters—are vital in these applications. Heat exchangers are critical in hydrogen production as they recover and recycle heat from the process, improving overall energy efficiency. For instance, in high-temperature electrolysis, heat exchangers capture waste heat and transfer it back to preheat incoming water or steam, reducing energy consumption. This heat recovery system is essential for optimizing the cost-effectiveness and sustainability of hydrogen production. Additional applications for Enerquip’s heat exchangers include: HVAC systems Chemical processing Ethanol production Feedwater heaters Fuel gas heaters Suction heaters Oil coolers Kettle reboilers General service condensers Partner With Enerquip Due to its ability to produce carbon-free hydrogen, electrolysis will continue to grow in popularity to support worldwide sustainability goals. There are several types of hydrogen production electrolysis systems available to meet the needs of your operation. Enerquip offers a variety of heat exchangers and other temperature control solutions for hydrogen production. Enerquip has delivered industrial heating, cooling, and sanitary solutions made in the USA since 1985. Contact us or request a quote to get started with your unique solution today.   More from the Enerquip Blog Is Landfill Gas a Renewable Energy Source? Plastic Pyrolysis: Transforming Waste into Resources How Economizers Enhance Thermal Oxidizers Five Ways to Increase Terminal Efficiency Biofuel Blending Solutions from Enerquip [Video] Waste Heat Economizer FAQs

Tank Coils FAQ: Answers to Common Questions About Steam & Thermal Oil Coils

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Curious about tank heating coils? You’re in luck. With decades of experience, we’ve compiled a comprehensive list of the most commonly asked customer questions regarding steam and thermal oil tank heating coils. What’s the difference between helical and longitudinal tank coils? The main difference between helical and longitudinal tank coils is the fin design. Helical tank coils feature fins wrapped in a spiral pattern around the pipe. Longitudinal tank coils have fins that run straight along the length of the pipe. Both designs are used to improve heat transfer in storage tanks, but fin height, fin thickness, and installation requirements can impact overall performance. Learn more about helically wound tank coils vs. longitudinal tank coils here.  Are helical or longitudinal fins the better option when it comes to tank coils?  Helically wound tank coils offer numerous advantages, including: Enhanced heat transfer: Finned tank coils with helically wound fins boast nearly double the heat transfer rate compared to those with longitudinal fins. Cost reduction: Tank coils equipped with helically wound fins can deliver twice the heat transfer to the tank product, necessitating only half the number of coils to achieve the same outcome. Consequently, they typically entail lower manufacturing and installation costs, yielding significant savings. Improved efficiency: With twice the heat transfer capability, helical coils operate notably more efficiently than longitudinal ones, leading to ongoing energy savings. Decreased coking: Unlike longitudinal designs where fins are welded horizontally, creating a shelf for the product, helically wound fins allow sediment and product to fall and flow between the coils, reducing the occurrence of coking. As you can see in the photo, fouling of the coil does not occur when the proper type of fin is used, even after two decades of use. What is the difference between finned and bare pipe? Bare pipe tank heating coils, simply put, consist of pipe without fins. While bare pipe may suffice for specific highly viscous applications, including helically wound fins often proves advantageous due to their augmented surface area. Helically wound coils boast several benefits over their bare pipe counterparts. As previously mentioned, they offer increased surface area, requiring significantly less pipe to heat the material within the tank. Consequently, opting for helical tank coils can translate into a considerably smaller investment for your facility. Moreover, finned tank coils can mitigate overcrowding issues at the bottom of the tank by occupying less space. Should my tank coils be ASME code stamped? The short answer to this question is Yes. ASME code was established in an effort to prevent accidents by making boilers, pressure vessels, and heating equipment safer. Equipment that is ASME stamped has been thoroughly inspected for quality and meets the standards established by the Boiler & Pressure Vessel Code.  All our tank coils meet ASME code standards and can be code-stamped. You can learn more about ASME code and why it matters here. Do you offer custom tank coils? We do! Our storage tank heating coils are custom-built to meet the specific criteria outlined by our clients and designed to meet each facility’s unique needs.  Our engineers can calculate the exact temperature based on your boiler or thermal fluid heater. We can also take the layout of your storage tank into account, enabling us to create a tank coil solution that’s completely customized for you.  Where are Enerquip tank coils manufactured? Our tank coils are manufactured in our facility in Oklahoma, USA. Our dedicated engineers are committed to excellence, ensuring that each coil we produce is reliable and built to last. When it comes to tank heating solutions, you can trust us to deliver superior performance every time. Have a question about tank coils that we didn’t answer here? Contact us.    More from the Enerquip Blog Tank Coils from Enerquip  Biofuel Blending Solutions from Enerquip [Video] Five Ways to Increase Terminal Efficiency Thermal fluid heater FAQs Benefits of Tank Coils with Helically Wound Fins How Tank Heating Coils Work