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Cyclone redesign meets changing emissions regulations

23 May 2024

Find out how AB Agri identified a solution that enabled it to adhere to changing emissions regulations while continuing to meet its quality and efficiency operating targets.

AB Agri is a manufacturer or animal feed, nutrition and technology-based products. Its Enstone site, a mill located just on the outskirts of Chipping Norton, processes animal feed for pig and poultry. 

The original cyclone employed at the mill  to remove and separate particulates, risked no longer meeting the new Best Available Techniques (BAT) emissions regulations, which had been reduced to 20mg3 from the previous limit of 50mg3.

The new Best Available Techniques (BAT) emissions regulations represent a significant shift in how agricultural technologies and practices need to align with environmental standards. The regulations focus on minimising the environmental impact of agricultural activities by setting more stringent emission limits for pollutants, emphasising the use of advanced technologies, and promoting practices that reduce the release of harmful substances into the air, water, and land.

For many agri-tech organisations, such as AB Agri, the updated regulations have required the adoption of new technologies or the modification of existing ones to meet the stricter emission criteria.

BAT compliance
Compliance with the BAT standards now also demands more comprehensive monitoring and reporting of emissions, making it essential for agri-tech companies to adopt robust data collection and analysis capabilities. This increased transparency aims to ensure that agricultural practices are not only efficient but also environmentally sustainable.

In some applications, cyclones are typically not as efficient as more traditional approaches such as filters, bags and cartridges. However, in this particular application the presence of damp and acid gas would run the risk of blocking a filter or bag. Added to this was the risk of warm, moist air and organic matter entering any traditional system and creating the perfect environment for harmful microbes and bacteria to breed. Even efforts to coat the bags would not negate the microbial risk in this instance. So the use of a cylone at the mill was a necessity.

The filtration team at FEG Global was tasked with designing and installing a solution that would help AB Agri meet the revised emissions limits. One challenge facing FEG was the site’s physical space constraints. It was important to take into account the space available and ensure any solution would fit while remaining cost-effective.

The FEG team started the project by looking at the current cyclones, their operating history, regimes and function. It identified some issues in the design that could be revised to help improve emissions targets and also the efficiency of the cyclone itself.  The team then set out to model the performance of the existing cyclone against new cyclone designs, while testing various theoretical efficiency and emissions outputs. 

Once the new design had been finalised FEG created and installed the revised cyclone, including a redesigned cyclone top, in keeping with space constraints and, importantly, existing equipment and processes. The final project piece was to organise and oversee testing of the cyclone to ensure targets were being met. 

The new cyclone not only met the new emissions standards but also operated more efficiently than the previous model – improving overall operations efficiency. The design was balanced and airflow were correct. 

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