Rendering Plant and Advanced Emission Cleaning Solutions

A Rendering plant, or a by-products processing plant, is a specialized facility designed to process inedible animal by-products such as bones, fat tissue, meat waste, and feathers. These materials are typically sourced from meat processing plants, slaughterhouses, butcher shops, and supermarkets.
The processing involves several stages:

1. Collection and transportation of by-products to the plant.
2. Pre-processing, where materials are ground to standardize their consistency.
3. Thermal treatment: By-products are cooked at high temperatures to separate solid components from liquids.
4. Pressing: After separation, remaining liquid is squeezed out of the solid fraction.
5. Drying: The remaining solid material is dried.
6. Grinding: The dried product is ground into powder or pellets.

The plant's products include:

• Meat and bone meal, used as an animal feed supplement.
• Animal fats, used in feed production, as well as in the food and chemical industries.
• Gelatin and other products for the food industry.
• Environmental significance: Rendering plants play an essential role in waste disposal by converting potential pollutants into valuable products. This reduces waste and prevents environmental harm.
• Challenges and regulations: Plants must strictly adhere to environmental and sanitary standards, including waste management and emission control, to minimize environmental impact and ensure product safety.

The company will invest 2.7 billion dollars in the reconstruction of the rendering plant, creating 450 new jobs by 2025. The plant will comply with the highest sanitary standards, allowing it to be certified for product shipments worldwide. It will also feature modern packaging lines and a new canning line.

The enterprise will increase its capacity to 720,000 heads per year. The modernization will make the plant the leading sheep farming enterprise in the country, covering all stages of lamb production, including breeding and fattening. The processing capacity will be 42 tons of product per day or 12,600 tons annually. The plant will produce natural lamb meat semi-finished products, minced meat, and canned goods certified to Halal and Kosher standards.

In this project, our TORNADO RP Vertical Wet Scrubber with Random Packing was used.

• Volume (cfm) — 10 000
• Scrubbing column pressure loss — Max pressure drop - 6 in.w.
• Maximum vacuum on the body — 4 000 Pa
• Weight — 8000 lbs

Temperature range — 40 to 180 ˚F

The client has chosen the most suitable scrubber in terms of its characteristics and budget, which will effectively handle air purification from HCl in small quantities and with infrequent tank loading.

Here is the efficiency table for gases, considering that the cleaning solution was ordinary water.


Devices used for measurements:

• Rotational gas meters
• Anemometer
• Aneroid barometer
• Psychrometer
• Stopwatch
• Gas analyzer
• Gas chromatograph
• Thermometer
• Scales
• Spectrophotometer

The table shows that the scrubber effectively removes emissions, and laboratory measurements did not detect any emissions. This indicates that our scrubber met the client's expectations.

We would also like to discuss a problem that arose with the client during operation. Since the client used regular water as the main cleaning liquid, bacteria started growing in the scrubber tank, which led to the release of an unpleasant odor. This was later resolved by periodically washing the scrubber with a reagent that the client uses for cleaning their production equipment. The client decided to continue using water as the scrubber solution because it is inexpensive.

Here, we are facing a common issue of insufficient adherence to technological processes. After purchasing the scrubber, it should be included in the equipment maintenance process, and when this is done, no issues with the scrubber arise.