The exhaust air flows to be removed are determined, the exhaust air properties (such as temperature and pollutant concentration) are verified and limit values for the clean air quality are defined. At the beginning of project planning, the number and procedures of the smoking plants are used as a basis. Custom exhaust air solutionsĪs different as the customer’s requirements are, so different are the specialist’s exhaust air solutions. The innovative KMA technology has received several awards, most recently the Ludwig Award for Medium-Sized Businesses in the Innovation 2018 category. Currently in discussion is a tax starting at around 35 euros per ton in 2020, which is expected to reach 185 euros by 2030. And the planned introduction of a CO2 tax will open this gap even wider. The ecological effect of the plant technology used at the Schwarzwaldhof is even more obvious: while the operation of a TNV under the above conditions would lead to an annual CO2 load of about 2,838 t, the carbon footprint using a KMA filter system is only 133 t – 95 percent less CO2 emissions. In comparison, the KMA filter system saves 92 percent of the annual operating costs of a post-combustion plant. They consist of electrical energy consumption, consumption of washing liquid and disposal of the discharged wood tar. In contrast, the operating costs of the KMA hybrid system are currently around 60,000 euros. This was based on 5,760 operating hours and a burner temperature of 750 ☌. If a conventional TNV were used, the annual operating costs would be around 713,000 euros due to the high consumption of natural gas and electricity. The alternating cleaning intervals of the three electrostatic precipitators ensure optimum cleaning results at all times. The smoking systems of the Schwarzwaldhof are operated with a maximum exhaust air volume of 16,000 m3/h on seven working days per week with a daily operating time of 24 hours. A calculation example shows the economic and ecological advantages of this process. The Schwarzwaldhof commissioned the filter specialist KMA Umwelttechnik GmbH (Königswinter, Germany) to design, install and commission an electric scrubber hybrid filter system. It was obvious that this energy-intensive process contradicted the sustainability goals of the Schwarzwaldhof, so an alternative was needed. This satisfies the goal of purified exhaust air, but at the expense of the environment, as the fossil fuel supply required for these high temperatures consumes immense natural resources and costs and releases secondary emissions such as NOx and CO2. Post-combustion plants must be operated at high temperatures greater than 750 ☌ to sufficiently separate emissions and odors from the smokehouse exhaust gases. In smoking plants, the thermal post-combustion plant (TNV) or so-called hybrid filters consisting of several filter modules are generally used to treat exhaust air. In addition, new smoking plants are already subject to an approval procedure under the Federal Emission Control Act (BImSchG) during the planning phase. Tight rules had to be observed: To meet the German TA Luft requirements, the smokehouse had to comply with the specified clean gas value of a maximum mass concentration for total carbon of 50 mg/Nm3, the odor units had to be kept below 3,000 GE/m3 and the formaldehyde limit value had to be below 10 mg/Nm3. The company was looking for solutions to intensively clean the odor-intensive exhaust air of the smoking chambers while simultaneously conserving resources. At the same time, existing plants were checked for sustainability and economic efficiency. There was no question that the plant’s exhaust air treatment should also be environmentally friendly, above all with the aim of significantly reducing CO2 emissions. Triggered by the steadily growing demand for their ham and sausage specialties, the management of the Schwarzwaldhof decided to expand production in Blumberg in Baden- Württemberg. It is firmly anchored in the company’s corporate culture to pay attention to sustainability in daily activities, conserve natural resources, and respect nature and the environment. Schwarzwaldhof attaches major importance to preserving the beauty of the region for future generations, in particular the cultural landscape of the Black Forest. Division Manager Andreas Göhring (left) and Head of Industrial Engineering Bernd Goder are satisfied with the new smoke cleaning system.
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