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Research Project Information




Research Project Summary Information



Central Regenerative Incinerator System(ST9086-1)

Quad Graphics, Incorporated

Background

The Saratoga Springs plant of Quad/Graphics, Inc is a commercial web-fed lithographic printer of magazines, catalogs, coupons, and newspaper inserts. The plant currently has 13 high-speed dual web presses and four high-speed single web presses. Building #5 at the Quad/Graphics plant has five of the most productive presses at the facility. Each press is connected to a catalytic fume incinerator that destroys 95% of Volatile Organic Compounds (VOCs) from the curing of low-volatility heat-set ink. The incinerators are very energy intensive, using natural gas to heat the VOCs to be oxidized in the catalyst bed and two constant-speed fans operating in each incinerator.

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Project Description

Quad/Graphics installed a central regenerative incinerator to destroy the VOCs emitted from the five presses located in building #5. The system, developed by Tann Corporation, will reduce the natural gas consumption by 300,000 therms per year and electricity by over 1,000,000 kwh per year.

Benefits

The central incinerator is estimated to save approximately 30,000 MMBtu of natural gas and 1,300,000 kWh annually. Also, 98% of the VOC will be destroyed, reducing total VOC emissions by more than 18 tons per year. Maintenance cost will be reduced by $320,000 by not having to replace the catalyst every four to five years. With the reduction in energy usage at the incinerators, product will be produced more efficiently, possibly attracting more contracts. More contracts could lead to new presses being added to production, bringing new jobs to the region. Down time will be reduced due to redundancy of incinerators, allowing for production to run continuously.

Project Results

The new incinerators have a positive effect on the environment by eliminating the need to replace and dispose of saturates catalyst as well as reducing the volatile organic compounds (VOC) emptied into the atmosphere. The incinerator process has reduced VOC emissions by 99%. The change will reduce the total emissions from the plant by more than18 tons per year; 14% overall reduction for this facility. Benefits Include: - Reduction in natural gas - Reduction in electricity - Reduction in maintenance costs - Reduction in air emissions

Contractor

Quad Graphics, Incorporated
56 Duplainville Rd
Saratoga Springs, NY 12866

Principle Investigator

Chuck Raymond

Universities Involved

Technologies

Project Type:

On-site Process Improvement


Technologies Types:

Air & Waste Remediation

NYSERDA Contact Information

Miriam Pye
MEP@nyserda.ny.gov

Program

R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST9086-1




Last Updated: 12/8/2011