thermal oxidizer, regenerative thermal oxidizer (rto ... 101 final.pdfregenerative thermal oxidizer...
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© 2018 Catalytic Products International
Catalytic Products International
Air Pollution Control
© 2018 Catalytic Products International
Catalytic Products International I Air Pollution Control
Oxidizer 101
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Catalytic Products International I Air Pollution Control
What Is (Thermal) Oxidation?
TEMPERATURE
To fully oxidize VOC’s; a combination of these three aspects is required:
Using this combination allows VOC’s to be converted to H2o and CO2with a capable destruction rate of =99.9%
TIME
TURBULENCE
The conversion (destruction) of hydrocarbons (VOC’S) to CO2 and H2O through the use of heat.
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Pollutants of Interest
Basically any organic vapor,
except methane, ethane and a
few others
Oxidizing methane to
carbon dioxide = 21x
GHG reduction
List of 187 chemicals
Hydrogen Sulfide common HAP in
NG industry
Hazardous Air
Pollutants (HAP)
Greenhouse Gases (GHG)
Volatile Organic
Compounds (VOC)
Volatile Organic
Compounds (VOC)
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Three Factors of (Thermal) Oxidation
Time Temperature Turbulence
• The amount of time required to hold the VOCs at oxidation temperature in order to convert 99.9% to CO2 & H2O
•Typically .5 - 1.5 seconds depending upon the VOC’s
•The temperature at which the VOC’s are held at for a specific period of time
• The higher the temperature, the shorter the time
• Typically 1300º - 1600º F
• The amount of mixing the process gas goes through to achieve temperature uniformity
• The better the temperature uniformity, the shorter the time, and the lower the temperature required to achieve VOC conversion
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The Right Solutions
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Common Types of Oxidizers
Type of Oxidizer % Destruction Efficiency
% Thermal Efficiency
Operating Cost Capital Cost
Regenerative Thermal Oxidizer (RTO)
98 to 99% 95 to 97% Low Medium
Recuperative Thermal Oxidizer (RECUP)
>99% 50 to 70% Moderate Higher
Catalytic Oxidizer (CATOX)
95 to 99% 50 to 70% Low Medium
Direct Fired Thermal Oxidizer (TO)
>99% None High Low
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Regenerative Thermal Oxidizer (RTO)
Typical Application Includes:
• 4,000 SCFM to + 100,000 SCFM• Ambient to medium process temperature • VOC loading less than 20% LEL• Typical VOC destruction rate of 98 – 99%
Because of the very high thermal efficiency the RTO offers the lowest operating cost ( in low VOC concentration applications)
Large footprint and heavy loads may present some installation challenges
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Regenerative Thermal Oxidizer (RTO)Triton III (3-Tower)
Triton II (Voc Polishing) Triton (2-Tower)
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Regenerative Thermal Oxidizer (RTO)
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Regenerator Media Technology
Specially engineered regenerators utilize a high surface area structured Ceramic MLM media. The TRITON Systems are all designed as standard
to achieve +95% thermal rate efficiency
Regenerative Thermal Oxidizer (RTO)
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Regenerator Media Technology
Regenerative Thermal Oxidizer (RTO)
Specially engineered regenerators utilize a WIDE VARIETY of high surface area MediaStructured Ceramic Std.
• Structure Monolith
• Random Minilith
• Random Saddles
The media beds are engineered to overcome customer specific challenges such as organic particulate buildup, silicate buildup, low pressure drop etc…
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Regenerative Thermal Oxidizer (RTO)
Two-Can Design Two-Can Design with VOC Entrapment
Three-Can Design
• 2-regenerator towers• 98.5% DRE• Factory assembled up to
15,000 SCFM• Modular construction from
16,000 SCFM to 80,000 SCFM
• 2-regenerator towers• 99% DRE• Adds a VOC Polishing
Chamber• Add-on to any TRITON 2
tower system
• 3-regenerator towers• 99.9% DRE• Any volume size• Multiple towers for
volumes over 50,000 SCFM
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Recuperative Thermal Oxidizer (RECUP)
• Typical Application Includes:
• 500 SCFM to 50,000 SCFM
• Ambient to Very High Process Temperature
• Low to Very High VOC Loading (~ 50% LEL with appropriate control)
• Capable of VOC Destruction Rate +99%
• Can handle particulate, mildly corrosive exhaust streams, silicones, cleanable without extensive maintenance, no moving parts. Special design for Silicone Coatings.
• Unless VOC loading is high, can be expensive to operate, but presents opportunities for heat recovery to lower total utility costs.
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Inlet Dispersion
Cone
Floating Tube Primary Heat Exchanger
Stainless Steel Tubes
High Velocity Combustion
Tube
Pressurization Chamber / Seal
Burner Cone
Combustion Tube
Internal Insulation
Hot Gas Bypass Damper
Exhaust Outlet
Recuperative Thermal Oxidizer (RECUP)
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Recuperative Thermal Oxidizer (RECUP)
6000 SCFM 1025F RAISED TO 1450F = 4MM BTU/HR
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Catalytic Oxidizers
Typical Application Includes:
• 500 SCFM to + 35,000 SCFM• Ambient to very high process temperature • Low to medium VOC loading (typical maximum of ~ 20%
LEL• Typical VOC destruction rate of 95 – 98%
Can handle mildly corrosive exhaust streams, cleanable without extensive maintenance, no moving parts.
Restricted to low amounts of contaminants such as: silicones, sulfurs, heavy metals and particulates.
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Catalytic Oxidizers
Access and Inspection Doors
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Catalytic Oxidizers
Concord - CONOxVector Series
Vanguard Ammonia Abatement Vector Electric Heated
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What Is (Catalytic) Oxidation?
• The conversion (destruction) of hydrocarbons (VOC’S) to CO2 and H2O through the use of catalyst
• To fully oxidize VOCs, It requires a combination of TEMPERATURE, TURBULENCE and CATALYSTto convert VOC’s to H2O & CO2 +98%
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Three Factors of (Catalytic) Oxidation?
Temperature Turbulence Catalyst
•The temperature in which the air stream need to be prior to the catalyst for the reaction/conversion to take place
• Typically 550-750º F
•The amount of mixing the process gas goes through to achieve temperature uniformity
• The better the temperature uniformity, the more efficient the reaction is through the catalyst
• catalyst is a substance which lowers the activation energy for a given reaction, without being consumed by the reaction
• To oxidize organic compounds, HEAT is the activation energy necessary to complete the reaction
• With a catalyst less heat is necessary
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Catalyst Process:
• Reactants(hydrocarbon (HxCy) & oxygen (O2) are adsorbed onto surface of catalyst
• Chemical reaction converts reactants to carbon dioxide(CO2) and water(H2O)
• Products from reaction are desorbed from surface of catalyst
• Catalyst is available to repeat steps 1-3
Catalyst – How Does It Work?
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Pre-Filtration System’s
Sentinel Traveling Filter
Sentinels FilterBaghouse
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Energy Conservation
Air to Air Air to Air
SteamSecondary Heat Recovery
Hot Water or Glycol
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Heat Exchanger’s
Plate and Frame
Shell and Tube
Floating Tube – Shell and Tube
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Catalyst Product’s
Monolith Bead
Ceramic Metal foil