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Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer...

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Page 1: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

© 2018 Catalytic Products International

Catalytic Products International

Air Pollution Control

Page 2: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Catalytic Products International I Air Pollution Control

Oxidizer 101

Catalytic Products International I Air Pollution Control

Page 3: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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.

Page 4: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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)

Page 5: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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

Page 6: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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The Right Solutions

Page 7: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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

Page 8: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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

Page 9: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Regenerative Thermal Oxidizer (RTO)Triton III (3-Tower)

Triton II (Voc Polishing) Triton (2-Tower)

Page 10: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Regenerative Thermal Oxidizer (RTO)

Page 11: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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)

Page 12: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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…

Page 13: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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

Page 14: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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.

Page 15: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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)

Page 16: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Recuperative Thermal Oxidizer (RECUP)

6000 SCFM 1025F RAISED TO 1450F = 4MM BTU/HR

Page 17: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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.

Page 18: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Catalytic Oxidizers

Access and Inspection Doors

Page 19: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Catalytic Oxidizers

Concord - CONOxVector Series

Vanguard Ammonia Abatement Vector Electric Heated

Page 20: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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%

Page 21: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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

Page 22: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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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?

Page 23: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Pre-Filtration System’s

Sentinel Traveling Filter

Sentinels FilterBaghouse

Page 24: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Energy Conservation

Air to Air Air to Air

SteamSecondary Heat Recovery

Hot Water or Glycol

Page 25: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Heat Exchanger’s

Plate and Frame

Shell and Tube

Floating Tube – Shell and Tube

Page 26: Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO ... 101 Final.pdfRegenerative Thermal Oxidizer (RTO) Typical Application Includes: • 4,000 SCFM to + 100,000 SCFM • Ambient

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Catalyst Product’s

Monolith Bead

Ceramic Metal foil


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