Regenerative Thermal Oxidizer (RTO)
PRODUCT DESCRIPTION
Epcon Industrial Systems takes great pride in having excellent engineering and manufacturing capability to design and fabricate highly-efficient, high-quality and high-performance Regenerative Thermal Oxidizers (RTO’s), which always meet or exceeded our customer expectations.
Founded in 1977, Epcon Industrial Systems has completed thousands of Oxidizer Systems around the world. Uniquely designed to achieve maximum desired performance, each system goes through exhaustive front-end and pre-engineering analysis. Once completed, the design and drafting process is started, followed up by the manufacturing process.
Epcon Regenerative Thermal Oxidizers (RTO’s) are designed to be highly energy efficient systems that achieve high levels of VOC destruction to keep processes well below required DRE emission levels.
Epcon Regenerative Thermal Oxidizer (RTO) systems have been successfully utilized on hundreds of industrial VOC air pollution control applications since 1977. Epcon has extensive RTO design and installation experience with VOCs (Volatile Organic Compounds), hydrocarbons, solvents, and HAPs (Hazardous Air Pollutants) as well as particulate laden processes which generally require pre-filtration prior to the RTO system. Because no two applications are alike, we look forward to preparing a custom RTO proposal for your specific application.
Additionally, we have extensive Regenerative Thermal Oxidizer (RTO) fabrication experience with stainless steel and other metallic compounds.
WHAT IS A REGENERATIVE THERMAL OXIDIZER ?
The two most typical methods of reclaiming heat are:
- Regeneration
- Recuperation
When the heat contained within a large thermal mass is regenerated, a thermal oxidizer employing this method is called a Regenerative Thermal Oxidizer.
Recuperation implies more of a direct heat transfer from the outgoing to the incoming air stream. When this method is used, the system is called a Recuperative Thermal Oxidizer.
Regenerative Thermal Oxidizers are a highly energy efficient and effective means of reducing and controlling air pollution.
The regeneration principle operates around multiple energy recovery chambers in use on the system, which are the housings for the ceramic heat recovery media. The ceramic heat recovery media acts as a heat exchanger for the system. The multiple chambers operate under a “swing bed” absorption principle: which is the principle of transfer through multiple beds by the use of flow reversal. In the use of this principle with ceramic stoneware, the process is called regeneration. As the dirty exhaust stream travels through the first bed of ceramic media, the exhaust stream adsorbs the heat energy stored in the ceramic media mass, which pre-heats the exhaust stream. The exhaust stream then enters the burner reactor chamber, where heat energy is added from the burner to reach the system operating temperature. After the temperature has been elevated, the clean exhaust stream then passes through the second energy recovery chamber.
As the exhaust stream passes through the chamber, the cold ceramic media mass absorbs the heat energy of the exhaust stream, and stores the heat energy for the reverse flow of the system. Once the heat energy of the first chamber has been depleted through the absorption of the incoming air stream, the flow through the system is rotated, so the incoming dirty air stream is then directed through the previous absorption chamber, with the clean waste gas now going through the previously purged chamber.
By using the reversal of exhaust flow through the ceramic beds, a minimal amount of heat energy needs to be added to the incoming exhaust stream to maintain the systems minimum operating temperature. The sizing of the ceramic media beds is such that a 95%+ heat recovery efficiency is possible through the regenerating, reversal flow process.
What happens with a Regenerative Thermal Oxidizer is intriguing. Gas laden with volatile and hazardous contaminants enters a Twin Bed RTO via an inlet manifold. Heating of the process gas and contaminants continues through the heat exchange media bed (aka stoneware bed) as the gas stream moves toward the combustion chamber.
Components of a traditional Regenerative Thermal Oxidizer (RTO) include a system fan, motor, burner, heat exchange media, flow control valves, electronic & automatic system controls, temperature recorder, and exhaust stack. The system’s outer skin is typically ceramic and lined, but comprised primarily of steel.
Depending on your needs, Epcon can employ either Regenerative Thermal Oxidizer (RTO), Recuperative Thermal Oxidizer, Catalytic Oxidizer and/or Direct Fired Oxidizer configurations.
Epcon has been engineering and manufacturing state-of-the art and leading-edge Thermal Oxidizers since 1977. We have been very successful in engineering and building all types of Oxidizers, both nationally and internationally.
Recuperative Thermal Oxidizers
PRODUCT DESCRIPTION
Epcon is an industry leader in Thermal Oxidizer technology specializing in the integration of customers’ process heating operations together with their Thermal Oxidizer requirements. In simple terms, a recuperative thermal oxidizer is the evolution of the direct fired thermal oxidizer through the addition of primary and/or secondary heat recovery.
Addition of heat recovery to the oxidation process can provide tremendous costs savings with respect to minimizing the use of natural gas for the air pollution control application as well as external process heat loads.
Primary heat recovery is accomplished when you direct the process exhaust vent stream through a heat exchanger, which crosses the outlet of the oxidizer exhaust, prior to inlet to the oxidizer. This results in recovering (recuperating) heat from the exhaust to pre-heat the air entering the combustion chamber reducing the thermal load and therefore gas consumption to achieve oxidation temperatures.
Secondary heat recovery is accomplished when you utilize waste heat from the oxidizer to support a secondary process (e.g. Oven, Washline, etc). This is accomplished by directing either fresh air or process air through a heat exchanger, which crosses the outlet of the oxidizer exhaust, and sending it to a secondary process. The recovered (recuperated) heat from the exhaust is often sufficient to support entire drying or curing operations. In many cases, energy saved with the addition of secondary heat recovery can offer paybacks in close to one year.
Epcon’s proprietary Recuperative Thermal Oxidizers are fabricated from select Stainless Steel Alloys to meet the process and duty cycle requirements for a given project.
Epcon’s Recuperative Thermal Oxidizers typically operate at 1400°F, with a residence time of 1 second and a heat recovery efficiency of up to 80%. Turbulent flow allows these systems to achieve such high destruction efficiency, up to 99.99% and high heat recovery as well. Higher operating temperatures are also achievable for hard to oxidize chlorinated compounds. Epcon also offers recuperative systems with catalytic modules suitable for VOC destruction.
The Recuperative Thermal Oxidizer is a thermal oxidizing system consisting of a combustion chamber with a shell and tube heat pre-heat exchanger. The high levels of destruction efficiency are achieved by the design of the system giving equal importance to three oxidation parameters:
- Temperature
- Time
- Turbulence
Epcon’s proprietary Tube and Shell Heat Exchangers are fabricated from select stainless steel alloys at our vertically integrated 250,000 Sq Ft manufacturing operations in The Woodlands, TX.
Direct Fired Thermal Oxidizers
PRODUCT DESCRIPTION
Epcon is an industry leader in Direct Fired Thermal Oxidizer (DFTO) control equipment technology specializing in custom modular units for stand alone as well as trailer-mounted applications. Epcon is pleased to offer different purchase, lease, and rental agreement options to suit any need.
Direct Fired Thermal Oxidizers may also be called Afterburners or Direct Flame Thermal Oxidizers. Thermal oxidation is a method of air pollution control that can be applied to incineration for air polluted with small particles or combustible solids or liquids.
Direct Fired Thermal Oxidizers are ideal solutions for high solvent loading and fluctuating operating conditions.
Operating temperatures range from 1,250 to 1,800°F, and gas residence times are typically 1 second or less. These conditions cause the process stream’s molecular structure to break down into simple carbon dioxide and water vapor.
Understanding the nature of the process stream is critical to sizing and configuring the Direct Fired Thermal Oxidizer. Selection and placement of flame arrestors between the vapor source and the thermal oxidizer as well as configuring the control and placement of the process stream are key to achieving the desired system performance.
We are experts in thermal process applications, and Epcon is ready to design and assemble your Industrial Direct Fired Thermal Oxidizer. Our experienced engineers will ensure that our Direct Fired Thermal Oxidizer accommodates your needs.
Epcon’s innovative and patented Direct Fired Oxidizer designs are built to your unique specifications. Our superior workmanship is evident in all of our custom Oxidizers, Ovens, Furnaces and Finishing Systems.
Thermal Catalytic Oxidizers
PRODUCT DESCRIPTION
Depending on the nature of the vent stream to be controlled, addition of catalyst to a thermal oxidation system may be a means to further optimize operating costs of the compliance strategy. Epcon has successfully employed catalysts for Regenerative Thermal Oxidizers (RTO), Recuperative Thermal Oxidizers and Direct Fired Thermal Oxidizer configurations.
Epcon designs thermal catalytic oxidizer systems to accept various types of catalysts. With our in-house catalyst experts, we can assure optimal catalyst selection and application to various process exhaust streams. Our experts work together with clients to understand the specific application requirements and working with global catalyst manufacturers match those requirements to the most appropriate catalyst type and control technology configuration.
Epcon’s Thermal Catalytic Oxidizers convert process exhaust stream Volatile Organic Compounds (VOCs) and Hazardous Air Pollutants (HAPs) into harmless amounts of carbon dioxide, water, and thermal energy, which are then safely discharged to the atmosphere. Catalytic
Oxidation occurs through a chemical reaction between the VOC hydrocarbon molecules and a catalyst bed that is integrated with the oxidizer system.
Catalytic treatment of volatile organic compounds (VOCs) and other air pollutants functions by reacting the harmful air pollutants over the selected catalyst. The resultant oxidation reaction occurs at a lower temperature thanks to the contribution of the Catalyst. Products of this reaction are carbon dioxide, water vapor, and potentially usable heat. The lower temperature reaction reduces demand for supplemental fuel driving significant operating cost savings. In many cases the oxidation process can be self-sustaining thanks to the energy value of the volatile compounds in the vent stream.
As the saying goes, “There are no free lunches”. While catalysts offer the potential to accelerate the oxidation reaction at lower temperatures providing significant energy savings, they are subject to limitations which affect their performance and life. Catalysts are designed to perform for a given set of compounds in the stream to be treated. Changes to the make-up of the vent stream may limit the effectiveness of the catalyst. In extreme cases, this can result in the “poisoning” or deactivation of the catalyst. Additionally, particulate matter in the vent stream may blind the catalyst inhibiting its performance.
As is the case with all Air Pollution Control, Ovens and Furnaces and Finishing systems that Epcon provides, our team of experts will work with the client to understand the application requirements under all operating conditions. This is particularly important when employing a catalyst.
With decades of experience, Epcon is uniquely capable of objectively guiding you through the selection process. Some of the questions we explore are; Is a thermal oxidizer the right solution to meet the compliance needs today and in the future? If so, what configuration (DFTO, Recuperative, Regenerative) is best suited to the application? Are their opportunities for secondary heat recovery? Can a catalyst be employed to further reduce operating costs?
Epcon has engineered systems based on cutting edge technologies as an industry leader in research and development with our own original designs. For select applications, incorporating a Catalyst into the thermal Oxidizer design has the potential to provide the lowest total cost of operation.
Source: Epcon Industrial Systems
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