Regenerative Thermal Oxidizer (RTO)

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One of today’s most widely accepted air pollution control technologies across industry is a Regenerative Thermal Oxidizer, commonly referred to as a RTO.  They are very versatile and extremely efficient – heat recovery efficiency can reach 95%.  This is achieved through the storage of heat by dense ceramic stoneware.  Regenerative Thermal Oxidizers are ideal in low VOC concentrations and during long continuous operations. 

Flow Diagrams of a 2-Canister RTO:

 

Regenerative Catalytic Oxidizer (RCO)

In some applications, the use of Catalyst with the ceramic media helps allow oxidation at reduced temperatures resulting in even lower operating costs compared to a Regenerative Thermal Oxidizer.

click on the image for more pictures of GCE Regenerative Catalytic & Thermal Oxidizers

 

Thermal Recuperative Oxidizer

A less commonly used thermal oxidizer technology is a thermal recuperative oxidizer. Thermal recuperative oxidizers have a primary and/or secondary heat exchanger within the system.  A primary heat exchanger preheats the incoming dirty air by recuperating heat from the exiting clean air.  This is done by a shell and tube heat exchanger or a plate-type exchanger.  As the incoming air passes on one side of the metal tube or plate, hot clean air from the combustion chamber passes on the other side of the tube or plate and heat is transferred to the incoming air through the process of conduction using the metal as the medium of heat transfer.  In a secondary heat exchanger the same concept applies for heat transfer, but the air being heated by the outgoing clean process stream is being returned to another part of the plant – perhaps back to the process.

 

Catalytic Oxidizer

Catalytic oxidation occurs through a chemical reaction between the VOC hydrocarbon molecules and a precious-metal catalyst bed that is internal to the oxidizer system.  A catalyst is a substance that is used to accelerate the rate of a chemical reaction, allowing the reaction to occur in a normal temperature range of 550°F - 650°F (275ºC to 350ºC). 

Pictured to the right is a typical Metal Monolithic Catalyst Bed inside a Catalytic Recuperative Oxidizer.

 

Direct Fired Thermal Oxidizer - Afterburner

A direct-fired oxidizer is the simplest technology of thermal oxidation.  A process stream is introduced into a firing box through or near the burner and enough residence time is provided to get the desired destruction removal efficiency (DRE) of the VOCs.  Also called afterburners, these systems are the least capital intensive, but when applied incorrectly, the operating costs can be devastating because there is no form of heat recovery.  These are best applied where there is a very high concentration of VOCs to act as the fuel source (instead of natural gas or oil) for complete combustion at the targeted operating temperature.

 

Rotor Concentrator System

One of the most efficient methods of VOC and HAP control is through the use of adsorption technology.  The successful application of absorption based rotor concentrators utilizing zeolite materials has been well proven in various industrial applications over the last 20 years.  Rotor concentrator systems are optimized using high process exhaust flows with low organic compound concentrations.

 

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