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    Thermal Oxidisers Aid in Pollution Control

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    Thermal Oxidisers Aid in Pollution Control

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    Thermal Oxidisers Aid in Pollution Control

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    PLANT SAFETY AND ENVIRONMENT SPECIALREPORT Thermal oxidizers aid in pollution control Choosing the correct media bed can help lower emissions and operating costs P. SIMS, Koch Knight LLC, East Canton, Ohic ‘generative thermal oxidizers (RTOs) and other types cffective and energy-efficient method for abating volacle organic compounds (VOCS) and other pollutants emitted by industrial planes. However, particulate macter in the emission stceam can be a particularly vexing problem that results in the media beds becoming fouled and plugged. Therefore, careful attention should be given to selecting the shape and material of the heat exchange media. This will mitigate potential problems with particulate matter and ensure reliable, economical and safe operation of thermal oxidation systems. Regenerative thermal oxidation. Thermal oxidizers are essentially incinerators that thermally or catalytically convert pol- fucant-laden emissions into carbon dioxide (CO,) and water vapor. ‘The oxidation process typically achieves better than 99% destruc- tion/removal efficiency levels for VOCs, hazardous aie pollutants and odors. RTOs minimize fel consumption by by the system. Fans draw air from col- lection systems and other sources, and enhance its operation the air is preheaced by heat exchanger ‘media to the thermal oxidation tempera ture, typically 1,400°F to 1,600°R, The air then moves into a combustion chamber for the specified residence time (0.5-2.0 see), Where an exothermic reaction takes place, converting the VOCS to CO, and water vapor. Prior to being exhausted to the atmosphere, the hot purified air passes through a media bed t0 capture heat energy that will be used to preheat incoming air. ‘Valves continually alternate the flow between media beds: a cycle with incoming cool air into a media bed that has just been heated by hot exhaust, followed by a cycle with hot exhaust air flowing through the media bed to reheat. RTOs can operate a chermal efficiencies of 85% to 99M, redue- ing or eliminating the need to burn natural gas in the combustion chamber, These ate particularly effective for process streams with low to moderate solvent loading and can be self sustaining at moderate lower explosive limit (LEL) level. In other words, once the system is, suficently heated, the natural gas burners can be tamed off ifenough flammable gas is present in the eshaust stream. Other thermal oxidizers. For lower solvent loading lev els, below 4% LEL, a catalytic system is often recommended. A It is important to choose erating” or reusing heat produced the correct media bed to regenerative catalytic oxidizer (RCO) has a similar design as an RTO, excepr that the ceramic heat exchange media closest to the combustion zone is coated or impregnated with precious metals that Function asa catalyst, thus enabling oxidation at significantly lover temperatures (600°F-1,000°).A catalytic system requires the presence of VOC types that will oxidize at these lower tem- peratutes. RCOs utilize the same principle as catalytic converters in motor vehicles that oxidize carbon monoxide and unburned hydrocarbons to CO, and water. For exhaust steams with high LEL levels, a simple thermal ‘oxidizer can be used withoue any thermal regeneration eapabil ity. In such cases, high solvent loading can support combustion without preheating and often with very litle or no burning of natural gas Air steams with relatively low VOC concentrations can use rotary adsorbers to concentrate the stream and to increase the LEL level, thus enabling the use of an oxidation device that is smaller and/or more energy efficient. The pollurant- laden process exhaust passes through the rotary adsorption unit where the VOC are adsorbed on zeolite or activated car- bon media. The purified ai is exhausted to the atmosphere, and the solvencis then removed from the media by desorption with a smaller stream of hot as, which i then delivered to an oxidation device. Upstream particulate removal. Although oxidizer sys- tems are used primarily for the abatement of VOCs, all emis: sion streams contain some quantity of particulate matter, and these particles can lead to bed fouling, performance degradation and even to dangerous and destructive fires. Some methods of upstream particulace removal methods include cascade (water swash), baffle and media filtration, Others—such as wet and dry

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