Catalytic Products International (CPI) recently completed the rebuild of a CPI QUADRANT SR-13,000 SCFM Recuperative Thermal Oxidizer at a Southern USA animal health and nutrition company for the abatement of odors, VOCs and ammonia from the animal feed manufacturing process.
During an annual service visit, the field service technician identified that the primary heat exchanger was showing serious signs of thermal failure. When the heat exchanger fails, untreated VOC’s bypass the combustion chamber and vent directly out of the exhaust stack. The bottom several rows of tubes were plugged and had become weakened. The tubes had pulled away from the floating tube sheet seals causing deformation and leaking. To extend the life of the recuperative thermal oxidizer and achieve the desired destruction rate efficiency (DRE), the CPI recommended the replacement primary heat exchanger.
The CPI Aftermarket Services team provided a turn-key solution, including the supply and installation of the new heat exchanger. CPI worked closely with the customer to minimize the downtime associated with the disassembly and removal of the old components and the installation of the new primary heat exchanger. This approach guaranteed that the entire system was installed correctly, and the facility was back up and producing product with minimal downtime.
The new replacement floating tube primary heat exchanger provides 70% nominal thermal rate efficiency (TRE) and includes new internal insulation, thermocouples, booster fan and exhaust stack flex connectors, and hinged access doors.
The rebuilt Recuperative Thermal Oxidizer is one of three (3) CPI thermal oxidizers controlling VOC emissions and odors from the air streams from fully enclosed reactors/dryers, conveyors, and dust collection systems with 99.5% destruction efficiency (DRE). Thermal treatment of VOCs and other air pollutants works by simply oxidizing the air pollutants with oxygen and heat. In this environment the VOCs are converted to harmless inert byproducts like CO2, water vapor (H2O), and usable heat. These harmless by-products are released to the atmosphere or used within primary or secondary energy recovery techniques to further lower the operational costs.
A Recuperative Thermal Oxidizer utilizes a superior combustion and dwell chamber coupled with a cylindrical design for efficient destruction of VOC’s. The unique design starts by drawing the solvent laden fumes into the high temperature primary heat exchanger where they are preheated. From there the process flow enters the high velocity combustion chamber where it then travels down the elongated combustion chamber at very high velocities, causing flame impingement and turbulence to occur and providing excellent mixing of the air stream. Next, the heated process stream enters the dwell chamber where the VOC and CO are converted to harmless CO2 and H20.
The Recuperative thermal Oxidizer’s floating tube primary heat exchanger incorporates free-floating tubes to eliminate thermal expansion. During the oxidizer's operation, each individual tube within the primary heat exchanger will expand and contract at different rates. By allowing the tubes to freely expand and contract, the equipment's life is greatly increased.
CPI has been “Enabling Clean Production Since 1969” and continues as a leading supplier of air pollution control equipment and aftermarket services. CPI is at the forefront in providing industries including animal feed manufacturing facilities with solutions to their air pollution control needs.
Today, CPI partners with its customers as a trusted resource in resolving the most complex air pollution and energy conservation problems. We provide our customers with innovative and cost-conscious solutions to their most complex VOC, NOx, and Odor pollution challenges. Our equipment is also at work meeting energy conservation strategies and minimizing greenhouse gas (GHG) emissions.