Air Pollution Control Oxidizer Case Studies

Recently, a contract drug manufacturing company faced violation of their state operating permit, costly fines, and potential Title V permit classification. To avoid penalties, a more robust abatement device had to be installed, one that met the necessary emissions standards for volatile organic compounds (VOCs).

An Oklahoma Petroleum Processor worked with Catalytic Products International to integrate a custom solution into their storage tank and transfer operations. This particular application required a special design that would meet a constant +98% destruction of the VOC’s and HAP’s across a wide range of solvent loadings (from low to high).

A multitude of chemical and petroleum processing facilities across the country are now faced with having to meet new National Emission Standards for Miscellaneous Organic Chemical Manufacturing. One specific NESHAP is 40 CFR part 63, subpart FFFF.

It’s in the news every day; the natural gas production industry is experiencing record growth. The gas reserves in the United States are thought to hold enough natural gas for hundreds of years and the gas and oil industry has improved extraction techniques that make gas production more affordable and less impactful on the landscape. Good news for the country and our environment.

A Silicone Tape Converter recently replaced a poorly designed thermal oxidizer with a custom engineered thermal oxidizer designed by Catalytic Products International, Inc. The process coated film with a silicone based adhesive. The silicone vaporizes with other VOC’s in the drying process and is ducted to the thermal oxidizer. The combustion process converts the silicone vapors to a powder – like Silicon DiOxide. In a traditionally designed thermal oxidizer, the SiO2 clings to metal surfaces and causes lost efficiency with excessive maintenance.

A chemical processing facility recently installed a VECTOR Catalytic Oxidizer to replace a competitors Regenerative Thermal Oxidizer. The RTO was installed 5 years earlier and could not provide the reliability demanded by the client. The problem stemmed from a basic mis-application of the technology. As is very common, many air pollution control equipment manufactures have abandoned recuperative technology in favor of focusing on regenerative technology.

Faced with meeting the needs of their Pharmaceutical Industry MACT Standards, one Fortune 100 Pharmaceutical Manufacturer called on CPI for assistance. The challenge for Catalytic Products International was to design a system that was able to process the ultra-high LEL (high concentration of VOC’s) and deal with corrosive acids produced in the process off gas and the post-combustion gases. Adding to the challenge, there were many more sources that use halogenated VOC’s in the process. A halogenated VOC is an organic hydro-carbon that contains chlorine (Cl). The post combustion gases will contain Hydrochloric Acid. In order to meet the needs of local regulations and the industry MACT, the HCl also has to be removed from the exhaust stream prior to atmospheric release.