Thermal Oxidizer - Recuperative Thermal Oxidizer

What is a Recuperative Thermal Oxidizer?

A Recuperative Thermal Oxidizer (also referred to as a thermal oxidizer or incinerator) is a combustion device that controls volatile organic compounds (VOCs), hazardous air pollutants ( HAPs), and odors by converting (destroying) the emissions into CO2 and H2O through the use of heat before exhausting them to the atmosphere. This technology integrates a heat exchanger into the design in order to minimize the fuel used for oxidation. By passing the hot exhaust gasses through a non contact air-to-air primary heat exchanger, recovered heat is used to warm the incoming air to the oxidizer, making the system energy efficient The results provide you with exceptional performance, substantially reduced operating costs, and industry-leading reliability

.Recuperative Thermal Oxidizers play a crucial role in promoting sustainable industrial practices by reducing emissions, conserving resources, and minimizing environmental impact.

CPI QUADRANT Recuperative Thermal Oxidizer 8,000 SCFM

How does a Recuperative Thermal Oxidizer work?

The CPI Thermal Recuperative Oxidizer (TRO) process begins with a booster fan designed to draw the volatile organic compound (VOC) laden process exhaust to the QUADRANT System. From there, the VOC-laden process air stream is then directed into the condensate evaporate section where it is preheated to eliminate any vapor droplets before entering the FLOATING TUBE primary heat exchanger. This step protects the leading edge of the heat exchanger from condensate build-up and subsequent preignition. When the stream enters the FLOATING TUBE heat exchanger, it is continuously preheated at close to the ignition temperature before being sent to the pre-heat burner. The exchange of energy in the primary heat exchanger makes up the basis for fuel savings and economical operation.

A pre-heat burner is used to precisely maintain the combustion chamber operating temperature. The burner is designed to promote mixing of the exhaust gases with oxygen when fired through our specialized combustion system. This innovative design provides the highest degree of flame impingement and high-velocity mixing, leading to airflow and temperature uniformity for which QUADRANT Oxidizers are known.

QUADRANT SR Thermal Oxidizer 3D Image Catalytic Products The contaminated air stream next passes through an elongated high velocity combustion chamber. Here a series strategically placed mixing baffles creates turbulence and improves mixing, helping to prevent temperature stratification. From there the air stream rebounds 180^ to assure proper mixing of all the effluent constituents. Even at low flow conditions, this mixing action provides the highest possible temperature uniformity for industry leading destruction ability at the lowest operational cost.

SR-Series-Thermal-Oxidizer-Process-3
Once mixed the air stream is held in the dwell chamber long enough to ensure complete combustion of the VOC's. From there the clean stream passes over the FLOATING TUBE primary heat exchanger prior to being discharged to the atmosphere or to auxiliary heating systems such as; secondary air to air recovery, air to water recovery, air to oil recovery, or directly back to the process in a closed loop direct recirculation process.

Your process is now in compliance with all clean air regulations!

Recuperative Thermal Oxidizer vs Regenerative Thermal Oxidizer

Choosing the appropriate oxidizer depends on various factors such as the air flow and VOC loadings of the air streams, process temperature, energy efficiency requirements, installation space, and budget considerations. Recuperative thermal oxidizers are simpler and more cost-effective for smaller-scale applications with lower emission requirements. RTOs offer higher energy efficiency and are better suited for larger-scale operations with higher pollutant concentrations.

Recuperative Thermal Oxidizer
Recuperative Thermal Oxidizers use metal plate or shell and tube heat exchangers to preheat the incoming process air using the clean “hot” air from the oxidizer combustion chamber. This primary heat recovery raises the temperature of the process gas before entering the combustion chamber, resulting in lower fuel requirements for the oxidizer burner system. Recuperative Thermal Oxidizers offer up to 80% thermal recovery efficiency.
Regenerative Thermal Oxidizer
Regenerative Thermal Oxidizers use ceramic media as heat exchangers and poppet valves which create airflow reversal. Rather than exhausting the clean, hot air to the atmosphere, the RTO system may capture up to 97% of the heat from the exiting stream to heat the incoming process air.

Recuperative Thermal Oxidizer Features

Round Modular Design

All QUADRANT SR-systems incorporate a proven round design which protects against stress and fatigue commonly found in other systems that utilize an antiquated "square box" design. Damaging thermal-mechanical stresses inherent in every thermal oxidizer are eliminated with the QUADRANT SR-Thermal Oxidizer and its round design.The modular design removes the heat exchanger from the combustion chamber to allow each component the ability to individually control growth. The modular design is key to long equipment life and the highest uptime reliability.

Internally Insulated

All QUADRANT SR-Thermal Oxidizers incorporate a specialized internal insulation system designed to retain heat for low cost and cool shell temperatures. The internal insulation works in conjunction with the round design to eliminate shell growth for industry leading uptime reliability and low maintenance. The advancement of internal insulation is just one of the continued enhancements that we have introduced, all in an effort to provide longer lasting equipment with lower overall operating costs.

FLOATING TUBE Primary Heat Exchangers

All QUADRANT SR-systems incorporate a proven round design shell and tube heat exchanger, which protects against stress and fatigue commonly found in other systems that utilize an antiquated "square box" design. Damaging thermal-mechanical stresses inherent in every thermal oxidizer are eliminated with the QUADRANT SR-Thermal Oxidizer and its round design. The modular design removes the heat exchanger from the combustion chamber to allow each component the ability to individually control growth. The modular design is key to long equipment life and the highest uptime reliability.

Center Combustion Tube and Burner

One of the most unique features found in any QUADRANT system is the center combustion tube coupled with the preheat burner. This paring of components has paved the way for QUADRANT systems to operate at the lowest temperatures while providing the highest VOC destruction. Faced with today's compliance requirements the old design strategies of time and temperature are not enough. Only the QUADRANT system, by maximizing turbulent mixing, flame impingement, and temperature uniformity can assure users of low cost - ultra high destruction. The preheat burner in every QUADRANT system is selected based on the exact needs of your application. Whether your application calls for nozzle mixing due to low oxygen, raw gas for energy savings, low NOx for compliance needs, or multi-blend fuel types, QUADRANT systems provide flexibility for any project.

Temperature Safety System

Every QUADRANT system is integrated to our customized PLC-control panel called TSS. TSS communicates with the QUADRANT system and your process for optimal performance, safety, and reliability. TSS optimizes fuel efficiency by managing temperatures, controlling drives, and positing valves. This user friendly system provides automated operations, one button start-stops, self diagnostics, and data monitoring options for simplified maintenance and compliance verification. Catalytic Products International, Inc. has vast processor experience and can integrate any industrial processor into your operations.

Optional Features

Heat exchanger efficiency based on the needs of your application
PLC control and man-machine-interface options based on your needs
Multiple fuel blends or oil fired combustion systems
Footprint design flexibility to suit your space availability
SD (Severe Duty) series system for corrosive air streams
Secondary Heat Recovery Solutions

Markets

Recuperative Thermal Oxidizer

What is a Recuperative Thermal Oxidizer?

How does a Recuperative Thermal Oxidizer work?

Recuperative Thermal Oxidizer vs Regenerative Thermal Oxidizer