Model RTO -Regenerative Thermal Oxidizers

VOC and HAP laden process gas enters the RTO (Regenerative Thermal Oxidizer) through an inlet manifold where valves (butterfly or poppet) direct this gas into energy recovery chambers where the process gas and contaminants are heated in the ceramic media beds as the gas moves toward the combustion chamber.

Once the VOCs in the process exhaust have been treated in the oxidizer combustion chamber, the hot purified air releases thermal energy as the organics is oxidized, also reducing fuel use. The hot ‘cleaned’ gas passes through the outlet media bed. The outlet bed is heated and the gas is cooled so that the outlet gas temperature is only slightly higher than the process inlet temperature.

Valves alternate the airflow direction into the media beds to maximize energy recovery within the oxidizer. The high energy recovery within these oxidizers reduces the auxiliary fuel requirement and saves on operating cost. The Air Clear RTO achieves high destruction efficiency and self-sustaining operation with no auxiliary fuel usage at low concentrations.

• Ceramic heat recovery beds capture and reuse up to 95% of the systems energy. The result is low fuels cost.
• Heat released from the oxidation of the VOCs is also captured in the heat recovery ceramic media beds which further helps reduce supplement fuel use. In fact, with a VOC concentration of about 3% of the LFL the ThermGen™ Regenerative Thermal Oxidizer (RTO) is self sustaining, that is no supplement heat input is required.
• Requirements for MACT, BACT, LAER and RACT making it the preferred oxidation technology for many applications.
• Highly effective at reducing VOCs by means of thermal oxidation, eliminates as much as 99%+ of the VOCs meeting the EPA requirements for MACT, BACT, LAER and RACT making it the preferred oxidation technology for many applications.
• “In house” fabrication… from controls to reactors… insures our customers that Air Clear maintains quality and schedule control over their projects
• Seamless interface between our customers process and the ThermGen™ RTO with PLC tailored to the processes operation
• Flexibility when selecting system components such as structured vs. random heat recovery media, burners vs. electric heating elements and carbon steel vs. alloy construction gives our customers the best of both worlds, proven technology custom tailored to their specific project conditions
• Carbon steel vs. alloy construction gives our customers the best of both worlds, proven technology custom tailored to their specific project conditions.
• “Dirty” process streams are controlled using a variety of pre-filter(s) and media “bake clean”
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• FAT – Factory Acceptance Test – reduces commissioning and start up time by running a thorough diagnostic system check PRIOR to shipment
• Air Clear has extensive knowledge of various materials of construction and metallurgy to insure long-term system performance and reliability, especially when working on Chlorinated applications. Air Clear has fabricated RTO’s from Hastelloy, ALX6N as well as 304, 316 SS.
• Air Clear quench / scrubbers are used to remove acids such as HCL, HbR H2SO4 when formed during the oxidation reaction. Secondary Heat (energy) Recovery (SHR) systems can be added to provide for a positive payback from Air Pollution Control Equipment.

• In some cases, the waste heat from the hot combustion exhaust (which normally is vented to the stack), is recovered in a secondary heat recovery system resulting in additional energy savings. Contact Air Clear Engineers to analyze your project for secondary heat recovery feasibility
• SFI – Safe Fuel Injection can be used to lower fuel use further by eliminating supplemental combustion air needed for the burner.

• In some cases, a Hot Bypass Valve is used to direct the clean (hot) oxidizer exhaust around the heat recovery bed, directly into the stack. Bypassing allows the RTO to tolerate higher solvent loads.

A key design feature of the ThermGen™ Regenerative Thermal Oxidizer is the use of high-density ceramic modules.

• A stainless steel frame supports each module; the frames are individually welded to the inside of the combustion chamber. When the adjacent module is put into place, it generates lateral support by compression.
• Insulating modules are made from high purity ceramic fibers. The modules are constructed to prevent spalling or erosion of the fibers which would normally result when the fibers expand in different directions when heated.
• Efficient, durable and low maintenance make the Air Clear insulating system a key component of the RTO System.

Coatings

Another advantage of the fabrication/insulation method used on the ThermGen™ Regenerative Thermal Oxidizer RTO System is that the low exterior shell temperature which allows the use of a variety of Standard Industrial Coatings.

• A typical ThermGen™ Regenerative Thermal Oxidizer… RTO System is epoxy coated in our shop.
• In addition to our epoxy coatings, Air Clear has applied numerous custom coatings in a virtual “Rainbow” of colors. The surface preparation is tailored to the coating requirement, and insures that the ThermGen™ Regenerative Thermal Oxidizer… RTO’s appearance will be as durable and long lasting as the rest of its components are.

PLC’s are available with input and output (I/O) options and electrical configurations that make them ideal for a wide range of applications.

Air Clear Engineers have experience with many PLC Manufacturers. Program Logic Controllers (PLC’s) provide the following advantages over relay logic control.

• Fast, specific diagnostics
• Easy data acquisition
• Easy operator use with various levels of access
• Interfaces/integrates easily with process operations
• Cost effect in most applications

Field support is provided throughout the world on all of Air Clear Systems

• Complete Turnkey Service
• Remote Monitoring Services
• Engineering Services
• Pilot Testing
• Inspection Services
• Scheduled Maintenance Services

• Our technical sales team is committed to understanding the unique requirements of our customers on every project.