CPI - Model TRITON II Series - Regenerative Thermal Oxidizers (RTO)
Thermal treatment of VOC’s and other air pollutants works by a simple reaction of the harmful air pollutants with oxygen and heat. In this environment the VOC’s are converted to harmless inert byproducts, water vapor (H2O), and usable heat. These harmless by-products are released to atmosphere or use an energy recovery technique to further lower the operational costs.
TRITON II-Series RTO’s are considered among the world’s most advanced recuperative thermal oxidation systems. These specially designed and proven systems combine the basic principles of time, temperature, and turbulence – matched to industry leading construction and design features. All resulting in exceptional performance, substantially reduced operating costs, and industry-leading reliability.
The TRITON II-Series Regenerative Thermal Oxidizer process begins with the touch of a button, which activates the system's PLC-based Temperature Safety System (TSS). The TSS control system automatically retrieves media temperatures, selects the hottest bed for damper positioning, opens the fresh air purge/idle damper, energizes the booster fan, purges the system with fresh air, ignites the burner, cycles the valves, and gradually brings the system up to the correct operating temperature. The TSS also monitors the temperature in the regenerators, combustion chamber in three places, and in the valve assembly's inlet and outlet. This helps safeguard the system from extreme temperature fluctuations that cause thermal stress and overall system fatigue.
As soon as the required operating temperature is reached, the TSS enables the process lines to feed into the oxidizer, or holds the system in idle mode until production is ready. When production is ready the fresh air purge damper closes and one or more of the diverting dampers open to draw the volatile organic compounds (VOC's) off of the process lines.
A booster fan draws one or more VOC-laden exhaust from your process lines into the system. From there, VOC's are directed into one of the systems regenerators (an internally insulated vessel containing ceramic media). The contaminated gases are passed through the first regenerator where energy is transferred from the ceramic media to the gas in order to elevate the temperature. This elevated temperature approaches the ignition level for most solvents and then is directed from the ceramic bed into the combustion chamber. As the stream exits the ceramic bed and travels through the internally lined combustion chamber minimal heat is added to ensure a proper oxidation temperature and a designed dwell time is maintained for the ultimate destruction of the streams VOC's. The oxidized gases are then directed to the second regenerator to absorb the heat energy. As the ceramic media loads with sufficient heat, the Posi-Seal Valves switch, and the gases are reversed through the system where the heating and oxidation process continues.
For the spilt second that it takes for the valve switch to occur, a 'puff' of un-treated gases are released to atmosphere. This small concentration of VOC lowers the removal efficiency in standard two-regenerator systems. By adding our VOC Polishing Chamber between the RTO and the exhaust stack, the TRITON II-Series RTO is able to recirculate the puff un-treated gases to the RTO for increased destruction efficiency. The VOC Polishing Chamber is comprised of a third Posi-Seal Valve and a holding vessel.
Your process is now in compliance with all clean air regulations!!
Catalytic Products International has been designing, manufacturing, and installing the world’s most innovative thermal oxidizers now for over 30 years. Throughout our long history, we have continually strived to offer the most advanced air pollution control equipment. These constant efforts have led us to the development of the TRITON-Series Regenerative Thermal Oxidizer (RTO) Each system is custom engineered to exceed all worldwide air compliance guidelines at the lowest overall costs. The TRITON II-Series RTO guarantees success because of these innovative design characteristics:
Modular Regenerator Technology
TRITON RTO’s are custom designed for the highest reliability with the lowest overall costs. The complete system is designed with a modular approach for the most cost-effective solution. The TRITON is supplied as a 2-tower regenerator system fitted to our Even-Flo Valve Manifold. This modular approach satisfies your needs for a competitive installation cost and insures that the Posi-Seal valves are properly installed and aligned prior to leaving the factory.
VOC Polishing Chamber Switching Valve
The polishing chamber switch valve is a third Posi-Seal Valve system that diverts the exhaust gas to the Polishing Chamber ( a holding vessel) or to the exhaust stack. This switch valve incorporates many of the unique features found in our successful Posi-Seal Valves and is the cornerstone of meeting +99% removal efficiency.
Complementing the regenerator design is our unique cold face support system. While other systems merely rely on a perforated plate to support the ceramic media, TRITON systems have utilized a superior supporting grid that allows the lowest pressure drops and highest structural integrity.
Based on the application needs, the TRITON-Series RTO can be supplied with stainless steel metallurgy to resist chemical attack or added thermal stresses.
Thermal Heat Transfer Matrix
Each TRITON system is designed around the specific ceramic heat transfer matrix recommended for the application. TRITON-Series systems can be designed using a layered structural ceramic matrix or a mix of structured and random media, depending on your application’s requirements. The thermal heat transfer matrix is the key to a well designed and efficient system. With thermal rate efficiencies (TRE) ranging from 85% to 97% you can be assured that even the lowest VOC concentrations can be economically destroyed.
Posi-Seal valves are designed to take advantage of a vertical axis that allows for soft seating action with self-centering guidance. The innovative feature about all Posi-Seal valves is the air tight machined seal that eliminates valve bypass and maintenance intensive gaskets. The Posi-Seal valve will be pneumatically operated and will cycle open or closed based on the program logic called for in your application.
Posi-Seal Shaft Cooling
TRITON Systems incorporate shaft and bearing cooling systems. This simple, yet often overlooked feature provides a cool supply of air in the bearing tube and on the bearings. This prevents leakage of the higher pressure air on the inside of the oxidizer from escaping to atmosphere and helps cool the shaft and bearings for long life.
EvenFlo Valve Manifolds
All TRITON systems are designed with our innovative “EvenFlo” Valve Manifold design. EvenFlo Manifolds are a revolutionary technique developed by Catalytic Products International that precisely locates the “Posi-Seal” valves in relationship to a specific distance away from the regenerator. TRITON system take advantage of a combination of duct-under orientation with the “EvenFlo” technique in order to minimize the flushing volume while maximizing flushing efficiency. The “EvenFlo” Manifolds allow TRITON systems to deliver +98% destruction rate efficiencies right upon startup because we can set the valve strokes in the factory.
Internal Insulation Systems
The TRITON-Series RTO is internally insulated with ceramic insulating modules. This system provides low shell temperatures and helps to retain heat for improved efficiency.
EvenFlo Manifold Insulation
In some cases, the EvenFlo Manifold can be insulated to ensure that the pollutants that enter the oxidizer remain in a gaseous state. If the process constituents should condense at some point in the oxidizer, they can become a maintenance issue, or worse yet, become a hazard to the equipment. Some pollutants will condense and collect on many of the surfaces of the oxidizer, leaving a sticky, tarry substance that is difficult to remove. Insulating our EvenFlo Manifold helps to prevent any condensation, and keeps your process air in a gaseous state.
Shop Assembled up to 15,000 SCFM
Our TRITON Series Regenerative Thermal Oxidizers com shop assembled, pre-piped and wired, and filled with media for units up to 15,000 scfm, which will help reduce the length and expense of installation.
Temperature Safety System
Every TRITON system is integrated with our customized PLC-control panel called TSS Control. TSS communicates with the TRITON System and your process for optimal performance, safety, and reliability. We use our proprietary thermal control logic and multiple temperature inputs to maximize the regenerator thermal efficiency. This unique control technique constantly adjusts valve timing to maximize thermal efficiency without compromise in destruction efficiency. No other supplier goes to these extremes to maximize the performance of their RTO.
- Hot gas bypass for higher VOC loading conditions
- Secondary Heat Recovery Solutions including direct or indirect heating systems
- Natural Gas Injection to help lower gas use and NOx emissions
- Induced Draft Systems to keep booster fans clean of condensation
- SD (Severe Duty) series system for corrosive air streams
- 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