thermal oxidizers

DEC IMPIANTI S.p.A. is a private corporation, focused on engineering and supply of turn key sustainable industrial VOC and HAP emission control systems for the flexible packaging, chemical, petrochemical and pharmaceutical industries. Backed with 75+ years of global experience, thanks to products of the highest quality, patented and/or innovative processes, with thousands of systems in operation, we are facing the global challenges, focusing on innovative sustainable technologies and research.

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VOC and HAP laden air from the process is drawn into the oxidizer system with the help of the fan system (V-1). Through high performance valves, the SLA flow is directed through high efficiency energy recovery chambers, where is pre-heated; the process gas and contaminants are progressively heated in the ceramic media beds as they move toward the combustion chamber.

The oxidation reaction is:

VOCs (CxHyOz) + O2 + thermal energy = CO2 + H2O + (HEAT)

The HEAT is usually recovered to pre-heat the SLA stream, in order to save on "thermal energy" (provided through gas CH4 - methane); if producing extra heat through oxidation of solvents, an energy recovery system shall be foreseen (typical applications are ranging from heating up air for dryers, steam production, heat tranfer fluid heating, water heating - industrial or sanitary, etc.).

Increased Efficiency, low emissions

In a regenerative thermal oxidizer (RTO) with multiple towers, the VOCs are oxidized in the combustion chamber. The hot gas released from the combustion chamber contains thermal energy. This thermal energy is accumulated through the ceramic media bed in one tower. The hot gas then cools down as it exchanges thermal energy with the ceramic media. The cooled gas is then discharged through the stack.

The process of accumulating and exchanging thermal energy in the ceramic media bed is called regenerative: this process allows the RTO to operate at a high efficiency, while also reducing the amount of energy required to heat the incoming gas.

Thanks to the specifically designed switching valves, the flow is alternatively reversed: thermal energy is recovered and the flow, in the following cycle, is pre-heated; this cycle is efficiently reducing the auxiliary fuel requirement, with self-sustaining operation (with no auxiliary fuel usage) even at low concentrations, thus representing an operational cost reduction.

RTOs with multiple towers can operate at a higher efficiency than simple thermal oxidizers: the regenerative process allows the RTO to recover heat from the outgoing gas, which can then be used to heat the incoming gas.

GHG and by-products

An oxidizer is handling the transformation of the pollutant(s) into differnt products, with a reduced environmental impact.

An oxidizer will have to deal with all or most of the following subjects:

  • VOCs emission (= non complete oxidation);
  • CO2 emission (= GHG, possible taxation);
  • CO emission (= GHG, non complete oxidation);
  • NOx emission (= nitrogen oxides, as a result of N2 presence);
  • N2O emission (= nitrous oxide);
  • Dioxin emission (as a result of possible chlorinated compounds);
  • High temperature emission (as a result of non complete thermal energy recovery).
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