Regenerative Thermal Oxidizer (RTO) - How it Works - CPI

Summary

A Regenerative Thermal Oxidizer (RTO) is a key device used by industrial manufacturers to control air pollution, ensuring EPA compliance and a reduced environmental footprint. The RTO operates by heating emissions to high temperatures, oxidizing volatile organic compounds (VOCs) into carbon dioxide and water vapor, and then cooling the air before releasing it safely. The regenerative heat exchange process maximizes thermal efficiency, reaching over 95%. This technology is vital for destroying hazardous pollutants and ensuring clean production practices in various industries.

Takeaways

• 😀 RTOs (Regenerative Thermal Oxidizers) are commonly used in industrial manufacturing to reduce air pollution and ensure EPA compliance.
• 😀 RTOs offer significant operational cost savings due to their regenerative heat exchanger design.
• 😀 The RTO process begins by igniting a burner to raise the combustion chamber temperature to the desired setpoint.
• 😀 Once the RTO reaches the setpoint, a booster fan draws in processed emissions and directs them into the RTO.
• 😀 The emissions enter a poppet valve manifold and flow through a ceramic media-filled regenerator column, where the temperature is raised significantly.
• 😀 The process stream is heated from 100°F to over 1,425°F in the regenerator column before moving to the combustion chamber.
• 😀 In the combustion chamber, the temperature is raised to approximately 1,500°F, where over 99% of VOCs are oxidized to CO2 and water vapor.
• 😀 The clean, hot air then passes through a second heat exchanger column, where it is cooled by the ceramic media before being released into the atmosphere.
• 😀 Every 3 to 6 minutes, the airflow reverses direction, allowing heat stored in the ceramic media to be transferred to the incoming process stream.
• 😀 The regenerative cycle enables RTOs to achieve greater than 95% thermal efficiency, making them a cost-effective solution for air pollution control.
• 😀 RTOs effectively destroy harmful pollutants like VOCs, hazardous air pollutants, and odorous emissions, preventing them from entering the atmosphere.

Q & A

What is a thermal oxidizer, and why is it used in industrial manufacturing?

A thermal oxidizer is a device used by industrial manufacturers and processing companies to combat air pollution, reduce their environmental footprint, and ensure compliance with EPA regulations. It works by oxidizing harmful gases at high temperatures to convert them into less harmful substances like carbon dioxide and water vapor.

What is a regenerative thermal oxidizer (RTO)?

A regenerative thermal oxidizer (RTO) is the most common type of thermal oxidizer. It features a regenerative heat exchanger design, which allows for significant operational cost savings by reusing heat to preheat incoming gases.

How does an RTO start its operation?

Upon startup, an RTO ignites a burner to raise the combustion chamber temperature to a preset target temperature. Once the system reaches the desired temperature, it begins processing the emissions.

What role does the booster fan play in the operation of an RTO?

The booster fan draws in processed emissions and forces these gases into the inlet of the RTO for further treatment.

How does the regenerator column function in an RTO?

In the regenerator column, the untreated process stream enters the ceramic media, where it is heated from around 100°F to over 1400°F before moving to the combustion chamber.

What happens inside the combustion chamber of an RTO?

In the combustion chamber, the pre-heated process stream is raised to a set point of approximately 1500°F, where the oxidation of volatile organic compounds (VOCs) occurs. At this temperature, over 99% of the VOCs are converted to carbon dioxide (CO2) and water vapor.

What happens to the clean air after the combustion process in an RTO?

After the combustion process, the clean, hot air is directed into a second heat exchanger column, where it is cooled as it passes through ceramic media, which absorbs the heat before the air exits through the exhaust stack.

How does the reversal of airflow work in an RTO, and why is it important?

Every three to six minutes, the airflow direction in an RTO reverses as poppet valves switch positions. This allows the heat captured in the ceramic media from the clean air to preheat the incoming process air, improving overall efficiency.

What is the primary benefit of the regenerative nature of an RTO's design?

The regenerative design of an RTO enables greater than 95% thermal efficiency. The ceramic heat exchanger media retains heat and transfers it to the incoming process air, reducing the need for additional fuel to reach the desired operational temperatures.

What types of emissions can be treated by a regenerative thermal oxidizer?

A regenerative thermal oxidizer is effective in destroying a variety of pollutants, including volatile organic compounds (VOCs), hazardous air pollutants, and odorous emissions, preventing them from being released into the atmosphere.