What are the Common Issues with RTO Gas Treatment Systems?

RTO, or Regenerative Thermal Oxidizers, are used to treat industrial exhaust streams that contain harmful pollutants. RTOs are widely used in many industries, including the chemical, petrochemical, and pharmaceutical industries. While RTOs are highly efficient in eliminating harmful pollutants, they often face several common issues. In this article, we will explore the most common issues with RTO gas treatment systems and how to address them.

1. Insufficient Heat Recovery

One of the most common issues with RTOs is insufficient heat recovery. RTOs rely on heat recovery to achieve high energy efficiency and reduce operating costs. However, if the heat recovery system is not designed correctly, the RTO might not recover enough heat, which could result in increased operating costs and decreased efficiency.

To address this issue, it is essential to ensure that the heat recovery system is correctly designed and optimized for the specific application. A heat recovery specialist should be consulted to identify the most efficient heat recovery system for the specific RTO.

2. Coking

Coking is another common issue that can occur in RTOs. Coking is the accumulation of solid carbon deposits on the heat recovery media, which reduces the heat transfer efficiency of the RTO. Coking can also lead to fouling and plugging of the RTO’s media beds, which can result in increased pressure drop and decreased efficiency.

To address coking, RTO operators should ensure that the RTO operates within the designated temperature and oxygen ranges and avoid abrupt changes in temperature or airflow. Regular maintenance, including cleaning and inspection of the heat recovery media, is also essential to prevent coking and maintain RTO efficiency.

3. Air Leaks

Air leaks are a common issue that can occur in the RTO’s media beds and ductwork. Air leaks can occur due to poor installation or wear and tear of the seals and gaskets. Air leaks can result in reduced efficiency, increased operating costs, and increased emissions.

To address air leaks, RTO operators should perform regular inspections of the media beds and ductwork to identify and repair any leaks. High-temperature silicone seals and gaskets should be used to ensure a proper seal between the media beds and the ductwork.

4. Pressure Drop

Pressure drop is the reduction in pressure across the RTO’s media beds due to fouling or plugging. Pressure drop can result in reduced efficiency and increased operating costs. If the pressure drop becomes too high, it can also lead to the shutdown of the RTO.

To address pressure drop, regular maintenance, including cleaning and inspection of the media beds, is essential. RTO operators should also ensure that the inlet gas temperature and flow rate are within the designated range to prevent fouling and plugging of the media beds.

5. Corrosion

Corrosion is another common issue that can occur in RTOs, especially in the presence of acidic or corrosive gases. Corrosion can lead to leaks and reduced efficiency, which can result in increased operating costs and emissions.

To address corrosion, RTO operators should ensure that the RTO is made of corrosion-resistant materials, such as stainless steel or Inconel. Regular inspections and maintenance are also essential to identify and repair any corrosion damage.

6. Flameless Operation

Flameless operation is a new technology that is gaining popularity in RTOs. Flameless operation reduces NOx emissions and increases energy efficiency by eliminating the need for a burner flame. However, flameless operation can also result in increased pressure drop and decreased efficiency if not designed and operated correctly.

To address flameless operation issues, it is essential to work with a specialist to design and optimize the flameless operation system for the specific application. Regular maintenance and inspections are also essential to identify and repair any issues.

7. Noise

Noise is another issue that can occur in RTOs, especially during the startup and shutdown phases. Noise can result in complaints from nearby residents and worker safety concerns.

To address noise issues, RTO operators should ensure that the RTO is properly designed and installed with noise reduction measures, such as silencers and enclosures. Regular maintenance and inspections are also essential to identify and repair any noise issues.

8. Electrical Issues

Electrical issues can occur in RTOs due to the high electrical loads required to operate the RTO’s fans and control systems. Electrical issues can result in increased operating costs and reduced efficiency.

To address electrical issues, RTO operators should ensure that the electrical system is correctly designed and installed with appropriate safety measures, such as circuit breakers and fuses. Regular maintenance and inspections are also essential to identify and repair any electrical issues.

We are a high-tech enterprise specializing in comprehensive treatment of volatile organic compounds (VOCs) waste gas and carbon reduction and energy-saving technology for high-end equipment manufacturing. Our core technical team comes from the Aerospace Liquid Rocket Engine Research Institute (Aerospace Sixth Institute). It has more than 60 R&D technicians, including 3 senior engineers at the researcher level and 16 senior engineers. We have four core technologies: thermal energy, combustion, sealing, and automatic control. Additionally, we have the ability to simulate temperature fields and air flow field simulation modeling and calculation. We also have the ability to test the performance of ceramic thermal storage materials, the selection of molecular sieve adsorption materials, and the experimental testing of the high-temperature incineration and oxidation characteristics of VOCs organic matter.

The company has built an RTO technology research and development center and an exhaust gas carbon reduction engineering technology center in the ancient city of Xi’an, and a 30,000m^2 production base in Yangling. The production and sales volume of RTO equipment is far ahead in the world.

– High-efficiency combustion control technology test bench: This test bench allows us to accurately control the combustion process and optimize energy efficiency.
– Molecular sieve adsorption efficiency test bench: With this test bench, we can evaluate the adsorption efficiency of different molecular sieve materials, ensuring effective VOCs removal.
– High-efficiency ceramic thermal storage technology test bench: This test bench enables us to assess the performance of ceramic thermal storage materials, which play a crucial role in energy-saving and carbon reduction.
– Ultra-high temperature waste heat recovery test bench: Using this test bench, we can explore innovative methods to recover waste heat at extremely high temperatures, contributing to energy conservation.
– Gas flow sealing technology test bench: This test bench allows us to develop and test advanced sealing technologies for gas flow systems, ensuring minimal leakage and optimal system performance.

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We have numerous patents and honors in our possession. We have applied for a total of 68 patents, including 21 invention patents, which cover key components of our technology. We have already been granted 4 invention patents, 41 utility model patents, 6 design patents, and 7 software copyrights.

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Our production capabilities include:

– Steel plate and profile automated shot blasting and painting production line
– Manual shot blasting production line
– Dust removal and environmental protection equipment
– Automatic painting booth
– Drying room

These production capabilities enable us to deliver high-quality and efficient equipment for various applications.

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We invite our customers to collaborate with us and benefit from the following advantages:

1. Cutting-edge technology and expertise in VOCs waste gas treatment.
2. Comprehensive solutions for carbon reduction and energy-saving in equipment manufacturing.
3. Extensive R&D capabilities backed by a highly skilled technical team.
4. State-of-the-art testing and simulation platforms for performance evaluation.
5. A strong portfolio of patents and honors in the field of environmental protection.
6. Advanced production facilities ensuring high-quality equipment and timely delivery.

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Author: Miya.