What are the common issues with RTO with heat recovery systems?

Regenerative thermal oxidizers (RTOs) are commonly used in industries to treat volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These systems are highly efficient and reliable, and they come in different types, including RTOs with heat recovery systems. While RTOs with heat recovery are effective in reducing emissions and energy consumption, they also face some common issues that can affect their performance and longevity. In this article, we will discuss the common issues with RTO with heat recovery systems and how to address them.

1. Fouling of Heat Exchanger Surfaces

The heat exchanger is a critical component of the RTO with heat recovery system that transfers heat from the hot exhaust gases to the incoming process air stream. However, the heat exchanger surfaces can become fouled with particulates and other contaminants, reducing their heat transfer efficiency and increasing pressure drop. This can lead to decreased thermal efficiency and increased fuel consumption, resulting in higher operating costs.

To prevent fouling, it is important to regularly inspect and clean the heat exchanger surfaces. Proper maintenance can involve mechanical cleaning, chemical cleaning, or a combination of both. Mechanical cleaning involves removing the fouling layer physically using brushes, scrapers, or high-pressure water jets. Chemical cleaning uses chemicals to dissolve the fouling layer, which can be more effective for certain types of fouling. Regular inspection and cleaning can help maintain the heat exchanger’s optimum performance and prolong its lifespan.

2. Inadequate Heat Recovery

The primary function of the heat recovery system in an RTO is to capture and reuse the heat from the exhaust gases to preheat the incoming process air stream. However, inadequate heat recovery can occur due to several factors, including poor design, improper sizing, and insufficient airflow. This can result in decreased energy efficiency, increased fuel consumption, and higher operating costs.

To ensure adequate heat recovery, it is crucial to design and size the heat recovery system correctly based on the specific process conditions, including flow rate, temperature, and composition of the process streams. The heat recovery system should also be equipped with proper controls to maintain the desired temperature and pressure levels. Regular monitoring and adjustment of the heat recovery system can help optimize its performance and reduce energy consumption.

3. Corrosion of Heat Exchanger and Ductwork

Corrosion is a common problem in RTOs due to the high temperatures and corrosive nature of the process streams. Corrosion can occur in various components, including the heat exchanger and ductwork, compromising their structural integrity and decreasing their lifespan. Corrosion can also lead to leaks, which can result in safety hazards, increased emissions, and decreased system efficiency.

To prevent corrosion, it is important to use corrosion-resistant materials for the construction of the heat exchanger and ductwork. The materials should be compatible with the process streams and should be able to withstand the high temperatures and thermal cycling. Regular inspection and maintenance can help detect and address any corrosion issues before they become severe.

4. Pressure Drop

Pressure drop is another common issue with RTOs that can affect their efficiency and performance. Pressure drop can occur due to several factors, including fouling of heat exchanger surfaces, clogging of the combustion air and exhaust air ducts, and improper sizing of the system. Pressure drop can increase the energy consumption of the system, reduce its capacity, and increase operating costs.

To prevent pressure drop, it is important to maintain the system’s components and ensure proper sizing and design. Regular inspection and cleaning of the heat exchanger, ductwork, and other components can help prevent fouling and clogging. The system should also be designed with appropriate pressure drop allowances to ensure optimal performance.

5. Inefficient Combustion

Inefficient combustion is a common issue with RTOs that can result in decreased energy efficiency, increased emissions, and increased operating costs. Inefficient combustion can occur due to several factors, including inadequate mixing of the process streams, improper sizing of the burners, and improper tuning of the combustion controls.

To ensure efficient combustion, it is essential to design and size the combustion system correctly based on the specific process conditions. The combustion controls should be tuned regularly to maintain the desired temperature and pressure levels. Proper mixing of the process streams can also help improve combustion efficiency and reduce emissions.

6. Poor Instrumentation and Controls

The instrumentation and controls are critical components of an RTO with heat recovery system that ensure optimal performance and safety. However, poor instrumentation and controls can lead to decreased efficiency, increased emissions, and safety hazards. Poor instrumentation and controls can occur due to several factors, including inadequate design, improper installation, and lack of maintenance.

To ensure proper instrumentation and controls, it is essential to design and install the system correctly based on the specific process conditions. The instrumentation and controls should be calibrated regularly to maintain accuracy and reliability. Regular maintenance can help detect and address any issues before they become severe.

7. Inadequate Safety Measures

Safety is a critical consideration in RTOs with heat recovery systems due to the high temperatures and potential hazards associated with the process streams. Inadequate safety measures can lead to safety hazards, equipment damage, and increased liability. Inadequate safety measures can occur due to several factors, including inadequate design, improper installation, and lack of maintenance.

To ensure adequate safety measures, it is essential to design and install the system with appropriate safety features, including fire and explosion protection, pressure relief devices, and emergency shutdown systems. The safety features should be tested regularly to ensure their proper functioning. Regular maintenance can help detect and address any safety issues before they become severe.

8. Lack of Proper Training and Documentation

Proper training and documentation are essential for the safe and efficient operation of an RTO with heat recovery system. Lack of proper training and documentation can lead to improper operation, decreased efficiency, and increased safety hazards. Lack of proper training and documentation can occur due to several factors, including inadequate training, lack of documentation, and insufficient communication.

To ensure proper training and documentation, it is essential to provide comprehensive training for the operators and maintenance personnel. The training should cover all aspects of the system operation, including safety, maintenance, and troubleshooting. Proper documentation, including operating manuals, maintenance logs, and training materials, should be provided and updated regularly.

In conclusion, RTOs with heat recovery systems are effective in reducing emissions and energy consumption in industrial processes. However, they also face some common issues that can affect their performance and longevity. Proper maintenance, regular inspection, and optimization of the system can help address these issues and ensure optimal performance and safety.

We are a high-tech enterprise specializing in the 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 comprises of more than 60 R&D technicians, including 3 senior engineers at the researcher level and 16 senior engineers from the Aerospace Liquid Rocket Engine Research Institute (Aerospace Sixth Institute). Our 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 30,000m2 production base in Yangling. The production and sales volume of RTO equipment is far ahead in the world.

Our company has four core technologies: thermal energy, combustion, sealing, and automatic control, and has 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. Our R&D platform includes:

– High-efficiency combustion control technology test bench
– Molecular sieve adsorption efficiency test bench
– High-efficiency ceramic heat storage technology test bench
– Ultra-high temperature waste heat recovery test bench
– Gas fluid sealing technology test bench

Our high-efficiency combustion control technology test bench is used to test the combustion performance of various fuels and the stability of combustion under various working conditions. The molecular sieve adsorption efficiency test bench is used to test the adsorption efficiency of different materials and the adsorption performance of different VOCs components. The high-efficiency ceramic heat storage technology test bench is used to test the thermal storage performance of different ceramic materials and the heat exchange efficiency of different devices. Our ultra-high temperature waste heat recovery test bench is used to test the waste heat recovery performance of different devices and the stability of operation under different working conditions. Finally, our gas fluid sealing technology test bench is used to test the sealing performance of different devices and the leakage performance under different working conditions.

Our company has applied for and obtained various patents on our core technologies, with a total of 68 patents, including 21 invention patents, and basic coverage of key components. Among them, we have been granted 4 invention patents, 41 utility model patents, 6 design patents, and 7 software copyrights.

Our production capacity includes a steel plate and profile automatic shot blasting and painting production line, a manual shot blasting production line, a dust removal and environmental protection equipment, an automatic painting room, and a drying room. Our steel plate and profile automatic shot blasting and painting production line is used to clean the surface of steel plates and profiles and to paint the surface of steel plates and profiles with high efficiency and high quality. Our manual shot blasting production line is used for surface treatment of small workpieces and special-shaped workpieces. Our dust removal and environmental protection equipment are used to purify the exhaust gas generated by different devices and to reduce environmental pollution. Our automatic painting room is used to automatically spray paint on different surfaces of products to improve the surface quality and corrosion resistance of products. Our drying room is used for the drying and curing of different products, especially for high-temperature and high-humidity environments.

We urge potential clients to work with us and benefit from our advantages, which include:

– Advanced technology and equipment
– Comprehensive technical services
– Experienced technical team
– High-quality products and services
– Competitive prices
– Timely delivery

We are committed to providing high-quality products and services to our clients, and we look forward to working with you.

Author: Miya.