What are the design considerations for a thermal oxidizer system?

A thermal oxidizer system is a pollution control technology used to treat industrial exhaust streams containing hazardous air pollutants (HAPs), volatile organic compounds (VOCs), and other harmful air emissions. The system works by using high temperatures to oxidize the pollutants into non-hazardous compounds before releasing them into the atmosphere.

thermal oxidizer system

1. Process Flow Rate

The process flow rate is the amount of exhaust gas that will be treated by the thermal oxidizer system. It is important to accurately determine the flow rate to ensure that the system is properly sized for the application. The flow rate can be calculated by measuring the volume of exhaust gas and the time it takes to pass through a specific point in the system.

2. Combustion Efficiency

The combustion efficiency is a measure of how well the thermal oxidizer system oxidizes the pollutants in the exhaust gas. A high combustion efficiency is desirable to ensure that the system is effectively treating the pollutants. Factors that can affect the combustion efficiency include the temperature of the system, residence time of the exhaust gas in the system, and the concentration of pollutants in the exhaust gas.

3. Heat Recovery

Heat recovery is the process of recovering the heat generated by the thermal oxidizer system and using it for other purposes, such as heating or process applications. This can help to reduce the operating costs of the system and improve overall energy efficiency. Different heat recovery methods can be used depending on the specific application, including air-to-air heat exchangers, water-to-water heat exchangers, and steam generators.

4. System Maintenance

Proper system maintenance is essential for ensuring the long-term performance and reliability of the thermal oxidizer system. This includes regular inspections, cleaning, and replacement of components as needed. It is important to follow the manufacturer’s recommendations for maintenance and to keep accurate records of all maintenance activities.

5. System Controls

The system controls are responsible for monitoring and maintaining the proper operation of the thermal oxidizer system. They include sensors for measuring temperature, pressure, and flow rate, as well as control valves and actuators for regulating the system’s operation. The controls should be designed to provide accurate and reliable operation of the system and to respond quickly to any changes in the operating conditions.

6. System Design

The system design is a critical factor in the overall performance of the thermal oxidizer system. It should be designed to meet the specific requirements of the application and to provide efficient and effective treatment of the exhaust gas. The design should take into consideration factors such as the type and concentration of pollutants in the exhaust gas, the process flow rate, and the available space for installation.

7. System Cost

The cost of the thermal oxidizer system is an important consideration for many applications. The cost will depend on factors such as the system size, complexity, and features. It is important to balance the initial cost of the system with the long-term operating costs and the benefits of reducing air emissions and complying with environmental regulations.

8. Regulatory Compliance

Regulatory compliance is a critical consideration for any industrial application that generates air emissions. The thermal oxidizer system must be designed and operated in compliance with all applicable environmental regulations, including emissions limits, monitoring requirements, and reporting requirements. Failure to comply with these regulations can result in fines, penalties, and reputational damage to the company.

Company Introduction

We are a high-end equipment manufacturing enterprise specializing in comprehensive treatment of volatile organic compounds (VOCs) emissions and carbon reduction energy-saving technology. Our core technical team comes from the Aerospace Liquid Rocket Engine Research Institute (Aerospace Sixth Academy). We have more than 60 research and development technical personnel, including 3 senior engineers at the researcher level and 16 senior engineers. We have four core technologies: thermal energy, combustion, sealing, and self-control. Our capabilities include temperature field simulation, air flow field simulation modeling, ceramic heat storage material performance, molecular sieve adsorption material selection, and VOCs high-temperature incineration oxidation experimental testing.

We have established RTO Technology R&D Center and Waste Gas Carbon Reduction Engineering Technology Center in the ancient city of Xi’an, and a 30,000m76 production base in Yangling. Our RTO equipment production and sales volume leads the world.

Research and Development Platforms

High-efficiency Combustion Control Technology Test Bench: This platform is designed to test and optimize the combustion efficiency of our equipment, ensuring effective VOCs treatment.
Molecular Sieve Adsorption Efficiency Test Bench: We utilize this platform to evaluate the performance and effectiveness of different molecular sieve adsorption materials in VOCs removal.
High-efficiency Ceramic Heat Storage Technology Test Bench: This platform allows us to study and develop advanced ceramic heat storage materials, which enhance the energy efficiency of our equipment.
Ultra-high Temperature Waste Heat Recovery Test Bench: With this platform, we explore innovative techniques to recover and utilize waste heat at extremely high temperatures.
Gaseous Fluid Sealing Technology Test Bench: We test and improve the sealing performance of our equipment using this platform, ensuring minimal leakage of VOCs during operation.

Patents and Honors

In terms of core technologies, we have applied for a total of 68 patents, including 21 invention patents. Our patent technologies cover key components. Currently, we have been granted 4 invention patents, 41 utility model patents, 6 design patents, and 7 software copyrights.

Production Capacity

Steel Plate and Profile Automatic Shot Blasting and Painting Production Line: This automated production line ensures high-quality surface treatment for our equipment, enhancing durability and corrosion resistance.
Manual Shot Blasting Production Line: We have a dedicated line for manual shot blasting, providing flexibility in processing different types of equipment.
Dust Removal and Environmental Protection Equipment: Our production capacity includes the manufacturing of advanced dust removal and environmental protection equipment to meet various industry requirements.
Automatic Spray Painting Booth: With this facility, we achieve consistent and high-quality paint application on our equipment.
Drying Room: We have a specialized drying room to ensure proper curing and finishing of our equipment.

Cooperate with Us

Advanced technology and extensive experience in VOCs comprehensive treatment.
Highly skilled research and development team specializing in thermal energy, combustion, sealing, and self-control.
Cutting-edge research platforms for efficient combustion control, molecular sieve adsorption, ceramic heat storage, waste heat recovery, and gaseous fluid sealing technologies.
Outstanding track record with 68 patent applications, including invention, utility model, design, and software patents.
Strong production capacity with automated lines for shot blasting, painting, dust removal equipment, and spray painting booths.
Commitment to quality and environmental protection, ensuring reliable and eco-friendly equipment.

Author: Miya