Regenerative Thermal Oxidizer

RTO Thermal Oxidizer /Regenerative Thermal Oxidizer System

RTO Oxidizer / Regenerative Thermal Oxidizer Manufacturers

 

One of the most widely accepted air pollution control technologies across the industry today is the regenerative thermal oxidizer system, commonly known as RTO. RTO uses a ceramic bed heated from the previous oxidation cycle to preheat the input gases to partially oxidize them. The preheated gas enters the combustion chamber, which is heated by an external fuel source to reach the target oxidation temperature between 760°C (1,400 °F) and 820°C (1,510 °F). For applications requiring maximum damage, the final temperature may be as high as 1,100 °C (2,010 °F). Air flow ranges from 2.4 to 240 standard cubic meters per second.

RTO (regenerative thermal oxidizer) is versatile and highly efficient – up to 95% thermal efficiency. They are often used to reduce solvents, fumes, odors, etc. from all walks of life. RTO regenerative thermal oxidizers are ideal for low to high VOC concentration ranges up to 10 g/m3 solvents. There are many types of regenerative thermal oxidizers on the market today that have a volatile organic compound (VOC) oxidation or destruction efficiency of 99.5+%. The ceramic heat exchanger in the tower can be designed for thermal efficiency of up to 97+%.

Rotary RTO Regenerative Thermal Oxidizer

Rotary RTO Regenerative Thermal Oxidizer 

Toptank rotary RTO high-end products have reached the world’s advanced level of product technology, with high-end quality to the market users more high-end choice, to help more enterprises to successfully embark on the road to green development, to achieve economic development and environmental protection win-win situation.

Rotary Regenerative Thermal Oxidizer Features

  1. Top quality stability: top purchased parts configuration, selection of super wear-resistant anti-aging fluoro silicone sealing materials;
  2. Excellent insulation and energy saving: vacuum shell insulation structure, reduce convection heat dissipation, energy saving effect increased by 3%;
  3. Super operation safety: top safety components, safety control software with artificial intelligence learning judgment and failure prediction ability;
  4. Convenient network interaction: mobile APP real-time online cloud monitoring, friendly network data interaction function;
  5. Aesthetic design of The Times: future industrial appearance, advanced anti-corrosion and anti-rust surface treatment process.
Regenerative Thermal Oxidizer for Sale

RTO systems destroy volatile organic compounds in industrial waste gases to reduce air pollution.

What is a Regenerative Thermal Oxidizer?

A regenerative thermal oxide (RTO) is a combustion device that controls volatile organic compounds (VOCs), hazardous air pollutants (HAPs), and odors by converting emissions into (destructive) emissions and by using heat to convert emissions into CO2 and H2O and then release them into the atmosphere. RTO can achieve a thermal efficiency of up to 97% and destruction efficiency of over 99%.

RTO oxidant is considered one of the most advanced thermal oxidation systems in the world. Compared to other thermal oxidizers, regenerative thermal oxidizers (RTOS) have a thermal efficiency of up to 97%, and destruction efficiency may exceed 99%, which will give you the highest removal rate at the lowest life cycle cost. — Matched with industry-leading structures and design features, all deliver superior performance, significantly lower operating costs, and industry-leading reliability.

What is a Regenerative Thermal Oxidizer

How Does a Regenerative Thermal Oxidizer Work?

  1. Regenerative thermal oxidizers (RTOS) work by pushing air filled with pollutants through the peroxide. usually with a system fan.
  2. The flow of air through the RTO is controlled by a valve that directs airflow into one of two heat exchangers (a chamber containing a ceramic dielectric bed).
  3. The RTO shall have at least two ceramic dielectric beds (saddles and/or structured dielectric blocks) as heat exchangers. As dirty air passes through the first medium bed, it absorbs heat from the hot ceramic medium and then enters the combustion chamber.
  4. In the combustion chamber, dirty air is kept at a temperature (> 1500°F) specific residence time (> 5 seconds). This oxidizes VOCs and HAP into carbon dioxide and water vapor.
  5. Hot and clean air leaves the combustion chamber and enters the second ceramic medium bed to absorb heat for reuse.
  6. The cooled clean air is then discharged into the atmosphere.

The valve changes direction every few minutes, thus reversing the direction of flow, so that heat transfer alternates between the two ceramic media beds. This is why RTO (regenerative thermal oxidizers) have high fuel efficiency and low operating costs, making them an ideal VOC reduction system.

RTO Regenerative Thermal Oxidizer Working Principle

Regenerative Thermal Oxidizer Working Principle

Regenerative thermal oxidizer process flow diagram

Rotary RTO Regenerative Thermal Oxidizers Design

12 heat storage packed beds are distributed in a circle and work alternately, with 5 in let and 5 out let, 1 purging, and 1 isolation

How Do Regenerative Thermal Oxidizers Work

Regenerative thermal oxidizer diagram

Types of RTO

Performance comparison table of different types of RTO

Type2-Beds RTO3-Beds RTORotary RTORemark
Technology of iterationFirst generationSecond generationThird generation
Number of regenerators2312
Purification efficiency95%99%99.5%
Thermal efficiency90%95%97.0%Temperature difference between inlet and outlet≤30℃
Occupation of land100%130%65%Take 2-Beds RTO as the benchmark

Technical Iterations of the RTO

technical iterations of the RTO

First generation(2-beds)

Temperature 120℃
Medium energy consumption
Purification efficiency 95%
Environmental protection does not meet the standard, thus eliminated

Second generation(3-beds)

Temperature 100℃
Medium energy consumption
Purification efficiency 99%
Meet environmental protection standard

Third generation(rotary RTO)

Temperature 60℃
Low energy consumption
Purification efficiency 99.5%
Meet environmental protection standard

The Structure of Rotary RTO

Rotary RTO comprises a combustion chamber, regenerative chamber, and rotary valve.

The furnace body is divided into 12 chambers, 5 inlet chambers, 5 outlet chambers, 1 cleaning chamber, and one isolation chamber.

The rotary valve is driven by the motor for continuous and uniform rotation. Under the rotary valve, the exhaust gas slowly switches continuously between 12 chambers. Its basic structure is shown in the figure on the right.

the structure of rotary RTO
technical iterations of the Rotary RTO

Generally speaking, the more regenerative chambers, the higher the purification and thermal efficiency. With the development of technology, the third generation OF RTO, namely rotary RTO, was born.

It has 12 circular regenerators and has the advantages of compact structure, small heat dissipation area, low energy consumption, high thermal efficiency, its purification efficiency can be up to 99.5%.

The Advantages of Rotary RTO

Ultra high purification efficiency 99.7%

Ultra high heat storage efficiency 97%

Stable core components for 10 years

Anti blocking, anti-corrosion and extended maintenance

The advantages of Rotary RTO

Choice of RTO Regenerative Thermal Oxidizers

3-chambers RTO (3 chambers)

RTO Regenerative Thermal Oxidizers

The three-chamber RTO has high exhaust temperature, high energy consumption, high operating costs, and the switching valve works 520,000 times per year with a short life span.

Rotary RTO (12 chambers)

Rotary RTO Regenerative Thermal Oxidizers

Rotary RTO exhaust temperature is less than 80 degrees and has low energy consumption, low operating costs, continuous operation of the rotary valve without switching, and long service life.

Solve the problem of ultra high heat storage rate

solve the problem of ultra-high heat storage rate

Diaphragm form

diaphragm form
solve the problem of ultra-high heat storage rate
solve the problem of ultra-high heat storage rate
solve the problem of ultra-high heat storage rate
solve the problem of ultra-high heat storage rate
RTO material type

Solve the problem of ultra high heat storage rate

solve the problem of ultra-high heat storage rate 5
solve the problem of ultra-high heat storage rate 6

Temperature distribution in the Z direction

solve the problem of ultra-high heat storage rate 7
olve the problem of ultra-high heat storage rate 8

Installation process of insulation cotton

Installation process of insulation cotton
Installation process of insulation cotton
Installation process of insulation cotton

Insulation shell

Thermal insulation and energy-saving performance

A vacuum insulation shell is designed on the surface of ” Toptank ” RTO furnace body to reduce convection heat dissipation

Insulation shell
Insulation shell

The simulation of the
temperature field of heat
loss in the windward face of
the outer surface of the
common RTO furnace shows
that the heat loss is 1.4×10 4
W/m 2

Insulation shell

The heat loss of the
outer shell of
Toptank RTO furnace
body is 0.5x 10 4
W/m 2

Insulation shell The heat

Solve the service life and stability of core components

Solve the service life and stability of core components
Solve the service life and stability of core components
Solve the service life and stability of core components
Solve the service life and stability of core components
Axial deformationBending deformation
Solve the service life and stability of core components
Solve the service life and stability of core components

After improvement, the valve shaft bending amount and shaft head torque in different states

Rotary valve seal

Solve the service life and stability of core components

lip seal

Solve the service life and stability of core components

Regenerative Thermal Oxidizer Advantage – Recovery of Waste Heat

1. Recovery of waste heat through steam

Recovery of waste heat through steam

2. Recovery of waste heat through hot water

Recovery of waste heat through hot water

3. Recovery of waste heat through conduction oil

Recovery of waste heat through conduction oil

4. Recovery of waste heat through hot wind

Recovery of waste heat through hot wind

Cloud service system

Internet of things big data interconnection Remote monitoring, remote diagnosis, fault troubleshooting, maintenance reminder, data recording, and other functions in one, to provide customers with high quality and efficient value-added services.

Cloud service system
Cloud service system
Cloud service system

Regenerative Thermal Oxidizer Marketing and Application

General situation of project signing

General situation of project signing

Application cases

Whole plant solution

Equipment configuration:

  • 3x40000Nm³/h-RTO
  • 1000000Nm³/h-Zeolite rotor
  • 3x6t/h-2.0MPa Steam boiler
What is a Regenerative Thermal Oxidizer Used for
What is a Regenerative Thermal Oxidizer Used for

High concentration waste gas solution

Equipment configuration:

  • 30000Nm³/h-RTO
  • 6t/h-heat conducting oil boiler
ProjectIndex
Concentration8600mg/m³
Volume30000Nm³/h
CompositionEthyl ester, toluene
Purification
efficiency
99.62%
Emission limit28.8mg/m³

Low concentration solution

Equipment configuration:

  • 10000Nm³/h-RTO
  • 80000Nm³/h-Zeolite rotor
ProjectIndex
Concentration620mg/m³
Volume80000Nm³/h
CompositionXylene, butyl
Purification
efficiency
96.1 %
Emission limit24.18mg/m³
What is a Regenerative Thermal Oxidizer Used for-Low concentration solution

Solutions for complex chemical waste gas

Organic waste gas: Alkanes, olefins, alkynes, aromatic aldehydes, ketones, ethers, sulfur/chlorine/nitrogen organics
Accompanying components: H2S,  SO2HCl       CO, NH3

DifficultyMeasuresDifficultyMeasures
Corrosive gasAlkaline washing,
pickling, dehumidification,
Corrosion resistant material, Anticorrosive coating
NOxSNCR/SCR
Denitration
Concentration surgeBuffer tank,
FTA concentration peak remote
warning
Viscous
polymer
Plate type heat storage ceramic and 12 manholes
for maintenance
dioxinactivated carbon adsorptionwaste heatHot air recovery

Waste gas solution of the sewage tank

Waste gas components:

  • Ammonia, hydrogen chloride, xylene Ammonia content 20%
  • The lower explosion limit Process composite of ammonia is 15%

Process composition:

  • Spray tower +RTO+SCR
  • 10000Nm³/h RTO
  • 50000Nm³/h RTO

Features:

  • Chlorine and corrosion-resistant materials
  • NOx emission control
Waste gas solution of sewage tank

Thermal energy utilization solutions

Equipment configuration:

  • 3x40000Nm³/h-RTO
  • 3x8t/h-2.0MPa boiler
  • 3000KW Steam type lithium
  • bromide refrigerator

Concentration surge solutions

Features:
Concentration surge, chlorine-containing
corrosion, amine-containing

Waste gas components:

3-methylpyridine, 3-cyanopyridine, 3-aminopyridine, methanol, toluene, ethanol, triethylamine, chloroform, short chain fatty acids, aliphatic hydrocarbons, ammonia and trichloroethylene

Process composition:

Concentration fluctuation pretreatment + RTO corrosion prevention + post-treatment to remove hydrogen chloride and dioxin

Concentration surge solutions

Equipment configuration:

  • 2x40000Nm³/h-RTO

Waste gas pipeline
Pretreatment system

Asphalt fume solution

Asphalt fume solution

Features:

High boiling point lipid aerosol, Dust

Process composition:

  • Pipe heat tracing
  • Oil drain
  • Fire fighting system
  • Cyclone filter
  • Screen filter
  • Quick replacement of Bottom heat storage ceramic

Regenerative Catalytic Oxidizer

The Regenerative Catalytic Oxidizer (RCO) system is based on the structure of an RTO, with a special catalyst material added to the oxidizer, which provides enough heat energy to destroy VOCs to lower the operating temperature of the RTO system and increase the rate of oxidation reaction. Unlike thermal combustion, RCO is flameless and automatically shuts down the heater when the treatment inlet gas exceeds 300°C. It is widely used because it is environmentally friendly and energy efficient.

Flameless Regenerative Thermal Oxidizer

Regenerative Thermal Oxidizer VS Thermal Oxidizer

Thermal oxidizers are used in a variety of industrial applications and are a preferred technology in the field of air pollution control. Their efficiency and durability make them an excellent choice for many processes. Advanced thermal oxidizer systems are particularly advantageous in air pollution control applications, where they are used to effectively destroy hazardous air pollutants and volatile organic compounds. They are also environmentally friendly and meet stringent environmental regulations.

Regenerative Thermal Oxidizers use a ceramic heat exchanger to heat up the exhaust gas in a controlled environment. The heated air then enters a combustion chamber, where it is preheated to a set temperature. Once heated, this clean air is then exhausted through a stack into the environment. Regenerative thermal oxidizers (RTO) are the excellent choice for any chemical plant and can significantly reduce operating costs, particularly when combined with an effective heat recovery system.

Recuperative Thermal Oxidizer VS Regenerative Thermal Oxidizer

The primary difference between a recuperative thermal oxidizer and a regenerative thermal oxidizer is the way in which the technology recovers energy.

A recuperative thermal oxidizer uses a heat exchanger to convert exhaust gas into useful heat. This heat can then be used to heat the incoming air. Both types of oxidizers can have multiple heat recovery devices.

Regenerative thermal oxidizers require more complicated technology than recuperative thermal oxidizers. They utilize valves that reverse the airflow and ceramic heat sinks that absorb heat from the hot air. The heated air then passes through a combustion chamber where VOCs are oxidized.

Regenerative thermal oxidizers are more versatile and efficient. Their high efficiency can make them ideal for long-running operations and high-VOC concentrations. They use ceramic media to capture heat and are more energy efficient. They are also a great choice for low-VOC concentrations.

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