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Flameless Regenerative Thermal Oxidation is a destructive technology for off or waste-gas treatment
of volatile organic compounds (VOCs) and semi-volatile organic compounds (SVOCs). The method
converts VOCs to carbon dioxide, water without subjecting the vapors to any flame. The technology
achieves thermal oxidation of VOCs using heated packed ceramic pieces. The vapors are oxidized
when they migrate through the heated ceramic media bed.


When comparing regenerative thermal oxidizers there are several different methods used in initiating
the pre heat stage of operation. Some regenerative thermal oxidizer systems have used heating
elements as the source to elevate the temperatures to destruction levels, while others use burners or
(after the pre heat stage) turn the burners off and inject natural gas as part of the emission stream to
influence the rise in temperature. These are called Flameless regenerative thermal oxidizers.

Electric systems have been around for some time, however for larger systems over 10,000 SCFM
many have proven to be a continuous maintenance nightmare with element failure, constant element
replacement, ceramic media melting and equipment down time. Advances in electrical element
technology may soon make this technology more viable. However, with the reduction in price of
natural gas, further advancements may be insignificant or may only be utilized in countries which
have limited natural gas quantities.

Often, regenerative thermal oxidizers which are exported outside the U.S market will pre-heat the
regenerative thermal oxidizer systems using propane, plant tail gas, or diesel fuel as the source of
Btu’s to bring the equipment up to temperature. Regenerative thermal oxidizers are very resilient and
as such are able to pre-heat and maintain temperatures using many types of Btu types and supplies.

Whatever energy source used to supplement the sustained required temperature it can become
costly with lower process VOC values. Many manufactures have tried various techniques and some
methods have proved to be viable while others simply use large amounts of fuel.

One such higher fuel system is the flameless regenerative thermal oxidizer. The terminology asserts
that no additional fuel would be required, this is simply not true. In plant processes that have lower
VOC’s, systems are unable to sustain an auto thermal condition. In these cases supplemental fuel is
injected and mixed with the plants VOC’s. As a result the injected supplemental fuel offers lower Btu
value than simply running the fuel through a burner system. Impart due to the lower combustion
temperature within the media bed. Burners typical flame temperatures operate between 2800°F to
3300°F. However flameless RTO systems offer lower NOx formation, almost none due to the fuel
being ignited within the ceramic media beds.

Many times these flameless regenerative thermal oxidizer systems use up to 20+% more fuel than
their counterparts which offer a direct burner flame. This amount can increase the operational fuel
costs thousands of dollars per year, not to mention the reductions in natural resources.
An example of fuel use comparison on a 25,000 SCFM Regenerative Thermal Oxidizer is listed below:

Thermal Destruction Temperature of 1500°F -
No VOC Loading: 4,100,000 Btu’s
Thermal Destruction Temperature of 1500°F -
Natural Gas Injection, No VOC Loading: 6,250,000 Btu’s.

With supplementing the VOC’s by means of natural gas you are in fact operating without a flame at typical higher costs. In this scenario a plant operating a regenerative thermal oxidizer system which has
VOC levels of 4,400 ppmv stated as methane. The required additional fuel used by the burner would approximate less than 1,000,000 Btu’s. Based on the national average cost would approximate less than
$4.75 per hour. However, using the same evaluation criteria for a natural gas injection or (Flameless) regenerative thermal oxidizer; the cost would approximate around $7.50 per hour.

These examples are based on field studies and are approximate considerations. Over a one year operating period natural gas injection the (Flameless) regenerative thermal oxidizer system would cost
$2.75 per hour more than its flamed counterpart at an annual cost of over $7,920.00. Calculations are based on operating periods of 8 hour days 360 days per year.
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in 3 steps

planing & strategy

test & deliver

design & develop
Implement proven equipment designs with
chemical, thermal and biological reactions
that achieves the required process result.
Results shall be based on reaction rates
and proper control logic.
Our Corporate goal is to implement the
correct design criteria with the use of
proper metals, instruments and controls to
achieve the required result with the least
amount of maintenance and associated
energy costs.
We pride ourselves in going the extra mile
before it leaves the plant. It is our way of
knowing that you are receiving correctly
designed equipment to meet your specific