|Regenerative Catalytic Oxidizer
Regenerative Catalytic Oxidizers are designed for plant processes where the waste gas stream has
VOC loading high enough to meet the energy requirement of regenerative catalytic systems for fuel-free
operation. However, VOC’s low enough to make a regenerative thermal oxidizer to costly to operate. In
that case a Regenerative Catalytic Oxidizer may offer the lowest operating costs. We use our
regenerative thermal oxidizer system with a catalytic top layer which provides conversion to
regenerative thermal oxidizer easy, should higher VOC levels at your plant occurs.
With corporate profit margins reducing at all time lows and the rising costs of utilities, air
pollution control manufactures along with industry has a desire to create a high breed with a small
carbon footprint. This has led plant operators and air pollution control equipment suppliers to seek
diverse technologies to reduce operating costs associated with air pollution emissions. Although, the
regenerative thermal oxidizer (RTO) generally is considered the most energy-efficient
volatile organic compound (VOC) control technology available, it can be expensive to operate
when handling large airflows and lower volatile organic compound concentrations.
Recent maximum achievable control technology (MACT) standards promulgated by the
Environmental Protection Agency (EPA) have allowed for emission reduction as low as 90 percent for
hazardous air pollutants (HAP's) on some applications (review if your plant qualifies, such as wood
manufactured products). This has opened the door for alternative technologies that typically achieve
higher destruction and removal (DRE) efficiencies in excess of 98 percent.
Regenerative catalytic oxidizer (RCO) is a common alternative to a regenerative thermal
oxidizer currently used for many types of applications. Both the technologies can be suitable for a
range of applications; however, marked differences exist between the two technologies. We will describe
many of the benefits using regenerative catalytic thermal oxidizers.
How would you define a Regenerative Catalytic Oxidizer?
The pure definition would be defined as a regenerative thermal oxidizer with a catalyst layer
added to the top layer or inner layers of the heat recovery exchange bed, this will allow the
system to run at a much lower temperature. These regenerative types of thermal oxidizers may require
additional fuel for operation, however a Regenerative Catalytic Oxidizer reduced operating temperature
provides substantial savings in fuel costs. New developments in heat exchange media designs
allow for much lower pressure drop for in both regenerative thermal oxidizer and regenerative
catalytic oxidizer technologies, resulting in less electrical usage and smaller fan requirements.
Other advantages in the designs of regenerative catalytic oxidizers is that they can be designed to
operate as both a regenerative thermal oxidizer or regenerative catalytic oxidizer and be
capable of changing in the middle of production or online between the two methods of treatment. These
regenerative catalytic oxidizers have the capability to provide the benefits of both regenerative and
catalytic oxidizer designs. They provide the ultimate flexibility to increase the operating
temperature of the regenerative catalytic oxidizer if destruction and removal efficiencies
should be increased by environmental agencies or if the catalyst has degradation.
Extensive studies have been completed on a number of regenerative catalytic oxidizers. While most
completed studies indicate that the oxidizing temperatures on regenerative catalytic oxidizer vary
between 550F to 650F. Studies are based on system designs with a minimum destruction
efficiency of above 98%. Most dual systems, regenerative thermal oxidizer and regenerative catalytic
oxidizers are designed to operate between 500F and 1450F to allow for the minimum thermal
requirement for a regenerative thermal oxidizer and the lower end of the regenerative catalytic
The lower operating temperatures for regenerative catalytic oxidizers have resulted in systems that
require no auxiliary fuel, producing the lowest operating cost. Recent environmental changes in
the level of destruction efficiency may allow you to benefit from these new standards. These savings will
allow you to reduce operating costs by approximately 50% over standard regenerative thermal
oxidizer units while maintaining the ability to achieve higher destruction efficiency and temperatures
should in the future be required.
|Yearly NG Usage Comparison
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