QUADRANT SR- Thermal Oxidizer Process Design & Environmental Control Benefits for the Sand Coating Industries

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1 > 99% VOC, HAP & CO Destruction Efficiency Time, temperature and turbulence are the basic design principles required for organic pollutant control. In the QUADRANT-SR SERIES Recuperative Thermal Oxidizers, process emissions are first directed to a unique primary heat exchanger that raises the process gas temperature prior to entering the specially designed combustion chamber. The main design feature of the QUADRANT System maximizes mixing and turbulence in the combustion chamber which works to provide maximum destruction of VOCs, HAPs & CO at the lowest possible operating temperature. QUADRANT Thermal Oxidizer Systems controlling sand coating process emissions operate at a 1,400 deg F (or less) and a 1.0 sec residence time resulting in a greater than 99% destruction of VOC, HAPs & CO. Thermal Oxidizers have been demonstrated as Best Available Control Technology (BACT) with control efficiencies for VOC & HAPs exceeding 99%. When compared to other technologies such as wet scrubbing, QUADRANT Thermal Oxidizers offer numerous operational, compliance, and economic advantages. Minimizing NOx conversion A major advantage the QUADRANT Series Thermal Oxidizer offers sand coating applications is the ability to create less Oxides of Nitrogen (NOx). When compared to other thermal oxidizer technologies, the use of the QUADRANT combustion chamber affords lower operating temperatures and mimics conditions found in proven SNCR reactions. Both of these design features work together to convert less NOx in the combustion process. Stack testing demonstrates that from the inlet to outlet of the QUADRANT Thermal Oxidizer, less than 10% of the total Nitrogen at the inlet of the oxidizer is converted to NOx. Ammonia (a common pollutant in sand coating) concentrations at the outlet of the oxidizer are at non-detect levels. PM2.5 PM 2.5 emissions are typically made up of organic molecules or sulfates. VOCs & HAPs are combusted in the QUADRANT Series Thermal Oxidizer, eliminating the precursor compounds that could contribute to PM 2.5 formation. The complete combustion technology of the QUADRANT Series Thermal Oxidizer prevents PM 2.5 precursor compounds from being formed, as the large ringed hydrocarbons are combusted into small carbon moledules, CO 2 and water.

2 QUADRANT SR- Thermal Oxidizer Round-Modular Design The round design of the QUADRANT Series Thermal Oxidizer is better suited to control expansion and contraction when compared to the typical square box designed unit. There is zero stress placed on the combustion chamber, thus eliminating downtime for combustion chamber repairs. The modular design removes the heat exchanger from the combustion chamber to allow each component the ability to individually control growth. The modular design is key to long equipment life and the highest uptime reliability. A large fluctuation in operating conditions (low to high air volume) will add to stress and strain especially in square systems. Internally Insulated All QUADRANT Series Thermal Oxidizer s are internally insulated with up to eight (8) inches of ceramic Z-block insulation modules. The Z-block modules will reduce shell temperatures, reduce heat losses to atmosphere, reduces spalling and refractory failure common in many thermal oxidizers. Other systems that use a blanket lining system or fiberboard are at risk to erosion over time. The Z-block lining system works especially well in the round QUADRANT system since our round design allows the modules to lock in place. Burner Technology QUADRANT Series Thermal Oxidizer s incorporate a unique burner technology when compared to other thermal oxidizer systems. Our burner is specially designed to work with our center combustion tube to promote mixing of the VOC s with air, thus offering the highest temperature uniformity regardless of the process operating volumes. This unique feature allows the QUADRANT system to achieve the very high VOC destruction rate efficiency at lower temperatures when compared to other systems especially when operating at lower air volumes.

3 FLOATING TUBE PRIMARY HEAT EXCHANGER CPI s FLOATING TUBE SHELL AND TUBE PRIMARY HEAT EXCHANGER is a revolutionary design that has set all thermal oxidizers apart from the QUADRANT system. When other manufacturers were replacing or repairing their heat exchangers, CPI was developing the FLOATING TUBE unit. The design is simple, remove all expansion joints and packed seals and allow each tube the ability to freely float. This design reduces tube stress, deformation, sag, or broken welds. Downtime for repairs is eliminated. No other supplier has the proven expertise for this type of reliability. The design of the FLOATING TUBE HEAT EXCHANGER is a critical element for large thermal oxidizer s that have to operate under a wide volume range. As the volume changes in the process, the temperature profiles change throughout the heat exchanger. There is a greater change in temperature between each and every tube in the system. It is this temperature gradient that drastically effects the expansion characteristics of the system. By utilizing the FLOATING TUBE HEAT EXCHANGER and eliminating the concern of uncontrollable expansion, the system inherently provides longer life and the highest uptime reliability. Each FLOATING TUBE Hx unit is supplied with 3/8-inch thick stainless steel tube sheets and baffles for added strength, durability, and uptime performance. No expansion joints to fail No stress Longest Equipment Life Highest Uptime Reliability The primary heat exchanger uses a proprietary floating tube design to allow for thermal expansion resulting in longer tube life. Hot air recovered by the tube bundles is reused as heated combustion air that greatly decreases energy costs and greenhouse gas emissions. The QUADRANT System is the only Thermal Oxidizer that uses such a revolutionary design that minimizes repairs, downtime, and most importantly leaking tubes. Production flexibility commonly requires variable air volumes. A large primary heat exchanger, fabricated in a square box style, utilizing expansion joints will be placed under extreme duty during start and stop thermal cycling (especially from power outages). We have found that those Hx's break tubes in all four corners, experience bent tubes throughout the bundle, and present a serious concern for Hx leakage even after only 2 years of operation.

4 50-75% Thermal Efficiency The FLOATING TUBE HEAT EXCHANGER is designed based on the needs of the application. The thermal efficiency usually ranges from 50-75% TRE. Greater thermal efficacy means lower operating costs. But higher thermal efficiency means more challenges for other systems that rely on expansion joints to control thermal expansion. There are no problems with high thermal efficiency systems when our FLOATING TUBE HEAT EXCHANGER is used. More importantly, the FLOATING TUBE HEAT EXCHANGER is designed for the highest uptime reliability and ZERO leakage, even when faced with: wide ranging air volumes that cause temperature gradients potential power outages that cause hard shut-downs TSS Control Systems Our TSS Control System is unique to our industry. With redundant safety in mind and damper and valve double checks before every startup, you can be assured that the system will be thoroughly protected. All Oxidizer systems are documented with individual component ID tags, these ID s are unique throughout the program and interface. So if a component trips the system to an alarm or shut down the fault annunciator will identify the component by its unique ID number and any maintenance technician can quickly find the defective part and move towards troubleshooting.

5 CPI as a vendor Catalytic Products International has been in industry leader for over 45 years. Our innovative thermal and catalytic products have paved the way for industry innovation and environmental leadership. With over 30 sand coating installations world wide, and sole supplier to the industries top companies, you can be assured that CPI has the expertise and knowledge to make your project a success. Experience: We have teamed up with the industry s best suppliers to deliver a complete integrated and seamless solution to a very troubling application. With our long history in sand coating to guide us, we have been able to design solutions to help you stay complaint, safe, and profitable for years to come. Our focus has been and always will be a total process design. That s why we ve carried our learned and innovative designs throughout the process starting at the mill and applicators to the ductwork and auxiliary component design to the thermal oxidizer. When it comes to thermal oxidation - coupled with direct or indirect heat recovery CPI is the leaders in the sand coating industry. With 45 years as only a thermal or catalytic oxidizer supplier, you can be assured that your system is backed by the highest degree of proven engineering. No other company can boast this fact. Catalytic Products International is a worldwide leader in the design and manufacture of custom air pollution abatement systems and innovative heat recovery and energy conservation systems. Further assistance may be found by consulting Catalytic Products International, Inc., please contact us at: Catalytic Products International 980 Ensell Road Lake Zurich, Illinois tel: fax: Catalytic Products International is proudly represented in the sand coating and foundry industries by: J Carpenter Environmental, LLC 6120 Norton Center Drive Muskegon, MI tel: fax: