Thermal and Catalytic Oxidation Systems

Transcription

1 SYSTEMS Thermal Oxidation A Met-Pro Product Recovery/Pollution Control Technologies Business Bulletin 1010 Thermal and Catalytic Oxidation Systems INLET FILTER DILUTE LADEN ROTARY CONCENTRATOR HOT DILUTE LADEN BLOWER CONCENTRATED IN OXIDIZER BLOWER DESORPTION BLOWER BLOWER FRESH CATALYTIC OXIDIZER DESORPTION HEAT EXCHANGER OXIDIZER HEAT EXCHANGER CATALYST BASKET

2 and Catalytic Oxidation Systems Regenerative Thermal Oxidizers Provide extremely high destruction efficiencies and are ideal for use with most VOC applications EXHAUST STACK A Regenerative Thermal Oxidizer (RTO) is the most efficient type of thermal oxidizer for air streams with low VOC concentration. Standard Met-Pro Systems RTOs achieve up to 95% thermal efficiency at very low VOC concentrations and can operate with little or no auxiliary fuel at 8-10% LEL. Alternate RTO designs can operate at up to 25% LEL. BURNER RTOs incorporate 2 or more beds of ceramic heat exchange media. For a two-bed RTO, the contaminated air feed stream is alternately directed to flow over one of the ceramic beds where it increases in temperature. After flowing across the first ceramic bed and being heated, the contaminated air stream is further heated with an auxiliary fuel burner to the required oxidation temperature and held for up to 1 second at that temperature to allow for adequate destruction of the VOCs. The resulting flue gas stream then flows over another ceramic bed and raises the temperature of the second bed. Periodically, switching valves reverse the direction of flow and the contaminated air feed stream flows over the hot ceramic bed that was just heated by the outgoing oxidizer flue gas. The back and forth switching between ceramic beds occurs every 3-6 minutes in most cases. The direct air to ceramic bed contact is what allows for the 95% fuel efficient RTO operation. HEAT RECOVERY MEDIA LADEN DIVERTER DAMPER FORCED DRAFT FAN (ID FAN AVAILABLE) Consider these advantages of Met-Pro regenerative thermal oxidizers: Up to 100% thermal efficiency (no auxiliary fuel consumption) Wide range of sizes from 5,000 to 60,000 scfm Destruction efficiencies up to 99% for 2 bed RTOs and >99% for 3+ bed RTOs Compact design to minimize plot space and installation cost Minimal moving parts reduces maintenance costs Turnkey installation available 6,000 SCFM RTO for paint and powder finishing application

3 Applications-Matched Thermal Met-Pro Systems has been solving emission problems for more than 40 years. Our ability to provide thermal and catalytic oxidation solutions is well known and respected throughout the world. Our expertise enables us to provide and install reliable, field proven, costeffective air pollution control systems for almost any volatile organic compound (VOC), reactive organic gas, air toxic or halogenated organic solvent. Catalytic Oxidizers VOC Concentration Systems Recuperative Thermal Oxidizers Regenerative Thermal Oxidizers Integrated Systems for Halogenated Organic Emissions While there may be more than one method or technology to solve a particular emission problem, there is generally one best way to solve that problem. When you work with Met-Pro Systems, you gain the benefits of our years of experience designing and building successful multi-discipline solutions to tough air pollution control problems with best available control technology. Met-Pro Systems offers full service capabilities from project design and development through turnkey system operation. Intermediate services include computational fluid dynamics (CFD) modeling, process simulation, RACT/BACT/LAER/MACT review, start-up and training, compliance testing, project engineering, project management and remote monitoring of the system and process.

4 Catalytic Oxidation Maximum flexibility and cost-effectiveness up to 99% destruction efficiency for VOCs Met-Pro Systems pioneered the development of catalytic oxidation technology as an extremely cost-effective method of managing solvent emissions. Catalytic oxidation may be used to control a wide variety of volatile organic compounds (VOCs). A key advantage of Met-Pro Systems catalytic oxidation systems is their ability to treat nitrogen-containing organic compounds without forming NOx. And since catalytic oxidation occurs at lower temperatures than thermal oxidation, energy consumption is also minimized. When compared with other oxidation technologies, catalytic oxidation offers advantages of lower capital expense, greater than 99% destruction efficiency and lowest possible operating costs. Met-Pro Systems catalytic oxidation systems perform a multi-step process by diffusing reactants from the bulk fluid phase to the catalyst pores where they are then adsorbed into the active surface. The reaction takes place on the catalyst site. Oxidation products are then desorbed and diffused back into the bulk fluid phase. A catalyst can convert many times its weight in reactants, with a useful life of over 70,000 hours of continuous operation. Consider these advantages of Met-Pro Systems catalytic oxidizers: LADEN DUCT BLOWER Easy catalyst change-out Modular design for flexibility Factory fabrication and testing CATALYTIC OXIDIZER Wide range of air flows to accommodate changing operating conditions Welded heat exchangers for reliable, long life Roof mounting for space savings and enhanced safety Elimination of supplemental NOx control equipment EXHAUST STACK HEAT EX- CHANGER CATALYST BASKET Catalytic Ignition Temperatures (98% destruction) Contaminant Temp. F Contaminant Temp. F Acetylene 395 MEK 700 Benzene 575 Methanol 550 Carbon monoxide 425 Propane 770 Ethanol 600 Propylene 500 Ethyl acetate 775 Toluene 575 Ethylene 810 Xylene 575 Hydrogen ,000 SCFM catalytic oxidizer system for granulating and coating pharmaceutical products

5 MIST ELIMINATOR CATALYST BASKET QUENCH ACID SCRUBBER CATALYTIC OXIDIZER FRP BLOWER LADEN BURNER OXIDATION Integrated Systems for Halogenated Organic Emissions Multi-discipline technologies for maximum performance and cost-effectiveness Eliminating halogenated solvents such as chlorinated, fluorinated, and brominated emissions with the highest possible destruction efficiencies (99% or greater) requires a unique combination of control technologies. In addition to solvent destruction, by-products of combustion HCl, HF, and HBr must also be removed before being exhausted to the atmosphere. For difficult applications such as these, Met-Pro Systems has designed systems which consist of a catalytic or thermal oxidizer matched with water quench and acid gas scrubbers. Combination systems such as these hybrid oxidizers eliminate standard VOCs and are designed using materials such as Hastelloy or Inconel to withstand the harsh environments created by the combustion of halogenated compounds. The catalytic oxidizer system depicted in the schematic above was used in a pharmaceutical application and is designed to oxidize more than 98% of both standard VOCs and chlorinated compounds. As a result of the oxidation of the chlorinated compounds, HCl is formed and must be treated prior to being exhausted to the atmosphere. The formation of HCl in this application facilitates the need for an integrated quench/scrubber system. While the water quench neutralizes some of the acid from the catalytic oxidizer, its main function is to reduce exiting air temperature from the oxidizer to 140 F prior to entering the scrubber. A sodium hydroxide solution is circulated through the packed bed scrubber to remove and neutralize up to 99.9% of the acid gases. Met-Pro Systems integrated systems include automated metering of caustic solution and ph monitoring of discharge water. A final mist eliminator removes remaining aerosols. Similar systems are used for soil and groundwater remediation and in pharmaceutical and specialty chemical applications. 8,000,000 BTU/hr. thermal oxidizer system with water quench and acid gas scrubber for butyl rubber manufacturer in China

6 Thermal Oxidation Combustion properties of common chemical compounds Extremely high destruction efficiencies greater than 99.9% Met-Pro Systems thermal oxidizers operate at high temperatures to combust solvents into water and carbon dioxide. They offer high destruction efficiencies and are ideal for use with most VOC applications. Met-Pro Systems thermal oxidation systems are available with heat recovery capabilities ranging from 50% to 80%, resulting in low operating costs. Consider these advantages of Met-Pro Systems thermal oxidizers: Modular design for flexibility Factory fabrication and testing Wide range of air flows to accommodate changing operating conditions Welded heat exchangers for reliable, long life Roof mounting for space savings and enhanced safety Multiple fuel burners for added flexibility EXHAUST STACK Chemical Btu/ Auto- LEL, UEL, lb* ignition vol.% vol. % temp, F Acetone 13, Acetylene 21, Acrolein 12, Acrylic acid 8, Acrylonitrile 13, Amyl alcohol 16, Benzene 18, Butane-N 21, Butyl alcohol 15, Carbon monoxide 3,984 1, Decane 20, Dichloro benzene Dichloro ethylene 1,1 Dodecane 20, Ethane 22, Ethyl acetate 10, Ethyl aceto- 10, acetate Ethyl alcohol 12, Ethylene 21, Ethylene glycol Ethylene oxide 12, Gasoline Heptane 20, Hexane 20, THERMAL OXIDIZER Chemical Btu/ Auto- LEL, UEL, lb* ignition vol.% vol. % temp, F Hydrocyanic acid 10, Hydrogen 61, Isoprene 19, Maleic anhydride Methyl ethyl ketone 14, Methyl alcohol Methyl iso-butyl 16, ketone Methyl N-butyl 16, ketone Methyl vinyl ketone 13, Mineral spirits Methane 23, Octane-N 20, Pentane-N 21, Petroleum ether Phenol 14, Phthalic anhydride Propane 21, Propyl acetate 14, Propyl alcohol 14, Propylene 21, Toluene 18, Vinyl acetate 10, Vinyl chloride Xylene 18, *Heat of combustion 24,000 SCFM thermal oxidation system for chemical processing application LADEN BURNER AS- SEMBLY Thermal and Catalytic Oxidizer Revamps How much energy are you wasting? Met-Pro Systems can tell you. Complete systems revamps for: Fuel Savings Stack Condensate Recovery Capacity Increases Emissions Improvements Heat Recovery PLC Programming Waste Heat Boilers Rapid Payback Replace/Recycle Catalyst Installations and Field Services MET-PRO SYSTEMS CAN MODIFY ANY MAKE OR MODEL OXIDIZER!

7 VOC Concentration Systems High efficiency removal of dilute solvents for high volume air emissions Met-Pro Systems unique activated carbon or zeolite rotary concentrators are used in applications that involve a combination of high volume of air with low concentration of solvents. The rotary concentrator reduces the solvent laden air flow by a factor of 10:1, thus minimizing the overall system size and operating costs. VOC concentrators can be combined with any Met-Pro Systems recovery or oxidation technology to create an advanced hybrid system that offers outstanding operating flexibility, performance and cost-effectiveness. Consider these advantages of Met-Pro Systems VOC concentrators: ROTARY CONCENTRATOR HOT INLET FILTER DILUTE LADEN Field-proven for hundreds of different applications Low operating and maintenance costs Small size, light weight for easy on-site installation Factory fabrication and testing CONCENTRATED IN TO OXIDIZER Automated controls speed and simplify operation Superior adsorbent life Wide flow range enhances system flexibility 100,000 SCFM concentrator for automotive paint spray booth application

8 Cost Effective Thermal and Catalytic Oxidizers This chart describes general operating parameters for Met-Pro Systems applications-matched emission control technologies. We ve included it here to provide a general overview for your planning considerations. We will be pleased to describe any of these data in detail to determine its suitability for your specific application. System Air Flow Range Solvent Loading (SCFM) (% LEL) Catalytic Oxidation , Thermal Oxidation , Regenerative Thermal Oxidizers 5,000-60, VOC Concentration Systems 5, ,000 <2 Met-Pro Systems fully integrated, turnkey system solution capabilities include system design, fabrication, training and support services from conception to completion. If desired, Met-Pro Systems can provide remote access monitoring for your entire system process via advanced telemetry links, with monitoring to predict routine maintenance as well as preventive maintenance schedules. How to get more information... Met-Pro Systems is a world class leader in advanced emission control systems capabilities. We can help you with your air pollution control requirements. To that end, we ll be pleased to provide additional technical data on any Met-Pro Systems application-matched emission control system or special capability to meet your requirements. To learn more, please contact us today. Two 210,000 BTU/hr. thermal oxidizers with waste heat boilers COPYRIGHT 2009 MET-PRO SYSTEMS SYSTEMS Thermal Oxidation A Met-Pro Product Recovery/Pollution Control Technologies Business 160 Cassell Road, Box 144, Harleysville, PA Phone: (215) , Fax: (215) ssales@met-pro.com,