Regenerative Thermal Oxidizers | Smart Modular System • DEC.RTO

Regenerative Thermal Oxidizers | VOC Emission Control
DEC.RTO_SMS™ | Smart Modular System

Regenerative Thermal Oxidizers (DEC.RTO_SMS™) are based on the award winning DEC modular platform (skid mounted, SMS™): a compact configuration of a Regenerative Thermal Oxidizer (DEC.RTO_CBS™). Unlike larger traditional RTOs requiring extensive on-site assembly, the compact RTO arrives fully integrated and rigorously tested, significantly reducing installation time and costs.

DEC.RTO_SMS™ represents a paradigm shift in Regenerative Thermal Oxidizer (RTO) technology, delivering unprecedented ease of deployment. This innovative, skid-mounted RTO is designed for rapid, single-truck delivery and immediate operation, minimizing downtime and maximizing environmental compliance.

The robust, self-contained skid platform provides a stable and easily positioned foundation, simplifying site preparation and minimizing footprint. The optimized design minimizes space requirements without compromising performance, making it ideal for facilities with limited space. The pre-fabricated nature of the unit consistently reduces the need for skilled labor on-site, lowering installation costs and minimizing disruption. Constructed with high-quality materials and engineered for demanding industrial environments, the DEC.RTO_SMS™ delivers reliable performance, making it the ideal solution for industries requiring efficient and rapid air purification.

how it works? • DEC.RTO_SMS™

In the RTO, multiple towers (or chambers) are used to achieve efficient and effective air pollution control: the exhaust gas flow is alternated between these towers, allowing for continuous operation; while one tower is used for the oxidation and removal of pollutants, the other tower(s) are undergoing a regeneration cycle to prepare for the next exhaust gas flow.

Inlet Phase: the contaminated solvent laden air (SLA) stream enters the RTO through an inlet duct, and a valve directs the flow into one of the ceramic honeycomb beds.

Preheating Phase: the incoming air passes through the heated ceramic channels (honeycomb), where the thermal energy from the hot exhaust gases is transferred to the incoming air stream. This preheating step helps in reducing the energy consumption of the system.

Combustion Phase: the preheated air stream enters the combustion chamber, where it is further heated to the required temperature (typically between 815°C and 980°C); in the presence of oxygen, the VOCs and other pollutants in the air stream undergo combustion, converting them into carbon dioxide (CO₂) and water vapor (H₂O).

Exhaust Phase: the hot, purified air stream exits the combustion chamber and passes through the outlet duct; at the same time, a valve directs the flow into another ceramic honeycomb bed.

Thermal Energy Recovery: the incoming air stream absorbs the thermal energy stored in the ceramic honeycomb bed, which helps in preheating the next batch of contaminated air; this heat exchange process is crucial for the high energy efficiency of RTOs.

This alternating process allows for energy recovery within the DEC.RTO_SMS™ system: the hot exhaust gases leaving the combustion chamber are passed through a ceramic heat exchanger, known as the "regenerator", in the tower undergoing the regeneration cycle. The regenerator absorbs the heat from the exhaust gases and stores it. During the next cycle, the stored heat is transferred to the incoming cold exhaust gases, reducing the energy consumption of the system.

The use of multiple towers in the DEC.RTO™ system provides several advantages, including improved operational efficiency, reduced energy consumption, and continuous operation. It allows for a consistent and reliable treatment of industrial exhaust gases while optimizing the use of energy resources.

oxidation reaction • DEC.RTO_SMS™

The oxidation reaction is:

VOCs (C_xH_yO_z) + O₂ + thermal energy = CO₂ + H₂O + (HEAT)

The heat is usually recovered to pre-heat the SLA stream, in order to save on "thermal energy" (provided through gas CH₄ - methane); if producing extra heat through oxidation of solvents, an energy recovery system shall be foreseen (typical applications are ranging from heating up air for dryers, steam production, heat tranfer fluid heating, water heating - industrial or sanitary, etc.).

In a skid mounted Regenerative Thermal Oxidizer (RTO_SMS) with multiple towers, the VOCs are oxidized in the combustion chamber. The hot gas released from the combustion chamber contains thermal energy. This thermal energy is accumulated through the ceramic media bed in one tower, allowing the hot gas to cool down as it exchanges thermal energy. The cooled gas is then discharged through the stack (FGS).

The process of accumulating and exchanging thermal energy in the ceramic media bed is called regenerative: this process allows the RTO to operate at the highesr efficiency, drastically reducing the amount of energy required to heat the incoming solvent laden air gas.

Thanks to the specifically designed switching valves, the flow is alternatively reversed: thermal energy is recovered and the flow, in the following cycle, is pre-heated; this cycle is efficiently reducing the auxiliary support fuel requirement, with self-sustaining operation (with no auxiliary support fuel usage) even at low concentrations, thus representing an operational cost reduction.

RTOs with multiple towers can operate at a higher efficiency than Direct Thermal Oxidizers (DTO™): the regenerative process allows the RTO to recover heat from the outgoing gas, which can then be used to pre-heat the incoming gas, resulting in lower fuel consumptions.

modular platform for Regenerative Thermal Oxidizer • DEC.RTO_SMS™

The DEC.RTO_SMS™ Smart Modular System is made up of a series of pre-engineered modules that can be arranged in different limitless configurations: this allows you to choose the configuration that best meets your needs in terms of capacity, solvent type, and recovery efficiency.

compact layout for modular Regenerative Thermal Oxidizer • DEC.RTO_SMS™

The DEC.RTO_SMS™ Smart Modular System's compact and modular design significantly reduces its footprint, making it exceptionally well-suited for industrial environments with limited space availability. Its adaptability not only optimizes valuable real estate within factories but also streamlines the path to construction permits, enabling faster deployment and reduced overall project costs, while minimizing project timelines.

main advantages of a modular Regenerative Thermal Oxidizer

Standardized Layouts: flexible module configurations adapt to various site conditions, minimizing the need for specifc custom designs and simplifying installation planning.

Reduced Engineering Time: pre-assembled skids streamline engineering, requiring only utility connections.

Minimized Civil Works: modular skids on dedicated frames reduce on-site construction needs, often limited to technical rooms.

Faster On-Site Assembly: workshop pre-assembly minimizes on-site work, reducing risks and delays from weather or mobility limitations.

Enhanced Product Quality: modular construction with pre-engineered components minimizes errors and simplifies quality control.

Transferable: easily relocate the modular plant to different industrial settings.

Easy Capacity Expansion: simply add modules/skids for future limitless upgrades, without disrupting existing operations.

Standardized Spare Parts: pre-engineered modular skids and appliances simplify spare parts management.

Energy Recovery at its best: recover and share thermal energy to save fuel, (DEC.WHR™).

Reduced Utility Needs: smaller modules reduce heat dissipation and utility demands, even with future expansion in mind.

Hot Gas Bypass module | DEC.HGB™ • DEC.RTO_SMS™

In case of peaks of concentration, in order for the RTO to correctly perform its duties, to prevent overheating (or oxidation to occur in the ceramic media), the system can be equipped of an automatic hot-gas bypass. The DEC.HGB™ diverts a portion of the hot gases directly from the combustion chamber, bypassing the ceramic media beds.

As the concentration of volatile organic compounds (VOCs) in the incoming stream increases, the combustion chamber temperature rises due to the additional heat generated by the combustion process. When the temperature reaches a pre-set safety limit, the DEC.HGB™ module is automatically enabled, allowing a portion of the hot exhaust gases, to directly bypass the ceramic media beds and exit to the exhaust stack (FGS). By diverting the hot gases, the DEC.HGB™ module safeguards the ceramic media from exposure to excessively high temperatures. This is crucial because the media plays a vital role in preheating the incoming air stream and maintaining the overall efficiency of the RTO.

The DEC.HGB™ components directly exposed to the high-temperature exhaust gases (around 900°C) are typically constructed from special high-grade materials like Stainless Steel or Inconel.

In essence, the DEC.HGB™ module acts as a safety mechanism and a way to optimize RTO performance. It prevents damage to the ceramic media while ensuring the RTO can continue to function effectively even during abnormal or unexpected spikes in VOC concentration.

Waste Heat Recovery module | DEC.WHR™ • DEC.RTO_SMS™

When the process conditions allows (e.g. when VOC in the emission stream reaches higher than normal), and the DEC.HGB™ module is installed, the diverted hot stream, can be used for beneficial purposes. DEC.WHR™ module acts as a secondary heat recovery.

Waste To Energy module | DEC.WTE™ • DEC.RTO_SMS™

Thanks to the optional DEC.WTE™ module, by utilizing the solvent waste as "alternative" fuel in the RTO, the system requires less external fuel to maintain the oxidation temperature. Instead of paying for solvent waste disposal, the facility can utilize it as a fuel integrative source, potentially creating a cost-saving opportunity.

Flameless Oxidation • DEC.e-RTO_SMS™

The flameless DEC.e-RTO_SMS™ operates on a similar principle to its combustion-based counterpart, but without the use of an open flame and auxiliary support fuel. Instead, electric heating elements provide the thermal auxiliary energy required to oxidize contaminants (VOCs).

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thermal oxidation | incinerators • GHG and by-products

Whenever you have to face a non-recoverable stream of VOCs, a XTO™ • thermal oxidizer could be the solution: sometimes the VOC stream composition may result too complex to be recovered or the quantity of solvents is not interesting to go for a SRU™ • solvent recovery units.

An oxidizer is handling the transformation of the pollutant(s) into different products, with a reduced environmental impact. However, it is important to consider the resulting GHG emissions, when selecting a VOC oxidizer; the amount of GHGs generated by a thermal oxidizer depends on the type of VOCs being treated, its quantity, the needed quantity of fuel to be added for sustaining the oxidation reaction and the selected oxidizer process configuration.

Any oxidizer will have to deal with all or most of the following issues:

VOCs emission (= non complete oxidation);

CO₂ emission (= GHG, possible taxation);

CO emission (= GHG, non complete oxidation);

NO_x emission (= nitrogen oxides, as a result of N₂ presence);

N₂O emission (= nitrous oxide);

Dioxin emission (as a result of possible chlorinated compounds );

High temperature emission (as a result of non complete thermal energy recovery).

These emissions contribute to climate change and should be taken into account when assessing the overall environmental impact of the system.

As mentioned earlier, oxidizers typically require a significant amount of energy to operate: if this energy comes from non-renewable or carbon-intensive sources, it will dramatically contribute to environmental degradation and offset any of the potential benefits of VOC emission reduction.

thermal oxidation | incinerators • greenwashing

Greenwashing will occur when a company promotes an oxidizer as an environmentally friendly or sustainable technology for VOC emissions control, while neglecting to address other significant negative aspects of its environmental impact, such as greenhouse gas (GHG) emissions and harmful by-products.

Greenwashing can happen when a company portrays an oxidizer as a comprehensive and eco-friendly solution to VOC emissions, creating the perception that it is a sustainable option without considering the complete environmental picture. While oxidizers can help reduce VOC emissions, they can have negative consequences that should not be overlooked.

To avoid greenwashing, companies shall provide transparent and comprehensive information about the environmental impact of their VOC emission control systems: this includes addressing greenhouse gas (GHG) emissions, harmful by-products, and the energy efficiency of the system. By doing so, companies can ensure that consumers have an accurate understanding of the technology's environmental implications and make informed decisions.