With the rise of passive energy technologies, companies formerly using huge amounts of energy and barely controlling emissions are quickly becoming the major players in efficiency and environmental responsibility. While upfront costs may appear daunting, several manufacturers have come to see the huge potential for investment in energy recovery technology. Through the use of energy recovery and regenerative energy sources, industrial concerns are able to save money, cut energy use and through scale offer the greatest positive impact to the environment.

Heat Recovery Steam Generators (HRSGs) are among the most exciting passive energy recovery technologies that have swept through manufacturing. Plants which used heat in the production process – think steel mills – formerly took huge pains to vent that heat from a plant. Now, manufacturers are looking to trap heat from the manufacturing process in order to create steam for on-site generators. In many instances, excess heat from a production process can provide enough energy through a HRSG to power an entire plant and create a surplus for the outbound power grid.

It is one thing to hope that a manufacturer could cut its power consumption, but few people thought it possible to contribute to the power grid through production. That’s one of the giant benefits of passive energy technology.

Another passive technology offers both energy savings and pollution controls. Regenerative catalytic oxidizers – or RCO – give manufacturers the ability to destroy volatile organic compounds (VOCs) created during the production of fuels, pesticides and paints. Formerly, this process required burners operating at nearly 1,000 degrees Celsius to destroy VOCs while burning off a ton of fuel. But with the RCO technology, those compounds are blown through a catalyst bed to transform them into sub-compounds that can be destroyed at much lower temperatures. The drop in temperature, and resulting drop in fuel, creates a huge saving in fuel and money.

The regenerative nature of an RCO also means the heat passing through the system is returned to an exchanger to keep the ambient temperatures inside the reaction chamber at a constant level without additional burning. Once the device is heated, it typically needs very little in the way of fuel to maintain an operational temperature, again saving fuel and money.

And RCO technology is nearly without maintenance. The only time a manufacturer would seek regenerative thermal oxidizer repair is in the flow control valves for gases, or to replace the components of the catalyst bed. Also, some maintenance for fouling, the deposits from the VOCs, may call for regenerative thermal oxidizer repair.

Through the use of heat exchange, energy is saved, fuel is conserved, money stays in the bank and the air gets cleaner.

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Operators looking to maintain the efficiency and safety of thermal oxidizing equipment for pollution control are best served finding a trusted service partner. Emission control engineers and regenerative thermal oxidizer technicians have specific experience in managing the service and repair of oxidizer equipment. Finding and fixing points of stress, these professionals preserve the operational efficiency for industrial enterprises destroying volatile organic compounds (VOCs) through the use of regenerative thermal oxidation. Operators can rely on the maintenance plans developed by regenerative thermal oxidizer technicians to keep plants running safely, productively and profitably.

The first priority of regenerative thermal oxidizer technicians and engineers is to protect the safety of plant employees. Through continuous exposure to corrosive gas and extreme heat in the destruction process of VOCs, regenerative thermal oxidizers can pose a major safety risk with only minor exterior evidence of malfunction. Trained technicians expertly evaluate and easily diagnosis these problems well before they cause a safety concern. Early detection and correction keeps plants safe.

Closely aligned with safety is the continued efficiency of thermal oxidizer equipment. Regenerative thermal oxidizers rely on well-maintained heat-recovery systems to efficiently destroy VOCs in the emissions stream. Moreover, the management of the waste stream and accurate monitoring of VOC loads is crucial to operations. Experienced regenerative thermal oxidizer technicians can wring the most efficiency from operational controls with updated materials and tuning equipment to fit custom applications.

Partnering with trusted regenerative thermal oxidizer technicians should include developing and executing a custom preventative maintenance plan. Avoiding emergencies – with the associated high cost of urgent service and downtime – is the best investment a plant manager can make. With planning and commitment, expert technicians can save huge expenses. With careful implementation and monitoring, operators can leverage decades of use out of these pieces of equipment despite constant abuse.

Experienced regenerative thermal oxidizer technicians preserve safety and efficiency of pollution controls for any operator. From planning and appraisal, through scheduled maintenance, these professionals are the frontline to continued operational capacity.

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Saving costs while ramping up efficiency is the goal of any project integrating regenerative thermal oxidizer products into air pollution controls. With designs able to capture up to 96 percent of operational heat, regenerative oxidizers are among the most economical, efficient means of destroying volatile organic compounds (VOCs) in air pollutant emissions. By saving supplementary fuel, these emissions control devices aid the environment while scrubbing out hazardous air pollutants (HAPs) from industrial exhaust.

Regenerative thermal oxidizer products diminish operational expense while maintaining nearly perfect VOC destruction capability. Stoneware beds retain heat from the oxidation process in a combustion chamber – in some cases requiring zero supplemental fuel when VOC levels are high enough to act as a fuel source on their own. This self-sustaining process relies on precision equipment and monitoring. Understanding the flow of emissions, adjusting temperatures in a combustion chamber to fit those needs and carefully documenting all processes are each steps in achieving consistent operation.

Consistent and efficient operation of regenerative thermal oxidizer products not only aids the environment with VOC and HAP destruction, but also keeps operators in regulatory compliance. With myriad regulations for air quality standards at the federal, state and municipal levels, these thermal oxidizer products keep plant managers in perfect step with legislation. By destroying nearly 100 percent of all HAPs in a waste stream, operators avoid conflict and expense with regulators. Not only are fines avoided, but resulting legal implications and possible forced downtime is sidestepped in one easy purchase.

Regenerative thermal oxidizer products installed and maintained by experts also protects the safety of operator employees. Operating in excess of 900 degrees Fahrenheit, there is no room for error with thermal oxidizer safety measures. With the right maintenance partner or installation consultant, regenerative thermal oxidizer products operate safely for decades at a time.

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Air pollution controls were not invented with the introduction of regenerative thermal oxidizer equipment, but these precision devices revolutionized the efficiency and cost impact of keeping industrial emissions free of hazardous air pollutants. Regenerative thermal oxidizers came into vogue with operators looking to conserve heat energy expended through direct combustion of volatile organic compounds (VOCs). This early pollution control process, introduced following the Clean Air Act Amendments of 1970, used vast amounts of supplemental fuel, costing a great deal and adding undo energy consumption to the pollution control process. Regenerative thermal oxidizer equipment improved energy efficiency so radically that in some cases it curtailed the use of supplemental fuel all together.

The solution provided by regenerative thermal oxidizer equipment is fairly simple, but requires understanding of the oxidation reaction process. A stream of VOC-laden emissions from industrial processes enters a chamber containing a heated stoneware bed. As the gas heats and rises, it approaches oxidization temperature. It then enters a combustion chamber where a small jet of heat may be applied to destroy the pre-heated VOCs in the gas. A valve opens, releasing the gas into a second stoneware chamber, heating the ceramic bed as the gas sinks while cooling. The entire stream, now void of VOCs and hazardous air pollutants (HAPs) exits as carbon dioxide. A new valve opens, allowing more VOC loaded gas to enter the freshly heated second stoneware bed, before starting the cycle in reverse across the combustion process.

This regenerative technique has profound implications on the efficiency and cost of industrial emissions controls. With the use of regenerative thermal oxidizer equipment, operators save up to 96% in normal operating conditions on supplemental fuel use – the major ongoing operating expense with traditional direct-fired oxidizer units. At the same time, the VOC and HAP destruction rate stays at nearly 100 percent, assuring compliance. While a larger capital investment at purchase, fuel savings alone over the course of 10 or more years of service assures that regenerative thermal oxidizer equipment is among the best investments for pollution controls.

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Solid planning and habitual monitoring are key strategies to saving huge costs on regenerative thermal oxidizer maintenance. Thermal oxidizing equipment relies on precision monitoring and valve equipment to insure complete efficiency; along with well-maintained stoneware beds to retain heat energy. Finding a technical partner to guide you through the creation of a routine maintenance schedule will save time and money by early avoidance of costly repairs and outages. Managing regenerative thermal oxidizer maintenance side steps emergency measures, keeping operators in compliance and worry-free.

Regenerative thermal oxidizer maintenance requires access to, and expert familiarity with, a number of components specific to these devices. Valve systems, with timed and complicated moving parts, are one source of failure that requires constant scrutiny. Stoneware beds used in capturing heat energy can be fouled from constant exposure to corrosive compounds and high heats, diminishing their efficiency. These components are designed for years of service under stress, but only to the extent experts in regenerative thermal oxidizer maintenance monitor them for failure.

The solution is easy. Operators team with consultants and expert technicians versed in the specific repair of thermal oxidizers to develop a routine maintenance plan. These partnerships assure quality service and keep parts on hand to quickly handle any regenerative thermal oxidizer maintenance issue. With routine maintenance and planned downtime, the lifetime efficiency of a thermal oxidizing unit actually climbs. Avoiding emergency outages is what keeps operators in compliance and out of the red with rushed repairs.

Operators can save themselves time and money with planned regenerative thermal oxidizer repair and partnerships with expert technicians. Otherwise, the integrity, and even safety, of their air pollution control systems may be put into jeopardy. Making the upfront investment in scheduled service pays big dividends over time.

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Not every operator can make a large upfront capital expense in new equipment, but still want the long-term cost savings of regenerative technology for their industrial air pollution controls. Thankfully, with the guidance of expert engineers and technicians, it is possible to purchase used regenerative thermal oxidizer units with the same reliability, efficiency and cost savings as a new or custom installation. By partnering with a firm deep in experience with regenerative thermal oxidizers, operators can extract the benefit without the worry of purchasing substandard or overworked devices. It’s a win-win situation for every party involved.

The first step in finding a used regenerative thermal oxidizer would come in planning and consultation to make sure this solution fits an operator’s business. While used thermal oxidizers could present a tremendous value, the use of certain models relies on the flow of VOCs, placement, heat generation and a number of other factors. Should the application be a fit for models available on the market, an operator’s consulting partner then helps in negotiating a fair price based on the hours of use, fouling and any retrofitting required to move the model into a new application.

Once onsite, a used regenerative thermal oxidizer requires the aid of expert technicians for installation and tuning to a specific application. In some cases, modifications with custom fabricated parts are also necessary. Only engineers experienced in emissions flow, VOC and HAP loads, and specific combustion capabilities should plan and execute a retrofit. Once the tuning and installation are complete, the employees and onsite engineers are trained in the management of the device. As well, a routine maintenance plan is developed and parts are ordered for onsite replacement in the event of an emergency malfunction.

Value can easily be extracted from used regenerative thermal oxidizer equipment, but only with the guidance of experience professionals. Operators can find partners to help them unlock this money saving technology without a giant purchase expense.

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Rotor concentrators employ rotary technology in combination with thermal and catalytic oxidizers to reduce physical size, energy use and recurring costs. For operators with high volumes of exhaust flow with low concentrations of volatile organic compounds (VOCs), these purified air concentrators can significantly reduce operating expenses while making more efficient use of valuable space in the plant environment.

Rotating concentrators provide a continuous stream of highly concentrated VOC-laden air to reduce the dependence on supplemental fuel during thermal oxidation. The process of concentration begins with a high volume of air with a low VOC concentration passing through a rotating absorption bed, releasing purified air as exhaust. The trapped VOCs rotate through the purified air concentrators to a separate stream where they are released in a desorption process. The VOCs are kept in higher concentrations by a constant, low-volume flow of heated air. The oxidizer abates the remaining hazardous air pollutants.

The high concentrations of VOCs reduce expense by lowering operating temperatures along with the need for supplemental fuel. Each specific client application receives absorption materials custom-designed to meet the unique needs for the waste stream. A fully integrated control system – including computer-assisted control panels and field bus integration – are included for each rotor concentrators. Clients receive proprietary design and custom materials for exceptional quality.

Purified air concentrators employ compact, skid-mounted designs to save space and ease installation. The units are easily expandable, in contrast to more expensive fixed designs. The simple, continuous design reduces the opportunity for malfunction, corrosion potential in the media and risk for fire. These advantages of rotor concentrators in combination with thermal oxidizers are completed with VOC destruction rates and initial capital expense comparable to fixed design units.

For more information about rotor concentrators in combination with our thermal oxidizer products, please contact the expert staff at Combustion Controls Solution & Environmental Services.

Control of toxic nitrogen oxides (NOx) calls for selective catalytic reduction systems (SCR). This air pollution control technology blends the exhaust waste streams with a reagent chemical – anhydrous ammonia, aqueous ammonia or urea – before passing the combination over a catalyst bed. Total NOx reduction takes place in the SCR systems through the resulting chemical reaction, transforming the previously hazardous air pollutants into harmless water and nitrogen.

This reduction chemistry is at the heart of selective catalytic reduction systems NOx control for particulate emission. Using either anhydrous ammonia or aqueous ammonia as the reagent chemical, the process can be expressed through the following equations:

4NO + 4NH3 + O2 → 4N2 + 6H2O
2NO2 + 4NH3 + O2 → 3N2 + 6H2O
NO + NO2 + 2NH3 → 2N2 + 3H2O

The use of urea as the reagent chemical for SCR Systems is expressed in the following equation:

4NO + 2(NH2)2CO + O2 → 4N2 + 4H2O + 2CO2

NOx control through selective catalytic reduction systems requires close attention to design and implementation of the SCR catalyst. The three fundamental elements of the design – proper size, composition and space velocity – take into account the ideal operating temperature range, the viscosity of the reagent chemical mixture, and the carefully estimated flow of NOx for abatement.

The design of SCR systems also rigorously controls the flow of ammonia to meet environmental requirements. The exacting standards and tuning of selective catalytic reduction systems are essential in meeting the specific requirements for each unique application.

All NOx control systems and stores of prepared reagent chemicals are fully integrated into all plant operations. Monitoring for the ideal reaction temperatures – between 440.33-836.33 degrees Fahrenheit depending on residence time – is easily maintained with integrated controls. Minimum temperatures required for the catalytic reaction to assure NOx control and compliance remains dependant on fuel types and catalyst geometry.

SCR systems are often used in conjunction with regenerative and recuperative thermal oxidizers to form a completely integrated air pollution control solution.

Contact the experts in selective catalytic reduction system design and implementation at Combustion Controls Solutions & Environmental Services today for a consultation.

Custom designed for high quality

Gas flares custom designed and manufactured by Combustion Controls Solutions and Environmental Services offer high-quality and efficient pollution controls for emissions from landfills. Waste gas from landfills – including methane and other HAPs – can be safely and efficiently abated using our custom designed gas flares.

Each of the over 1,000 waste gas flares we installed met or exceeded regulatory standards for ultra-high destruction efficiency. Furthermore, CCS&ES waste gas flares for landfills automatically monitor and respond to the ever-changing composition and flow rates inherent to the chaotic operating environment of a landfill.

Custom-designed waste gas flares from CCS&ES employ compact, skid-mounted designs to save space and ease installation. Each of our gas flares are made to fit unique absorption media specifications in order to maintain high destruction efficiency of hazardous air pollutants under the changing operating environment of a landfill. All of our waste gas flares are fitted with a fully integrated control system for clear and easy continuous monitoring. Our gas flares include complete field bus integration.

All CCS&ES gas flares are designed and engineered with proprietary materials to produce products of exceptional quality. Meet or exceed regulatory compliance for air pollution controls for decades to come with our unique installations.

Contact the experts at CCS&ES today for complete information on the value and quality available in our custom designed waste gas flares.

The purchase of a used thermal oxidizer gives operators looking to expand their air pollution controls a great option for long-term value and cost savings. By lowering the upfront capital expense, ownership and plant managers can account for the investment in these thermal oxidizer products and their lower operating costs, even during harsh economic conditions. However, navigating the specifics of the secondary market for a used thermal oxidizer can prove challenging to even the most technically educated operator.

CCS&ES takes the guesswork out of purchasing a used thermal oxidizer. Our expert engineers and technicians reliably rebuild each certified pre-owned thermal oxidizer system – assuring operators of all the benefits offered by the highest quality air pollution controls with lower upfront and continued operating costs. Designed for decades of use, used thermal oxidizer units require careful attention and consultation for purchase to provide this exceptional value.

CCS&ES also enhances each certified pre-owned thermal oxidizer system with advanced retrofits to incorporate the latest upgrades in thermal oxidizer technology. CCS&ES used thermal oxidizers surpass all MACT, RACT and BACT Standards to assure continued regulatory compliance for plant operators. Like all thermal oxidizers offered, used units can claim VOC and HAP abatement of up to 99.99 percent.

Each used thermal oxidizers undergoes a thorough 250 point inspection to correct even the most minute flaws in a pre-owned oxidizer. All component upgrades – including new recuperative, regenerative or catalytic media depending on the type of used thermal oxidizer – are included in the purchase price. Special attention to complex systems such as valves and heat exchange saves operators time and money.

CCS&ES provides a complete operational history, including the original date of purchase and hours of operation, for each used thermal oxidizer sold. Complete documentation of mechanical and electrical specifications is also available. Each certified pre-owned thermal oxidizer system is sold with a standard 5-year warranty, with the opportunity to purchase a warranty extension available. Consultation, engineering and installation services for custom implementation of a used thermal oxidizer are also available.

Contact the experts at CCS&ES today for complete information on the value and reliability available in a used thermal oxidizer.