GeoTherm II RTO and GeoCat II RCO

GeoTherm II RTO and GeoCatII RCO

The GeoTherm® II RTO provides the highest performance possible to maximize the collection efficiency, minimize maintenance requirements, and provide the protection necessary for trouble-free operation of the emission control systems.

Thermal oxidizers have been used for air pollution control for many decades and are the most reliable technology for the destruction of Volatile Organic Compounds (VOCs), Hazardous Air Pollutants (HAPs), and to some degree odor. Oxidizers come in many different sizes, shapes, and configurations but all operate on the same basic principal of thermal oxidation.

The most common oxidizer type in the marketplace today is the Regenerative Thermal Oxidizer (RTO). It is the preferred oxidizer technology for most applications due to its high destruction efficiencies and its ability to recover most of the thermal heat that is generated for the destruction of VOCs and HAPs.

RTO Basics

An RTO operates based upon two processes: chemical thermal process and mechanical process. The chemical thermal process of an RTO is the application of heat to a process exhaust stream that contains pollutants (VOCs and HAPs), which are usually hydrocarbon based.

The application of heat to a process exhaust stream will oxidize the pollutants from their initial chemical formula into two very simple inert compounds; CO2 and H2O.

Examples of typical hydrocarbon compounds:

Chemical Name

Acetal
Acetone
Benzene
Butanol
Cyclohexanol
Formaldehyde
Heptane
Isopentane

Formula

C6H14O2
C3H6O
C6H6
C4H10O
C6H12O
CH2O
C7H16
C5H12

Examples of Conversion of VOC to inert compounds:

Formaldehyde:
Heptane:
Hexane:

CH2O + O2 CO2 + H2O
C7H16 + O2 7CO2 + 8H2O
2C6H14 + 19O2 12CO2 + 14H2O

RTO Basics

An RTO operates based upon two processes: chemical thermal process and mechanical process. The chemical thermal process of an RTO is the application of heat to a process exhaust stream that contains pollutants (VOCs and HAPs), which are usually hydrocarbon based.

The application of heat to a process exhaust stream will oxidize the pollutants from their initial chemical formula into two very simple inert compounds; CO2 and H2O.

Examples of typical hydrocarbon compounds:

Chemical Name: Acetal
Formula: C6H14O2


Chemical Name: Acetone
Formula: C3H6O


Chemical Name: Benzene
Formula: C6H6


Chemical Name: Butanol
Formula: C4H10O


Chemical Name: Cyclohexanol
Formula: C6H12O


Chemical Name: Formaldehyde
Formula: CH2O


Chemical Name: Heptane
Formula: C7H16


Chemical Name: Isopentane
Formula: C5H12


Examples of Conversion of VOC to inert compounds:

Formaldehyde:
CH2O + O2 –> CO2 + H2O

Heptane:

C7H16 + O2 –> 7CO2 + 8H2O

Hexane:

2C6H14 + 19O2 –> 12CO2 + 14H2O

RTO Destruction Efficiency of 95-99%
Thermal Efficiencies +97%
Most Efficient Technology for VOC Abatement

RTO Operation ProcessCO2 and H2O coming out of a process exhaust stack can be identified by its white plume.  This white plume indicates that the CO2 and H2O rapidly become a cool water vapor.  A white color exhaust plume is a good sign.

The RTO mechanical process operates on the premise of alternating air flow through multiple “beds” of ceramic heat exchange media.  The inlet air is first drawn into the system and up through the inlet bed whereby it is pre-heated via ceramic heat media.  As the process exhaust air moves up through the ceramic media, it draws heat from the material reaching temperatures of 1400°F to 1475°F.  The process exhaust air then enters the combustion chamber where a burner management system (typically natural gas fired) is operating to increase the air temperature to 1500°F to 1750°F.

CO2 and H2O coming out of a process exhaust stack can be identified by its white plume.  This white plume indicates that the CO2 and H2O rapidly become a cool water vapor.  A white color exhaust plume is a good sign.

The RTO mechanical process operates on the premise of alternating air flow through multiple “beds” of ceramic heat exchange media.  The inlet air is first drawn into the system and up through the inlet bed whereby it is pre-heated via ceramic heat media.  As the process exhaust air moves up through the ceramic media, it draws heat from the material reaching temperatures of 1400°F to 1475°F.  The process exhaust air then enters the combustion chamber where a burner management system (typically natural gas fired) is operating to increase the air temperature to 1500°F to 1750°F.

This temperature is referred to as Combustion Chamber Set Point and is proven to be the point whereby nearly all VOC and HAP compounds are destroyed or converted to CO2 and H2O.  At this point the process air, now cleaned of contaminants and heated, is directed downward through the outlet bed.  The gas at the combustion chamber temperature relinquishes its heat to the ceramic media as it travels downward through the outlet bed.

After a two to three minute period, the RTO cycles whereby the valves reverse the airflow through the system.  As the RTO valves cycles the inlet and outlet beds switch operation (see above), this process is continuous every two to three minutes while in operation. This process is what is referred to as a Regenerative thermal process.

This temperature is referred to as Combustion Chamber Set Point and is proven to be the point whereby nearly all VOC and HAP compounds are destroyed or converted to CO2 and H2O.  At this point the process air, now cleaned of contaminants and heated, is directed downward through the outlet bed.  The gas at the combustion chamber temperature relinquishes its heat to the ceramic media as it travels downward through the outlet bed.

After a two to three minute period, the RTO cycles whereby the valves reverse the airflow through the system.  As the RTO valves cycles the inlet and outlet beds switch operation (see above), this process is continuous every two to three minutes while in operation. This process is what is referred to as a Regenerative thermal process.

This thermal process initiated through the cycling of the RTO valve system is typically referred to as Thermal Efficiency Recovery (TER) and is one of the key aspects of the RTO system.  This regenerative process allows for a very high percentage of heat recovery and is rated based upon the percent of heat recovered.  Typical TER values of the RTO will be in the 95-97% range.

The main purpose of an RTO is the destruction of VOCs and HAPs which is referred to as its Destruction Requirement Efficiency (DRE).  DRE is the percentage of VOCs / HAPs that are destroyed in the RTO. The DRE is determined by measuring the inlet concentration to the outlet concentration, typically in parts-per-million (ppm).  Most RTOs are designed to achieve 95%-99% DRE.

GeoTherm® II RTO

The GeoTherm® II RTO system is a state of the art air pollution control device that has been used successfully for over 20 years for the removal of VOCs and HAPs from multiple industrial applications.

The GeoTherm® II RTO uses multiple poppet-style diverter valves located at ground level to control the direction of flow through the RTO unit. These valves act together to direct the gas stream into and out of heat recovery chambers located directly above each valve.

Poppet Valve Design

Simple, fast-acting poppet valve design

The GeoTherm® II RTO system is a state of the art air pollution control device that has been used successfully for over 20 years for the removal of VOCs and HAPs from multiple industrial applications.

The GeoTherm® II RTO uses multiple poppet-style diverter valves located at ground level to control the direction of flow through the RTO unit. These valves act together to direct the gas stream into and out of heat recovery chambers located directly above each valve.

Poppet Valve Design

Simple, fast-acting poppet valve design

Features

This simple design results in the important operating and maintenance features described below:

Resistance to Organic Buildup – This feature is particularly important for gas streams containing condensable organics. Because the valve disk is heated by the outlet gas stream during each valve cycle, the valve is always hotter than the temperature of the inlet gas stream. This prevents condensation of organic compounds that buildup on the valves and seats.

Resistance to Solids Accumulation – With the valve disk and valve seat located approximately eight (8) inches above the floor of the housing, the unlikely occurrence of heavy deposits of solids do not interfere with the function of the valve.

Resistance to Deformation of Valve or Seat – Since the valve disk seats in both directions (on both the inlet and outlet seats), the disk will not take a permanent set from seating in only one (1) direction.

GeoTherm® II RTO System Benefits

  • 95 to 97% thermal efficiency (TER)
  • Up to 99% destruction efficiency (DRE)
  • Customized Ceramic Media Bed Configuration – plugging / chemical corrosion resistant
  • Simple, fast-acting poppet valve design
  • Resists condensation of organics on the poppet valve – valve remains hotter than the inlet gas stream, remaining free of buildup
  • Minimal moving parts per Heat Recovery Chamber (HRC) – Only one (1) poppet valve per HRC, i.e., only two (2) valves per RTO

GeoTherm® II RTO System Benefits

  • 95 to 97% thermal efficiency (TER)
  • Up to 99% destruction efficiency (DRE)
  • Customized Ceramic Media Bed Configuration – plugging / chemical corrosion resistant
  • Simple, fast-acting poppet valve design
  • Resists condensation of organics on the poppet valve – valve remains hotter than the inlet gas stream, remaining free of buildup
  • Minimal moving parts per Heat Recovery Chamber (HRC) – Only one (1) poppet valve per HRC, i.e., only two (2) valves per RTO

Industries Served

  • Carbon Fiber
  • Chemical Manufacturing
  • Pharmaceutical
  • Automotive
  • Petrochemical
  • Foundry
  • Styrene
  • Waste Water Treatment
  • Printing & Flexography
  • Flooring
  • Pulp & Paper
  • Rendering
  • Ethanol
  • Oil & Gas
  • Semiconductor
  • Engineered Wood Products
  • Fiber Manufacturing
  • Fiberglass/Mineral Wood Insulation
  • Surface Finishing/Coating

Industries Served

  • Carbon Fiber
  • Chemical Manufacturing
  • Pharmaceutical
  • Automotive
  • Petrochemical
  • Foundry
  • Styrene
  • Waste Water Treatment
  • Printing & Flexography
  • Flooring
  • Fiber Manufacturing
  • Pulp & Paper
  • Rendering
  • Ethanol
  • Engineered Wood Products
  • Oil & Gas
  • Fiberglass/Mineral Wood Insulation
  • Surface Finishing/Coating
  • Semiconductor

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Dustex - Clean Air Technologies

Dustex is a global supplier of engineered systems that reduce air emissions and improve operational efficiencies. We are at the forefront of engineered solutions for clean air technologies with an exceptional and experienced staff. Our outstanding service combined with our wide breadth of technology allows us to provide practical and economical solutions for our customers that fit their unique needs.

 

Contact Details

Dustex - Clean Air Technologies

Corporate Office

60 Chastain Center Blvd NW, Ste 60
Kennesaw, GA 30144 USA

Send us a message

Dustex is a global supplier of engineered systems that reduce air emissions and improve operational efficiencies. We are at the forefront of engineered solutions for clean air technologies with an exceptional and experienced staff. Our outstanding service combined with our wide breadth of technology allows us to provide practical and economical solutions for our customers that fit their unique needs.

Contact Details

Corporate Office 
60 Chastain Center Blvd NW, Ste 60
Kennesaw, GA 30144 USA

info@dustex.com

770-429-5575

Send us a message

© 2018 Dustex - Clean Air Technologies. All Rights Reserved.

EPA regulations support or require NOx control installations to achieve the lowest emissions level possible. Two of the solutions for post-combustion control systems are Selective Non-Catalytic Reduction (SNCR) and Selective Catalytic Reduction (SCR).   Both are of the most cost-effective and fuel-efficient technologies used to reduce stationary source emissions. Utilizing our field experience and injection technology, Dustex offers complete SCR and SNCR NOx control systems for various plants. State-of-the-art design, simulation, and technology ensure advantages with results that will surpass your requirements and meet guarantees.

© 2018 Dustex - Clean Air Technologies. All Rights Reserved.