Dürr can revamp or upgrade your oxidizer to optimize its efficiency and performance, saving you energy costs and increasing reliability.
The pressure drop associated with the random-packed heat exchange media originally used in older RTOs is very high when compared to today’s structured media. By replacing the random-packed media with structured media, the pressure drop across the unit is reduced, thus increasing flow capacity.
Replacing media can also mean reduced operating cost and improved thermal efficiency. Lowering the pressure drop across the oxidizer at its original rated capacity causes the exhaust fan to operate at a lower brake horsepower, resulting in reduced electrical costs. In addition to reduced electrical costs, thermal efficiencies can be substantially improved.
Dürr can supply cost-effective direct replacement heat exchangers as well as customized units that address specific needs such as corrosive environments, thermal expansion or cleanability.
Solutions offered include:
- Multi-stage burner, low NOx burner upgrades
- Gas injection/efficient use of fuel to keep operating costs to a minimum
- VOC concentrator with split desorption
- Replacement of the ceramic heat exchanger
- Blockage detector for regenerative thermal oxidation systems
- Installation of a heat exchanger
- Thermal oil distillation
- Sight glasses for combustion chambers
- Preventing the formation of condensate/deposits
- Review of particulate matter (PM) in process flows
- Rental RTOs or TOs
Operating costs are an important factor for air pollution control systems used to reduce VOC emissions from paint shops. Dürr has developed the new HEX-BLOCK honeycomb blocks for regenerative thermal oxidation, which have much lower operating costs than equivalent systems with conventional honeycomb blocks. The unique shape and newly developed structure of the ceramic honeycomb block heat exchangers keep electricity and gas consumption to a minimum.
However, not only new air pollution control systems can benefit from our new HEX-BLOCK honeycomb blocks. They can be used with existing air pollution control systems of all makes to reduce operating costs or the waste air volume flow and therefore to increase the capacity of the system.
The Oxi.X TR.Com VI burner is fitted as standard in the new Oxi.X TR recuperative thermal oxidizer systems and offers significant improvements in emissions, which is an important consideration with respect to the future introduction of lower emissions thresholds. The burner can be retrofitted to existing systems of any make.
- Reducing the consumption of utilities: Improvements in the air ducting of the sight glass cooling system reduce compressed air consumption by 50%.
- Optimized operation under partial load: A significant reduction in the process air volume compared with its predecessor. Considerable savings potential in combination with the EcoSmart VEC
- Lower NOx emissions: Reduced nitrogen oxide emission levels as a result of the improved fuel feed and the lower combustion chamber temperatures, despite the higher pre-heating temperatures.
- Reduced CO emissions: Better clean gas figures as a result of the optimized flow control in the reaction zone, which leads to an obvious improvement in the conversion of hydrocarbons (VOCs) in existing Oxi.X TR systems.
- High temperatures for pre-heated process air: A special design for pre-heating the process air to up to 600°C allows for the cost-effective treatment of waste air flows containing solvents.
An engineering study (including an as-is analysis) of your existing system can identify whether retrofitting the burner is financially reasonable. Alternatively, you can complete a questionnaire about your current system configuration, mode of operation, and consumption. Dürr will evaluate your answers to the questionnaire and inform you about the results.
You are welcome to visit us at our Bietigheim-Bissingen site for a demonstration of the Oxi.X TR.Com VI burner. Of course, we will also be happy to provide you with individual consultancy at your own plant.