CONTROLLED OXIDATION WITH HEAT RECOVERY TO TREAT CONTINUOUS EMISSIONS AND IMPROVE THE PLANT’S ENERGY EFFICIENCY
Recuperative thermal oxidisers are units designed to destroy pollutants through thermal oxidation in a controlled chamber; they incorporate a heat recovery system that improves the overall energy efficiency of the unit and reduces auxiliary fuel consumption.
They are used to treat continuous emissions of VOCs, BTEX, organic vapours and other combustible streams when, in addition to thermal destruction, the project requires optimising the overall energy balance or utilising the heat available in the process.
At PREMATECNICA, we design and supply recuperative thermal oxidisers tailored to the conditions of each installation: flow rate, composition, inlet temperature, emissions targets, thermal recovery potential and integration with other equipment and utilities.
WHEN TO CHOOSE A RECUPERATIVE THERMAL OXIDISER
A recuperative thermal oxidiser is suitable when a plant needs to treat continuous emissions with a high degree of control, whilst also reducing energy consumption. Compared to a direct thermal oxidiser without heat recovery, it reuses the heat from the exhaust gases and reduces fuel consumption, thereby improving the system’s overall efficiency.
It is particularly useful in stable services with many hours of annual operation, where the energy balance affects the project’s viability. It is also suitable where there is internal thermal demand, for example to preheat streams, heat process fluids or produce steam as an integrated process.
OPERATION AND PRINCIPLE OF RECOVERY
The destruction of pollutants depends on temperature, residence time, mixing and oxygen. The recuperative oxidiser incorporates a heat exchanger that recovers heat from the treated gases to reuse energy within the system.
This heat is used to preheat the feedstock or combustion air, thereby reducing energy consumption. As a result, oxidation takes place under controlled conditions with lower external energy requirements and greater overall efficiency.
The system can operate using primary recovery, within the plant itself, or secondary recovery, by integrating energy into other processes. The aim is to break down compounds with a low calorific value with greater thermal efficiency and lower operating costs.
DESIGN AND PERFORMANCE CRITERIA
The design must take into account flow rate, gas composition, inlet temperature, contaminant concentration and emission targets, together with the actual potential for heat recovery and its impact on the plant as a whole.
It is not enough simply to add a heat exchanger: factors such as fouling, material compatibility, energy integration and operational stability across the entire operating range must be taken into account.
Heat recovery is most effective in continuous operation with significant heat demand, where it improves the plant’s overall performance and reduces operating costs on a sustained basis.
INTEGRATION WITH OTHER SYSTEMS
It can be integrated with steam generation, auxiliary heat exchangers, DeNOx systems, scrubbers, particulate filters or emissions monitoring, forming part of a complete process architecture.
This integration makes it possible to optimise the overall energy balance and ensure stable and efficient operation under varying operating conditions.
PREMATECNICA DESIGNS AND IMPLEMENTS YOUR RECUPERATIVE THERMAL OXIDISER
Each piece of equipment requires a specific design basis. At PREMATECNICA, we analyse the process, the contaminants, the flow rate range, the inlet temperature and the potential for heat recovery.
We define the configuration and integrate the system with the plant, including heat recovery, steam generation, auxiliary equipment and control systems. Furthermore, we optimise combustion and heat recovery using CFD to maximise efficiency and durability.
Our aim is to provide reliable solutions that integrate emissions control and energy efficiency within a single process strategy.
