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Mistakes Can Cause Non-Compliance Issues on Regenerative Thermal Oxidizers
Listed are commmon errors made when you order a regenerative thermal oxidizer without knowing many of the various aspects listed below.
1. Incorrect material for the composition of the waste gas process. Choosing materials that are right for the application will promote equipment life and regenerative thermal oxidizer dependability.
A. Skin or Shell Material Selection (Metal Type i.e. Carbon, Stainless Steel, Inconel, Thickness 3/8")
B. Valve Selection (Poppet Valves vs. Butterfly) Poppet valves have tendency to wear the internal bearing and cause process blowby.
C. Heat Recovery Media (HRC) bed support (Thickness, Material Type, Quanity) provides for a stable ceramic media bed and prevents craking or breaking.
D. Paint (High Temperature vs. Hot Dipped Galvanized Metal) From the high heat many units will require high temperature painting to prevent rusting each year.
E. High Quality Solenoids, Compressors, etc. This is the heart of the valve system, buy high quality.
2. Characterization of the Plant Process Stream.
A. Misrepresentation or making an educated guess of the density of plant waste-off gases. It is extremely important to know the amount of VOC's, HAP's or other gases that the regenerative thermal oxidizer system will be processing. This is especially important when the off gases contain halogens or H2S. Specify the amount lbs. per hour or ppmv, increasing the success of design and engineering of the regenerative thermal oxidizer.
3. Plant's required vacuum pressure or the amount of VOC's.
A. This is a very common occurrence in the industry. Either the OEM builds a system to fit a budget as part of the available capitol or the plant tries to get by with less. Either way, when start up occurs the real problems will begin. Process waste-off gas amount is to great, inadequate vacuum pressure on process line, or the system operates outside design considerations.
4. Sizing the Regenerative Thermal Oxidizer Heat Recovery System.
A. A common problem is when equipment companies size the heat recovery system for normal plant VOC volume and not for high loading or spiking conditions that may exist in the plant from time to time. Often the designer will manufacture a thermal oxidizer system for the average VOC loading condition, only to find that the plant has frequent spike conditions. The regenerative thermal oxidizer system should be able to handle these frequent spikes. The RTO system may have spikes, these spikes may be addressed by the use of a hot air by-pass system that operates during the spike or high loading phases. Soon after, maximum heat recovery efficiency will occur on normal running VOC conditions. When spikes in the process flow occur your heat recovery efficiency will not be an issue.
5. Incorrect Heat Recovery Media or Heat Recovery Media Placement.
A. Incorrect media sizing or type can result in system fouling (plugging) or loss in thermal efficiency. Improper media placement can result in inefficiencies by means of the process stream channeling. Proper media size and media protection can protect the media material and give the system better thermal efficiency. Often air pollution manufactures may specify ceramic media that is in stock or readily available and quality is inferior.
6. Improper Plant Particulate Filtration.
A. Poor or lacking maintenance of upstream particulate removal. This is very common issue when the plant maintenance department fails to maintain proper filtration of the plant process gases going to the regenerative thermal oxidizer. Poor filtration or lack of equipment in many off gas processes will result in early media replacement or continual media cleaning.
7. Compliance Testing.
A. Testing the regenerative thermal oxidizer equipment above the permit requirement. Often companies wish to run the system at higher destruction. This is great; however testing above the permit level can cause a new set of problems. You may be required to operate the regenerative thermal oxidizer equipment on an established baseline. After a period of time the thermal oxidizer may be running in compliance with the original permit, but fails to be in the higher baseline due to aging of valve seals or particulate within the media. At this point you may be out of the established baseline compliance.
About the Author
Scott Manes: For more information about regenerative thermal oxidizers visit American Environmental Fabrication & Supply or call us at +1 918 708-1253 Ext. 4001
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