MetPro System Thermal Oxidation

8/9/2019 MetPro System Thermal Oxidation

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FRESHAIR

DESORPTIONAIRBLOWER

CONCENTRATEDSOLVENT INAIR

HOTAIR

DILUTESOLVENTLADENAIR

INLETFILTER

ROTARYCONCENTRATOR

DILUTESOLVENTLADENAIR

BLOWER

OXIDIZERAIRBLOWER

COMBUSTIONAIRBLOWER

DESORPTIONAIRHEATEXCHANGER

OXIDIZERAIRHEATEXCHANGER

CATALYSTBASKET

COMBUSTIONCHAMBER

Bulletin 1010

CLEANAIR

CLEAN

AIR

CATALYTICOXIDIZER

Thermal and CatalyticOxidation Systems

SYSTEMS

A Met-Pro Product Recovery/Pollution Control Technologies Business

Thermal Oxidation


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RegenerativeThermal Oxidizers

Consider these advantages of Met-Proregenerative thermal oxidizers:

Up to 100% thermal efficiency (no auxiliary fuelconsumption)

Wide range of sizes from 5,000 to 60,000 scfm

Destruction efficiencies up to 99% for 2 bed RTOs and>99% for 3+ bed RTOs

Compact design to minimize plot space andinstallation cost

Minimal moving parts reduces maintenance costs

Turnkey installation available

6,000 SCFMRTO for paint andpowder finishingapplication

Provide extremely high destruction efficiencies and areideal for use with most VOC applications

A Regenerative Thermal Oxidizer (RTO) is the most efficienttype of thermal oxidizer for air streams with low VOC concen-tration. Standard Met-Pro Systems RTOs achieve up to 95%thermal efficiency at very low VOC concentrations and canoperate with little or no auxiliary fuel at 8-10% LEL. AlternateRTO designs can operate at up to 25% LEL.

RTOs incorporate 2 or more beds of ceramic heat exchangemedia. For a two-bed RTO, the contaminated air feed stream

is alternately directed to flow over one of the ceramic bedswhere it increases in temperature. After flowing across the firstceramic bed and being heated, the contaminated air streamis further heated with an auxiliary fuel burner to the requiredoxidation temperature and held for up to 1 second at that tem-perature to allow for adequate destruction of the VOCs. Theresulting flue gas stream then flows over another ceramic bedand raises the temperature of the second bed. Periodically,switching valves reverse the direction of flow and the contami-nated air feed stream flows over the hot ceramic bed that wasjust heated by the outgoing oxidizer flue gas. The back andforth switching between ceramic beds occurs every 3-6 minutesin most cases. The direct air to ceramic bed contact is whatallows for the 95% fuel efficient RTO operation.

CLEANAIR

DIVERTERDAMPER

BU

HEATRECOVERYMEDIA

COMBUSTIONCHAMBER

SOLVENTLADENAIR

EXHAUSTSTACK

FORCEDDRAFTFAN(ID FANAVAILABLE)

and Catalytic Oxidation Systems


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Met-Pro Systems has been solving emission problems for more than40 years. Our ability to provide thermal and catalytic oxidation solutions is well known and respected throughout the world. Our expert-

ise enables us to provide and install reliable, field proven, cost-effective air pollution control systems for almost any volatile organiccompound (VOC), reactive organic gas, air toxic or halogenatedorganic solvent.

While there may be more than one method or technology to solve aparticular emission problem, there is generally one bestway to solvethat problem. When you work with Met-Pro Systems, you gain thebenefits of our years of experience designing and buildingsuccessfumulti-discipline solutionsto tough air pollution control problems withbest available control technology.

Met-Pro Systems offers full service capabilities from project design and

development through turnkey system operation. Intermediate servicesinclude computational fluid dynamics (CFD) modeling, process simula-tion, RACT/BACT/LAER/MACT review, start-up and training, complance testing, project engineering, project management and remotemonitoring of the system and process.

Catalytic Oxidizers

VOC Concentration Systems

Recuperative Thermal Oxidizers

Regenerative Thermal Oxidizers

Integrated Systems forHalogenated Organic Emissions

Applications-Matched Therma


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Catalytic Oxidation

Maximum flexibility and cost-effectivenessup to 99% destruction efficiency for VOCs

Met-Pro Systems pioneered the development of catalyticoxidation technology as an extremely cost-effectivemethod of managing solvent emissions. Catalyticoxidation may be used to control a wide variety ofvolatile organic compounds (VOCs). A key advantageof Met-Pro Systems catalytic oxidation systems is theirability to treat nitrogen-containing organic compoundswithout forming NOx. And since catalytic oxidationoccurs at lower temperatures than thermal oxidation,energy consumption is also minimized. When comparedwith other oxidation technologies, catalytic oxidationoffers advantages of lower capital expense, greater than99% destruction efficiency and lowest possible operatingcosts.

Met-Pro Systems catalytic oxidation systems perform amulti-step process by diffusing reactants from the bulkfluid phase to the catalyst pores where they are then

adsorbed into the active surface. The reaction takesplace on the catalyst site. Oxidation products are thendesorbed and diffused back into the bulk fluid phase. Acatalyst can convert many times its weight in reactants,with a useful life of over 70,000 hours of continuousoperation.

Consider these advantages ofMet-Pro Systems catalytic oxidizers:

Easy catalyst change-out

Modular design for flexibility

Factory fabrication and testing

Wide range of air flows to accommodatechanging operating conditions

Welded heat exchangers for reliable,long life

Roof mounting for space savings andenhanced safety

Elimination of supplemental NOxcontrol equipment

Catalytic Ignition Temperatures(98% destruction)

Contaminant Temp.F Contaminant Temp. F

Acetylene 395 MEK 700

Benzene 575 Methanol 550

Carbon monoxide 425 Propane 770

Ethanol 600 Propylene 500

Ethyl acetate 775 Toluene 575

Ethylene 810 Xylene 575

Hydrogen 220

40,000 SCFMcatalytic oxidizersystem forgranulatingand coatingpharmaceuticalproducts

CLEANAIR

COMBUSTIONAIRDUCT

COMBUSTIONAIRBLOWER

HEATEX-CHANGER

CATALYSTBASKET

COMBUSTIONCHAMBER

SOLVENTLADENAIR

EXHAUSTSTACK

CATALYTOXIDIZE


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Multi-discipline technologies for maximumperformance and cost-effectiveness

Eliminating halogenated solvents such as chlorinated,fluorinated, and brominated emissions with the highest

possible destruction efficiencies (99% or greater)requires a unique combination of control technologies.In addition to solvent destruction, by-products of combus-tion HCl, HF, and HBr must also be removed beforebeing exhausted to the atmosphere. For difficult applica-tions such as these, Met-Pro Systems has designed sys-tems which consist of a catalytic or thermal oxidizermatched with water quench and acid gas scrubbers.Combination systems such as these hybrid oxidizerseliminate standard VOCs and are designed usingmaterials such as Hastalloy or Inconel to withstandthe harsh environments created by the combustion ofhalogenated compounds.

Integrated Systemsfor HalogenatedOrganic Emissions

The catalytic oxidizer system depicted in theschematic above was used in a pharmaceutical ap-plication and is designed to oxidize more than 98%of both standard VOCs and chlorinated compounds.As a result of the oxidation of the chlorinated com-pounds, HCl is formed and must be treated prior tobeing exhausted to the atmosphere. The formation ofHCl in this application facilitates the need for an inte-grated quench/scrubber system.

While the water quench neutralizes some ofthe acid from the catalytic oxidizer, its main functionis to reduce exiting air temperature from the oxidizer

to 140 F prior to entering the scrubber. A sodiumhydroxide solution is circulated through the packedbed scrubber to remove and neutralize up to 99.9%of the acid gases. Met-Pro Systems integrated sys-tems include automated metering of caustic solutionand pH monitoring of discharge water. A final misteliminator removes remaining aerosols.

Similar systems are used for soil and groundwaterremediation and in pharmaceutical and specialtychemical applications.

QUENCH

CLEANAIR

MISTELIMINATOR

ACIDSCRUBBER

OXIDATIONCHAMBER

BURNER

FRP BLOWER

CATALYST

BASKET

SOLVENTLADENAIR

CATALYTICOXIDIZER

CLEANAIR

8,000,000 BTU/hrthermal oxidizer syste

with water quench andacid gas scrubberfor butyl rubbermanufacturer in China


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Thermal Oxidation Combustion properties of common chemical compoundsChemical Btu/ Auto- LEL, UEL,

lb* ignition vol.% vol. %temp,F

Acetone 13,100 1000 2.15 13.00Acetylene 21,600 635 2.50 80.00Acrolein 12,536 572 2.60 31.00Acrylic acid 8,188 820 3.10 Acrylonitrile 13,286 898 3.05 17.00Amyl alcohol 16,210 667 1.40 10.00

Benzene 18,000 1076 1.40 8.00Butane-N 21,300 806 1.60 6.50Butyl alcohol 15,500 693 1.70 9.00Carbon monoxide 3,984 1,204 12.50 74.20Decane 20,492 500 0.67 2.60

Dichloro- 8459 1198 1.50 benzene

Dichloro- 4231 860 5.60 11.40ethylene 1,1

Dodecane 20,419 397 0.60 Ethane 22,294 950 3.30 10.60Ethyl acetate 10,950 907 2.18 11.50

Ethyl aceto- 10,451 800 1.30 acetate

Ethyl alcohol 12,800 799 3.28 19.00

Ethylene 21,600 1009 3.02 34.00Ethylene glycol 8223 775 3.20 Ethylene oxide 12,353 804 3.00 80.00Gasoline 495 1.30 6.00Heptane 20,700 452 1.00 6.00Hexane 20,800 477 1.25 6.90

Extremely high destruction efficienciesgreater than 99.9%

Met-Pro Systems thermal oxidizers operate at hightemperatures to combust solvents into water andcarbon dioxide. They offer high destructionefficiencies and are ideal for use with most VOCapplications. Met-Pro Systems thermal oxidationsystems are available with heat recovery capabili-ties ranging from 50% to 80%, resulting in lowoperating costs.

Consider these advantagesof Met-Pro Systems thermaloxidizers: Modular design for flexibility


Wide range of air flows toaccommodate changing

operating conditions Welded heat exchangers

for reliable, long life

Roof mounting for spacesavings and enhanced safety

Multiple fuel burnersfor added flexibility

BURNERAS-SEMBLY

CLEANAIR

EXHAUSTSTACK

SOLVENTLADENAIR

THERMALOXIDIZER

COMBUSTIONCHAMBER

24,000 SCFMthermal oxidationsystem for chemicaprocessingapplication

Thermal and CatalyticOxidizer Revamps

How much energy are you wasting? Met-Pro Systemscan tell you. Complete systems revamps for:

Fuel Savings

Capacity Increases

Heat Recovery

Waste Heat Boilers

Replace/Recycle Catalyst

Stack Condensate Recovery

Emissions Improvements

PLC Programming

Rapid Payback

Installations and Field Services

MET-PROSYSTEMS CAN

MODIFYANY MAKE

OR MODELOXIDIZER!

Chemical Btu/ Auto- LEL, UELlb* ignition vol.% vol. %

temp,F

Hydrocyanic acid 10,999 1000 5.60 40.0Hydrogen 61,100 1076 4.10 74.2Isoprene 19,943 428 1.30 Maleic anhydride 6228 899 3.00 Methyl e thy l ketone 14,600 960 1.81 11.5Methyl alcohol 9600 878 6.00 36.5

Methyl iso-butyl 16,090 854 1.10 7.95ketone

Methyl N-butyl 16,090 842 1.22 8.00ketone

Methyl vinyl ketone 13,610 940 1.90 Mineral spirits 475 0.77 Methane 23,940 999 4.80 13.5Octane-N 20,600 450 0.84 3.20Pentane-N 21,100 588 1.40 8.00Petroleum ether 475 1.40 5.90Phenol 14,017 1319 1.40 Phthalic anhydride 9500 1083 1.30 9.2Propane 21,657 874 2.30 7.30Propyl acetate 14,300 842 1.77 8.00Propyl alcohol 14,300 812 2.15 13.5Propylene 21,027 927 2.00 11.1

Toluene 18,300 1026 1.27 7.00Vinyl acetate 10,420 800 2.00 Vinyl chloride 7875 966 4.00 22.0Xylene 18,400 924 1.00 6.00

*Heat of combustion


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VOCConcentrationSystems

100,000 SCFMconcentrator forautomotivepaint spray boothapplication

CONCENTRATEDSOLVENT INAIR

TOOXIDIZER

ROTARYCONCENTRATOR

HOTAIR

CLEANAIR

INLETFILTER

DILUTESOLVENT

LADENAI

High efficiency removal of dilute solventsfor high volume air emissions

Met-Pro Systems unique activated carbon or zeoliterotary concentrators are used in applications thatinvolve a combination of high volume of air with lowconcentration of solvents. The rotary concentrator re-duces the solvent laden air flow by a factor of 10:1, thusminimizing the overall system size and operating costs.VOC concentrators can be combined with any Met-ProSystems recovery or oxidation technology to create anadvanced hybrid system that offers outstanding operat-ing flexibility, performance and cost-effectiveness.

Consider these advantages of Met-Pro SystemsVOC concentrators:

Field-proven for hundreds of differentapplications

Low operating and maintenance costs

Small size, light weight for easy on-siteinstallation


Automated controls speed and simplifyoperation

Superior adsorbent life

Wide flow range enhances systemflexibility


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Cost Effective Thermaland Catalytic Oxidizers

Met-Pro Systems fully integrated, turnkeysystem solutioncapabilitiesinclude system design, fabrication, training and support services fromconception to completion.If desired, Met-Pro Systems can provideremote access monitoring for your entire system process via advancedtelemetry links, with monitoring to predict routine maintenance as wellas preventive maintenance schedules.

How to get more information . . .Met-Pro Systems is a world class leader in advanced emission control systemscapabilities. We can help you with your air pollution control requirements. Tothat end, well be pleased to provide additional technical data on any Met-Pro

Systems application-matched emission control system or special capability tomeet your requirements. To learn more, please contact us today.

System Air Flow Range Solvent Loading

(SCFM) (% LEL)

Catalytic Oxidation 500-50,000 0-25

Thermal Oxidation 500-50,000 0-25

Regenerative Thermal Oxidizers 5,000-60,000 0-12

VOC Concentration Systems 5,000-300,000

MetPro System Thermal Oxidation

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