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Lantec: Regenerative Thermal Oxidizer Design Considerations

The document discusses considerations for designing regenerative thermal oxidizers (RTOs). It defines thermal efficiency (TE) and thermal energy recovery (TER) and provides equations to calculate them. It notes that burner air flow rate, fuel gas heating value, moisture content, particulate matter, and VOC loading should be specified to ensure reliable RTO design. Incomplete specifications could result in inadequate designs.

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94 views

Lantec: Regenerative Thermal Oxidizer Design Considerations

The document discusses considerations for designing regenerative thermal oxidizers (RTOs). It defines thermal efficiency (TE) and thermal energy recovery (TER) and provides equations to calculate them. It notes that burner air flow rate, fuel gas heating value, moisture content, particulate matter, and VOC loading should be specified to ensure reliable RTO design. Incomplete specifications could result in inadequate designs.

Uploaded by

jayaram432
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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LANTEC

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Regenerative Thermal Oxidizer Design Considerations

Thermal Efficiency and Thermal Energy Recovery

The thermal efficiency (TE) of an RTO operating at steady state is defined as the percentage
of preheat energy supplied by the ceramic heat-exchange media. Preheat energy is the energy
required to bring process air from its inlet temperature to the combustion chamber temperature.

(Minlet + Mburner )(Tcomb − Toutlet )


TE = × 100%
(Minlet )(Tcomb − Tinlet )

where Tinlet is the temperature of process air entering the RTO (°F or °C),
Tcomb is the temperature in the combustion chamber (°F or °C),
Toutlet is the average stack gas temperature (°F or °C),
Minlet is the flow rate of process air entering the RTO (scfm or Nm³/h), and
Mburner is the flow rate of unheated air entering the combustion chamber (scfm or Nm³/h).

Mburner is usually just the air fed to the burner in the combustion chamber, although it may also
include unheated gas used to cool nozzles, etc.

In some RTOs the burner in the combustion chamber is used only for start-up, and once the
oxidizer has come to steady state the burner is turned off and auxiliary fuel gas is added to the
process air. In that case, if Mburner = 0, the thermal efficiency will be the same as the thermal
energy recovery (TER), defined as the percentage of available heat recovered by the heat-
exchange media.

(Tcomb − Toutlet )
TER = × 100%
(Tcomb − Tinlet )

When referring to heat recovery, please indicate clearly whether TE or TER is being specified.

The RTO stack temperature rises and falls during each cycle. Note that its average value Toutlet
(determined by integrating the gas temperature over an entire cycle) is not simply the arithmetic
mean of the minimum and maximum temperatures observed.

For example, if an RTO treats 2,400 scfm of process air entering at 80°F, fuel gas is added as
required to maintain a combustion chamber temperature of 1,500°F, 36 scfm of unheated com-
bustion air is fed to the burner, and the average stack temperature is 151°F, then

(2,400 + 36 scfm)(1,500 − 151°F) 1,500 − 151°F


TE = × 100% = 96.4% , TER = × 100% = 95.0%
(2,400 scfm)(1,500 − 80 °F) 1,500 − 80 °F

Operating Mode and Fuel

The valve switch time (or cycle time) must always be indicated. If auxiliary fuel is supplied
through the burner during operation, please specify the burner air flow rate (if it is constant), or
else the burner air / fuel gas ratio and the heating value of the fuel gas (Btu/scf or kWh/Nm³).
. .
Lantec Products, Inc. 5302 Derry Ave., Unit G Agoura Hills, CA 91301 818-707-2285 (fax) 707-9367 [email protected]
If a regenerative thermal oxidizer has more than two heat-recovery canisters, the air flow con-
figuration must be indicated, including the purge air flow rate and duration (or at least the
average value of the purge air flow rate).

Uniform Air Distribution

Heat-recovery calculations are performed assuming that air flows through all parts of the heat
exchange media at the same mass velocity (scfm/ft² or Nm/s). Gas inlet and outlet transitions
must be designed to provide uniform air flow. If local gas velocities (determined by anemometer
readings above the media when cold air is blown through it) deviate from the average by more
than ±15%, then heat recovery may be significantly less than predicted for uniform flow.

For example, if the superficial air velocity through the media is 300 scfm/ft², no velocity vector
measured just above the media should exceed 345 scfm/ft² nor be less than 255 scfm/ft².

Moisture Content

Unless otherwise specified, calculations assume that the process air entering an RTO is rela-
tively dry, containing <5% water vapor (v/v). Air more humid than this will have higher heat
capacity, and so more heat-exchange media may be needed to heat or cool it to a given tem-
perature. The same is true of air containing >5% CO2.

Note that 5% is not the relative humidity, but rather the moisture content by volume. For exam-
ple, process air saturated with water vapor at atmospheric pressure and 92°F (33°C) would
contain 5% water vapor (v/v).

Condensable or Particulate Matter

If process air entering an RTO is expected to contain dust or other aerosols, this must be indi-
cated in the design specification, as it may affect the choice of heat-exchange media and/or
maintenance requirements.

VOC Loading Rates

When possible, the estimated VOC content of the process air and the average caloric value of
the VOCs should be indicated. If the VOC load is expected to vary widely, average and maxi-
mum values should be estimated. TE and TER are measured with clean air flowing through an
RTO, but VOC loading estimates can give an indication of whether the combustion chamber will
tend to overheat.

Detailed Specifications for Reliable Designs

Any unusual aspects of an RTO or its operation should be noted. When in doubt, include more
information. Remember that incomplete specifications can result in inadequate designs.

. .
Lantec Products, Inc. 5302 Derry Ave., Unit G Agoura Hills, CA 91301 818-707-2285 (fax) 707-9367 [email protected]

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