Regenerative Thermal Oxidizers (RTO)

Regenerative thermal oxidizers (RTOs) have a heat recovery (efficiency) of 95% typically. This technology has the lowest operating cost of all thermal oxidizer systems – not to mention the longest service life and highest reliability. It’s even possible for an RTO to operate with no auxiliary fuel use whatsoever if process VOC concentration levels are >3-4% lower flammability limit (LFL).

RTOs typically operate at 1500^o – 1600^o Fahrenheit depending upon the VOC characteristics. Thermocouples inside the chamber monitor temperature and adjust gas burner firing as needed. Adequate temperature is essential to ensure VOC destruction efficiency. In most cases a data log of chamber temperature is required for air quality compliance.

The refractory lining insulates the combustion chamber and helps retain heat. If the refractory becomes cracked, worn, or damaged, heat can escape from the chamber, forcing the burner to fire more frequently to maintain temperature. Over time, this increases fuel consumption and can create hot spots that shorten equipment life.

We can evaluate your current oxidizer’s capacity alongside the new process requirements to recommend the best upgrade approach. Options may include adding new heat exchanger media, installing a larger fan, or modifying the burner and combustion chamber to meet destruction needs. For some cases, using a VOC concentrator to reduce pollutant levels before the oxidizer can be an effective solution. Please note that existing equipment may not be sufficient, even with changes or upgrades.

It depends on some design factors that need to be scrutinized but typically, no. Advancements in new structured media designs can sometimes increase the thermal efficiency and reducing pressure drops through the media beds. This can sometimes can provide a couple percentage points of capacity increases over RTOs that utilize saddle ceramic media.