Manufacturing

Thermal Oxidizer Manufacturing and Fabrication

BCE thermal oxidizers are necessary when the processed air contains small, combustible particulates. The idea of using a thermal oxidizer is to reduce toxic, explosive, or otherwise dangerous pollutants to simpler, non-toxic substances by subjecting the pollutants to very high temperatures, where the chemical bonds are broken. The decomposed material may then be released safely to the atmosphere.

Clean Air Solutions: BCE prides itself on creating optimum clean air solutions for you and your project.

Thermal Oxidizer Classifications

Regenerative Thermal Oxidizer (RTO)

In a regenerative thermal oxidizer (RTO), energy used in the oxidation process is recovered very efficiently by ceramic heat transfer beds coupled to the oxidation chamber.

Advantages
  • Thermal efficiency can be around 95%
  • Excellent energy recovery
  • Lower operating costs long-term
Considerations
  • Expense of replacing ceramic media if plugging occurs
  • Often run at higher pressure drops than recuperative oxidizers

Recuperative Thermal Oxidizer

In a recuperative thermal oxidizer, heat from oxidation is passed through a heat exchanger, which in turn heats the inlet air.

Advantages
  • Lower initial equipment cost
  • Simpler design than RTO systems
  • Energy recovery of roughly 70%
Considerations
  • Energy usage can be about six times that of an RTO
  • Higher operating costs may offset initial savings long-term
  • Operating temperature typically around 1400°F

Catalytic Recuperative Thermal Oxidizer

A catalytic recuperative thermal oxidizer uses a catalyst such as platinum or rhodium to allow decomposition at a much lower temperature.

Advantages
  • Operating temperature reduced from 1400°F to about 650°F
  • Fuel usage about a quarter of the recuperative thermal oxidizer
  • Lower temperature operation extends equipment life
Considerations
  • Higher fuel usage than RTO systems
  • Catalyst replacement costs over time
  • Potential catalyst poisoning from certain contaminants

Expert Consultation: BCE is ready to discuss your application with you. We will provide initial and operating cost estimates for the different types of thermal oxidizers so you can be sure you are getting the right oxidizer for your specific needs. Our engineering team will analyze your process requirements, emissions profile, and operational constraints to recommend the optimal solution.