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(936) 273-3300

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epcon@epconlp.com

Air Pollution Control

THERMAL OXIDIZER MANUFACTURER

Depending on your needs, Epcon can employ either Regenerative Thermal Oxidizer (RTO), Recuperative Thermal Oxidizer, and/or Catalytic Oxidizer.

Epcon has been engineering and manufacturing state-of-the art and leading-edge Thermal Oxidizers since 1977. We have been very successful in engineering and building all types of Oxidizers, both nationally and internationally.

The primary function of the Thermal Oxidizer is to destroy the VOC contaminants in the exhaust coming out of a process. The operation of the Thermal Oxidizer is based on the principle of combustion. The process of combustion is the most commonly used method to control emissions of organic compounds.

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To date, Epcon has manufactured nearly 4,000 systems operating worldwide. Most of these systems are within the United States; however, we have systems in many other countries.

Epcon can provide a standard design or custom built oxidation system for thermal destruction of volatile organic compounds (VOC) and other gases that can be eliminated by thermal destruction. Your Thermal Oxidizer will combine the right combination of high temperature, turbulent conditions, and residence time to assure complete combustion of volatile organic compounds or other contaminants in the air stream.

Our Thermal Catalytic Oxidizers can be built to handle any size volume of gas. Customers can count on Epcon to design air pollution control systems or any number of custom systems specific to your process.

Air pollution is a global problem and Epcon is committed to solving the problem through expert engineering and design services.

We offer numerous solutions for control of pollution products, suitable for various industrial needs. We can employ H2S Scrubbers, Recuperative Thermal Oxidizer, Regenerative Thermal Oxidizer (RTO) or Catalytic Oxidizer, depending on your requirements.

As reputed air pollution control equipment manufacturers in Woodlands, Texas and around the world, we provide our state-of-the-art solutions to several industries. We also offer custom solutions to meet individual project requirements.

AIR POLLUTION CONTROL PRODUCTS

CUSTOM THERMAL OXIDIZERS

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Epcon’s technical sales staff works together from concept to completion, ensuring customers an efficient, customized product.

Design & Engineering

Epcon’s technical personnel comprises a competent staff of highly experienced engineers. Our SolidWorks & AutoCad specialists have an in-depth knowledge of our products and the needs of industries we serve.

Manufacturing & Testing

Epcon is one of the few companies in our industry that has its own on-site manufacturing facility. This modern facility with state-of-the-art fabricating machinery allows Epcon to maintain complete control over the project’s quality and schedule. Each unit is built with high-quality materials, and because welding is one of the most crucial phases in the fabrication, our welders are both TIG- and MIG-certified.

All systems are pre-assembled at our facility and undergo rigorous quality checks and testing prior to shipment. Thus, providing reassurance to our customers that the system will perform well when it is delivered and installed.

Thermal oxidizers are typically one of two types: Regenerative Thermal Oxidizers (RTO) or Recuperative Thermal Oxidizers. Regenerative Thermal Oxidizers use an oxidation technology that uses two or more ceramic heat transfer beds that act as smaller heat exchangers and a retention chamber where the organics are oxidized. It can often recover 90 to 95% of the heat generated by oxidation. A recuperative thermal oxidizer uses an oxidation technology (thermal or catalytic) that uses a plate, shell, and tube, or other conventional type of heat exchanger to heat incoming air with air from the oxidation process. Recuperative systems can often recover 50 to 75% of the heat generated by oxidation.

Another technology that can be found on the market are rotor concentrators. Rotary concentrators use an oxidation technology add-on that reduces air volume and increases VOC concentration. The process stream flows through a continuously rotating wheel impregnated with adsorbent. Here the VOCs are adsorbed and the clean air is exhausted into the atmosphere. The wheel is then regenerated by passing through a stream of warm, low volume desorption gas that produces a concentrated stream that can be more efficiently destroyed by an oxidizer.

Retention Chamber Design

Thermal destruction of most organic compounds occurs between 590°F and 650°F. However, most hazardous waste incinerators are operated at 1400°F. The time for which the pollutants stay in the incinerator is called residence time. The higher the residence time, the lower the temperature can be for the combustion chamber.

The residence time of gases in the combustion chamber is calculated by t = V / Q
where,
t = residence time, seconds
V = chamber volume, ft3
Q = gas volumetric flow rate at combustion ft3/s.

Adjustments to flow rates must be made for the extra combustion air added. For complete combustion to occur, every particle of waste and fuel must come in contact with air (oxygen). If this does not happen, unreacted waste and fuel will be exhausted from the stack. Second, not the entire fuel or waste stream is able to be in direct contact with the burner flame.

In most incinerators, a portion of the waste stream may bypass the flame and be mixed at some point downstream of the burner with the hot products of combustion. A number of methods are used to improve mixing the air and waste streams, including the use of refractory baffles, swirl-fired burners, and baffle plates. Unless properly designed, many of these mixing devices may create “dead spots” and reduce operating temperatures.

The process of mixing flame and waste stream to obtain a uniform temperature for the decomposition of wastes is the most difficult part in the design of an incinerator. A thermal oxidizer must be designed very carefully and with proven methods to achieve maximum mixing of airflows and to avoid dead spots.

THERMAL OXIDIZER OPERATION

A Thermal Oxidizer consists of a combustion chamber, a burner, and a blower to draw air through the complete oxidizer. Along with the contaminant-laden gas stream, air and fuel are continuously delivered to the combustion chamber where the fuel is combusted.

The products of combustion and the unreacted feed stream enter the reaction zone of the unit. The pollutants in the process air are then reacted at elevated temperature. The average gas velocity can range from 10 fps to 50 fps. These high velocities are useful in preventing the particulates from settling down. The energy liberated by the reaction may be directly recovered from process or indirectly recovered by using a heat exchanger.

Insulation

The Thermal Oxidizer should be constructed of material which can withstand high temperatures and the walls of the equipment are insulated to avoid overheating of the outside walls of the unit. These units are usually provided with sophisticated flame detection devices. The layer of insulation exposed in the Combustion Chamber is typically ceramic block that is 7″ thick and a density of 10 lbs./ft3.

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