Thermal Oxidizers (TOX)
A thermal oxidizer is a combustion system used to control air pollution by destroying hazardous air pollutants (HAP), volatile organic compounds (VOC), and odorous emissions discharged from industrial processes. Also referred to as TOX or thermal incinerator, a thermal oxidizer is designed to oxidize hydrocarbon-based pollutants into CO2 and H2O before exhausting them to the atmosphere.
Thermal Oxidizer Options
Because of their near universality DFTOs can be re-applied easily for permanent use or sometimes as a temporary system in an emergency situation.
Fully refurbished with a parts and performance warranty — you won't believe they're not new!
Custom DFTOs are simple systems with shorter lead times than other technologies.
Common Types of Thermal Oxidizers
Direct Fired Thermal Oxidizers (DFTO)
Direct fired thermal oxidizers (DFTO), also known as afterburners, are the most basic type of thermal oxidizer technology. They are cost-effective in terms of both capital investment and maintenance, and are efficient in treating process air with high concentrations of volatile organic compounds.
DFTOs are common in Industries with small to moderate VOC emissions, such as batch processing industries.
Regenerative Thermal Oxidizers (RTO)
Regenerative Thermal Oxidizers are the most popular air pollution control technology. They are known for their high reliability and long service life, while offering the lowest operating costs among thermal oxidizer systems. This is due to their using heat left over from previous operating cycles to preheat incoming process air to the right temperature for combustion.
Industries with heavily VOC-laden emissions, like pharmaceuticals, painting, and chemical manufacturing rely on RTO units to clean their process exhausts.
Recuperative Thermal Oxidizers
Recuperative thermal oxidizers (TOX) - similar ato RTOs - feature an integrated air-to-air heat exchanger using the hot treated air exiting the combustion chamber to preheat the incoming process air. This heat recovery reduces the fuel consumption of the burner during the combustion stage.
Certain sectors whose processes generate moderate-to-high VOC emissions will incorporate TOX units, like the chemical and pharmaceutical industries.
Catalytic Recuperative Oxidizers
Catalytic recuperative oxidizers (CATOX), consume less fuel due to lower operating temperatures (typically between 600°F and 650°F) compared to other thermal oxidizer systems. They’re best used for clean applications that do not involve halogens, sulfur, silicone, or particulates.
CATOX units are most often used in sectors with VOC emissions that can be oxidized at lower temperatures, including coating, printing, and petrochemical industries.
Regenerative Catalytic Oxidizers (RCO)
Regenerative Catalytic Oxidizers function similarly to RTOs but incorporate a layer of catalyst-impregnated ceramic media, making them even more fuel-efficient. RCOs provide a long service life and are suitable for low-VOC process airstreams (below 16%).
Applications for using RCOs are often found in chemical, pharmaceutical, and coating industries.
VOC Rotary Concentrators
Although not oxidizers themselves or standalone solutions, VOC Rotary Concentrators pre-condition an airstream before it is sent to a paired oxidizer for VOC destruction. These concentrators adsorb VOCs from high-volume, low-VOC concentration process air and send these adsorbed VOCs, in a reduced airstream, to a thermal or catalytic or regenerative thermal oxidizer for final VOC destruction.
Learn more about the differences between thermal oxidizer types >>
Thermal Oxidizer Service Options
For emergency & scheduled service, call: 920-615-8804.
Emergency DFTO Thermal Oxidizer Fabrication for Recycling Emissions
An oil recycling company in the Southwest needed a new thermal oxidizer shell ASAP. This case study shows how KKI came through despite supply chain challenges.
