What is a thermal oxidizer?
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.
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How does a thermal oxidizer work?
(1) A pollutant-filled airstream is pushed through the oxidizer, usually with a system fan. If the process airstream doesn’t have enough oxygen for combustion, ambient air is added.
(2) The flow of air passes through an air-to-air heat exchanger (if equipped) to preheat the air before entering the burner/combustion chamber. Thermal oxidizers can operate with an integral heat exchanger for fuel savings, or without one for capital cost savings.
(3) In the combustion chamber the air is heated to a sufficiently high temperature and held at high temperature with turbulence, to ensure VOC destruction. Typical operating temperatures are >1400°F, with dwell times of .5 – 1.0 second. This combusts the VOCs into CO2 and H2O.
(4) The hot, clean air continues through the hot pass of the heat exchanger (if equipped).
(5) Cooled, clean air is then exhausted to the atmosphere.
The 3 T’s of Thermal Oxidizers: Time, Temperature & Turbulence
The three T’s are critical and co-dependent factors that determine oxidizer performance. Industrial thermal oxidizers achieve very high VOC destruction efficiency by heating and maintaining a polluted airstream at high temperature for a set length of dwell time. Typical VOC destruction with thermal oxidizer systems is 99+%.
Time: Given a constant rate of flow, the larger the combustion chamber, the longer the dwell time. More time typically equates to greater VOC destruction efficiency. In most applications the dwell time requirement is between .5 – 1 second.
Temperature: The combustion chamber maintains a high temperature ranging from 1400°F to 1600°F and higher. 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.
Turbulence: VOCs must combine with oxygen and heat to trigger the chemical reaction that breaks them down into CO2 and H2O. There are many successful thermal oxidizer designs that ensure sufficient turbulence, such as introducing the process air at an angle to induce spin or creating internal choke points. The better the mixing and heat distribution, the higher the VOC destruction.
Types of Thermal Oxidizers
There are several different kinds of thermal oxidizer technologies. If you’re unsure which system is best for your application, we can help.
Direct Fired Thermal Oxidizers (DFTO)
Direct fired thermal oxidizers (aka afterburners) represent the most basic thermal oxidizer technology. DFTOs have the lowest capital/maintenance costs compared to other systems, and are very effective in treating process air with high VOC concentrations.
Regenerative Thermal Oxidizers (RTO)
Regenerative thermal oxidizers are the most widely used air pollution control technology today. They have the lowest operating cost compared to other thermal oxidizer systems, with high reliability and long service life. Learn more about regenerative thermal oxidizers or check out our used RTO inventory.
Recuperative Thermal Oxidizers
Recuperative thermal oxidizers have an integrated air to air heat exchanger that uses hot treated air from the combustion chamber to pre-heat inbound process air. Because of this heat recovery, less fuel is consumed by the burner.
Catalytic Recuperative Oxidizers
Catalytic recuperative oxidizers (aka catalytic oxidizers) use less fuel because they operate at a lower temperature compared to other thermal oxidizer systems (typically 600°F – 650°F). They’re best for clean applications without halogens, sulfurs, silicone or particulates. Learn more about catalytic recuperative oxidizers or check out our current used catalytic oxidizer inventory.
Regenerative Catalytic Oxidizers (RCO)
Regenerative catalytic oxidizers operate similar to RTOs (see above) but include a layer of catalyst impregnated ceramic media, making them even more fuel efficient than RTOs. RCOs work well for low-VOC process airstreams (below 16%) and have a long service life.
VOC Rotary Concentrators
VOC rotary concentrators are air pollution control systems that pre-condition the airstream before it goes to a thermal oxidizer. VOC concentrators work by absorbing VOCs from high-volume, low-VOC process air, then releasing the concentrated VOCs into a smaller vapor stream that is treated in a thermal oxidizer. Learn more about VOC rotary concentrators.
Who uses thermal oxidizers?
Thermal oxidizers are used by manufacturers in a wide range of industries and applications. The Kono Kogs team has experience with practically every possible oxidizer application across many industries around the globe.
Some of the processes thermal oxidizers are used to treat include:
- Fiberglass gel coating
- Beer / beverage can production
- LCD panel production
- Semiconductor fabrication
- Steel furniture paint booths
- Wood furniture surface finishing
- Paint spray
- Spray dryer
- Rotogravure printing
- Flexographic printing
- Heatset web offset printing
- Label printing
- Rubber production
- Automotive paint processes
- Medical products film coating
- Metal coating
- Material coating
- Pressure sensitive tape
- Surface coating
- Wood composite fabrication
- Chemical processing/manufacturing
- Spiral core winding
- Foil stamping
- Coil coating
- Flow coating
We have an in-depth understanding of every process airstream our systems are used to treat. Explore our thermal oxidizer case studies or contact us with questions about the different technologies available for your specific application.
How much does a thermal oxidizer cost?
The cost of a thermal oxidizer addition includes the initial capital investment in the equipment as well as the operating and installation costs. Buying a pre-owned, fully refurbished thermal oxidizer from Kono Kogs can save you 40% or more in capital costs compared to the cost of new, with comparable guarantees and warranties.
Kono Kogs recommends carefully thinking through the total cost of ownership (TCO) before making a purchase. A thermal oxidizer system with a low capital cost might not represent your lowest TCO in operation over time. As a rule of thumb, consider a two-year period when calculating the total cost.
Capital costs include:
- Commissioning (start-up)
Operating costs include:
- Compressed air
- Maintenance service
Both capital and operating costs can vary widely between different thermal oxidizers. Some TOX technologies have fuel costs 5-10x higher than other systems. A thermal oxidizer with a low initial cost could have a higher TCO over two years compared to that of a catalytic oxidizer or regenerative thermal oxidizer.
Kono Kogs is happy to provide a cost-benefit analysis for your project. We’ll compare multiple technologies, explain the trade-offs of each option, and give you our professional recommendation on the most cost-effective system.
Questions to ask when considering a thermal oxidizer (TOX)
- Is a thermal oxidizer the most cost-effective oxidizer solution for my airstream? (See: Selecting an Oxidizer)
- Would a heat exchanger be cost effective?
- Is a plate heat exchanger or shell and tube style heat exchanger a better choice?
- Shell and tube heat exchangers are more robust than plate style heat exchangers.
- Is there a potential for particulates that could plug the heat exchanger?
- Shell and tube heat exchangers are better than plate for particulate applications.
- Tube size is an important consideration when particulates are expected.
- Is there a need for heat or steam in your plant?
- Secondary heat recovery has good payback with thermal oxidizers.
- Do local codes require low NOX operation?
- Low NOX burners can be retrofit for these applications.
Thermal Oxidizer Manufacturers
The best-built thermal oxidizers make the best used thermal oxidizers. Kono Kogs selects only the best pre-owned thermal oxidizers and stands behind them.
Check out our inventory of oxidizer systems from OEMs such as:
- CECO ADWEST Technologies
- Dürr MEGTEC Systems
- CMM Group
- REECO (Dürr)
- TANN Corp.
Kono Kogs Knows Everything About Thermal Oxidizers
Kono Kogs is the world’s leading supplier of used thermal oxidizers, sold as-is or fully refurbished. We also offer thermal oxidizer services including turnkey installation, repair, preventive maintenance, and upgrades. Our team has over 150 years of combined experience, and a 100% success rate in meeting performance guarantees. Whether we can help you get more years out of your existing system or find a replacement, we look forward to the challenge!