RTO operates with no fuel consumption at full design solvent loading

RTO operates with no fuel consumption at full design solvent loading

Client:

American Biltrite Corporation

Location:

Moorestown, New Jersey

Background:

American Biltrite was expanding production by adding a new high-speed coating line to their existing plant. A new pollution control device was required to meet stringent New Jersey Department of Environmental Protection (NJDEP) air emission requirements. The permit issued by NJDEP required a destruction removal efficiency (DRE) of greater than 99% for control.

Problem:

The new coating line was sized for twice the capacity of the existing lines to allow for future expansion. The customer wanted a reliable solution with the lowest annual operating cost that would exceed their permit requirements.

Over 1,650 pounds per hour of solvents were to be released from the new production line. Heptane and toluene were the most significant Hazardous Air Pollutants (HAP’s) in the process emissions.

Case Study

Solution:

Air Clear engineers performed a through review of the operating conditions and designed, fabricated and installed a three-can Regenerative Thermal Oxidizer with Natural Gas Injection (NGI) to meet the stringent New Jersey Department of Environmental Protection air emission regulations. It has successfully passed annual emissions tests for 20 years with a greater than 99% DRE and performance is monitored daily by a Continuous Emission Monitoring System (CEMS).

The system operates with very low to no fuel consumption at full design solvent loading. In addition, a continuous emissions monitoring system (CEM), continuously monitors oxygen, carbon monoxide and hydrocarbons in the stack emissions. The system operates at >99% DRE with less than 10 ppm hydrocarbons and less than 5 ppm CO in the stack emissions.

The system is a three-can design, with fresh air purge to ensure no puffs during valve switching. This feature allows the Air Clear RTO to provide such high destruction reduction efficiency. In addition monolith heat recovery media was utilized to provide a low pressure drop across the system. This, combined with a variable frequency drive, minimizes electrical consumption.

This unit was manufactured at Air Clear’s facility in Elkton, MD and installed in 2000. The RTO continues to provide daily reliable operation with greater than 99% DRE today.