Three-bed RTO
Product Introduction: The three-bed regenerative thermal oxidizer (RTO) is a medium- to low-concentration organic waste gas treatment system that features the lowest operating energy consumption and exceptionally high removal efficiency. Compared with conventional catalytic combustion units, direct-fired thermal oxidizers (TO), and two-bed thermal oxidizers, the RTO boasts high thermal efficiency (≥95%), low operating costs, and the ability to handle large air volumes of low-concentration waste gases. When the concentration is slightly higher, secondary waste heat recovery can be implemented, further reducing production and operational expenses. Process Principle: The low-temperature organic waste gas to be treated is drawn by the inlet fan into the ceramic media bed of Regeneration Chamber A, where the ceramic media has already “stored” the heat from the previous cycle. As the ceramic releases heat, its temperature drops, while the organic waste gas is heated to a higher temperature before entering the combustion chamber. In the combustion chamber, the burner combusts fuel and releases heat, raising the gas temperature to the set oxidation temperature of 760°C, at which point the organic compounds in the waste gas are decomposed into CO2 and H2O. Because the waste gas has been preheated by the regenerative chamber, the oxidation process itself also releases some heat, thereby reducing the amount of fuel required by the burner. The oxidation chamber serves two functions: first, to ensure that the waste gas reaches the set oxidation temperature; and second, to provide sufficient residence time for complete oxidation. After the waste gas is purified and becomes high-temperature clean gas, it exits the combustion chamber and enters Regeneration Chamber C (where the ceramic media from the previous two cycles have already been cooled and purged), releasing heat and lowering its temperature before being discharged. Meanwhile, the ceramic in Regeneration Chamber C absorbs heat and stores a large amount of thermal energy for use in heating during the next cycle. During this cycle, Regeneration Chamber B performs the purging function. Once the cycle is complete, the inlet and outlet valves of the regenerative chambers are switched: Regeneration Chamber C takes in the incoming gas, Regeneration Chamber B exhausts the treated gas, and Regeneration Chamber A is purged. In the subsequent cycle, Regeneration Chamber B takes in the gas, Regeneration Chamber A exhausts the treated gas, and Regeneration Chamber C is purged, and this alternating sequence continues indefinitely. When the RTO is not yet ready to operate or is shut down, the waste gas can temporarily bypass the RTO and be discharged directly through the stack. To enhance environmental protection and energy efficiency, a heat exchanger can be installed at the RTO’s tail end for waste heat recovery. Process Flow Diagram Performance Characteristics: ● Can treat virtually all waste gases containing organic compounds. ● Capable of handling large air volumes and organic waste gases across a wide range of concentrations. ● Offers great flexibility in processing organic waste gas flow rates (nominal flow rate ranging from 20% to 120%). ● Adapts well to variations and fluctuations in the composition and concentration of VOCs in the waste gas. ● Insensitive to small amounts of dust and solid particles entrained in the waste gas. ● Achieves the highest thermal efficiency among all thermal combustion-based purification methods (>95%). ● Under appropriate waste gas concentration conditions, can operate on self-generated heat without the need for auxiliary fuel. ● High purification efficiency (three-chamber system >99%). ● Requires minimal maintenance and offers safe, reliable operation. ● Organic deposits can be periodically removed, and the heat storage media can be replaced. ● The entire system exhibits low pressure drop. ● Long service life. Application Fields: Widely used in painting and coating processes for automobiles, vehicles, shipbuilding, and industrial products; in the petroleum, chemical, ink, and dye industries; in the rubber and plastics, leather, adhesive tape, electrical insulation, enameled wire, electronics, and printed circuit board industries; in printing, packaging, metal sheet coil coating lines, laminating lines, tinplate can manufacturing, and textile dyeing industries; in the building materials, decoration, and furniture painting and coating sectors; as well as in the pharmaceutical, food, and additive industries. Applicable Waste Gases: ● Types of organic waste gases: alkanes, alkenes, alcohols, ketones, ethers, esters, aromatics, benzenes, and other hydrocarbon-based organic waste gases. ● Low concentrations of organic compounds (simultaneously meeting the requirement of being below 25% of the lower flammable limit) and large air volumes. ● Waste gases containing multiple organic components, or those whose organic composition frequently changes. ● Waste gases containing substances that can easily poison catalysts or reduce their activity. ● Not suitable for waste gases with high silicon resin content.
Category:
Keywords: Three-bed RTO
Three-bed RTO
Product Introduction
The three-bed regenerative thermal oxidizer (RTO) is a medium- to low-concentration organic waste gas treatment system that features the lowest operating energy consumption and exceptionally high removal efficiency. Compared with conventional catalytic combustion systems, direct-fired thermal oxidizers (TO), and two-bed regenerative thermal oxidizers, it boasts high thermal efficiency (≥95%), low operating costs, and the ability to handle large-volume, low-concentration exhaust streams. Moreover, when the concentration of the exhaust stream is slightly higher, secondary waste heat recovery can be implemented, further reducing production and operational expenses.
Process Principle
The low-temperature organic exhaust gas to be treated is drawn by the inlet fan into the ceramic media bed of heat storage chamber A, where the ceramic media has already “stored” the heat from the previous cycle. As the ceramic releases heat, its temperature drops, while the organic exhaust gas is heated to a higher temperature before entering the combustion chamber. In the combustion chamber, the burner combusts fuel and releases heat, raising the exhaust gas temperature to the set oxidation temperature of 760°C, at which the organic compounds in the exhaust gas are decomposed into CO. 2 and H 2 O. Since the exhaust gas is preheated in the heat-storage chamber and its oxidation also releases a certain amount of heat, the fuel consumption of the burner is reduced. The oxidation chamber serves two purposes: first, to ensure that the exhaust gas reaches the set oxidation temperature; second, to provide sufficient residence time for complete oxidation of the exhaust gas.
After the exhaust gas is heated to a high temperature through purification, it exits the combustion chamber and enters heat storage chamber C (where the ceramic media from the previous two cycles have already been cooled and purged), releasing heat in the process. As its temperature drops, it is then discharged, while the ceramic media in heat storage chamber C absorbs heat and stores a substantial amount of thermal energy for use in heating during the next cycle. Meanwhile, heat storage chamber B performs a purging function in this cycle.
Upon completion, the inlet and outlet valves of the heat storage chambers are switched: Heat Storage Chamber C takes in air while Heat Storage Chamber B exhausts, and Heat Storage Chamber A is purged. In the subsequent cycle, Heat Storage Chamber B takes in air, Heat Storage Chamber A exhausts, and Heat Storage Chamber C is purged, with this alternating sequence continuing indefinitely. When the RTO unit has not yet reached operating conditions or is shut down, the waste gas may temporarily be diverted through a bypass and discharged directly into the stack.
To promote environmental protection and energy conservation, a heat exchanger can be installed at the outlet of the RTO to recover waste heat.
Process Flow Diagram
Performance Features
● Can handle virtually all exhaust gases containing organic compounds.
● Capable of handling large air volumes and organic exhaust gases across a wide range of concentrations.
● Wide flexibility in handling organic waste gas flow rates (nominal flow rate ranging from 20% to 120%)
● Can adapt to variations and fluctuations in the composition and concentration of VOCs in organic waste gases.
● Insensitive to small amounts of dust and solid particles entrained in the exhaust gas
● Highest thermal efficiency among all thermal combustion purification methods (>95%)
● Self-heating operation can be achieved without the addition of auxiliary fuel under appropriate exhaust gas concentration conditions.
● High purification efficiency (three-chamber > 99%)
● Minimal maintenance requirements and safe, reliable operation
● Organic deposits can be periodically removed, and the heat storage unit is replaceable.
● The entire device exhibits low pressure loss.
● Long service life of the equipment
Application Fields
It can be widely used for spraying and coating applications in the automotive, vehicle, shipbuilding, and industrial product sectors.
Petroleum, chemical, ink, and dye industries;
Rubber and plastic, leather, adhesive tape, cables, enameled wire, electronics, and printed circuit board industries;
Printing, packaging, metal coil coating lines, laminating lines, tinplate printing and can manufacturing, and the printing and dyeing industries;
Coating and spraying industries for building materials, interior decoration, and furniture;
Pharmaceutical, food, and additive industries.
Applicable exhaust gas
● Types of organic waste gases handled: alkanes, alkenes, alcohols, ketones, ethers, esters, aromatics, benzenes, and other hydrocarbon-based organic waste gases.
● Low-concentration organic compounds (simultaneously meeting the criterion of less than 25% LFL) and high air volume
● The exhaust gas contains multiple organic components, or the organic components frequently change.
● Exhaust gases containing components that can easily poison the catalyst or cause its activity to decline
● Not suitable for exhaust gases containing high levels of silicone resin.
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