The Science Behind the System
A high-performing thermal oxidizer system doesn’t just happen; it is the result of precise thermal oxidizer design. Whether you are treating emissions from a chemical reactor or a painting line, the design must balance destruction efficiency (DRE) with operating costs (OPEX).
At ABOUT US, we don’t use cookie-cutter templates. We engineer every system to match the specific “DNA” of your exhaust stream.
1. Core Principles of Thermal Oxidizer Design
Any effective thermal oxidizer design is built on the “3T” rule of combustion. Cadair engineers optimize these parameters for every project:
- Temperature: The chamber must reach 1400°F–1600°F (760°C–870°C) to break VOC bonds.
- Time (Residence Time): The gas must stay in the chamber for 0.5 to 1.0 seconds. Our design ensures no “short-circuiting” occurs.
- Turbulence: Proper mixing of air and fuel is critical. We use advanced burner modeling to ensure uniform heat distribution.
2. Anatomy of a Complete Thermal Oxidizer System
When you commission a thermal oxidizer system from Cadair, you are getting a fully integrated package. Key design components include:
- Combustion Chamber: Lined with high-grade ceramic fiber to withstand thermal shock.
- Burner Assembly: We select low-NOx burners that modulate based on the incoming VOC load.
- Heat Recovery Section:
- For RTO: We design vertical towers with ceramic media to recover 95% heat.
- For Recuperative units: We use shell-and-tube heat exchangers for rapid startup.
- Control System (PLC): The brain of the design, managing safety interlocks (NFPA 86) and LEL levels.
3. Choosing the Right Design for Your Application
The “best” thermal oxidizer design depends on your process data:
- High Volume, Low Concentration: The RTO design is mandatory here to prevent massive fuel bills.
- High Concentration: A Direct Fired Thermal Oxidizer (TO) design is safer and simpler, using the waste gas as fuel.
- Space Constrained: A Catalytic Oxidizer (CO) design offers a compact footprint and lower weight.
Conclusion: Engineering Your Compliance
Don’t settle for a generic unit. A tailored thermal oxidizer design ensures you meet EPA limits without wasting energy.
Get a System Design Proposal Send us your airflow and VOC data. Our engineering team will generate a 3D model and quote for your custom thermal oxidizer system.
