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Oxi. X Thermal Processes - Durr India
A giant leap in containing industrial pollution
Air quality of India has been degrading at an alarming rate from the past few years. Industrial production plays a very vital role in contributing to this cause. The Government of India has come up with various regulations to curb this growing problem. As a result, there is widespread awareness about this problem, and the industry understands its responsibility towards the people and the environment. The enterprises have started working towards controlling the ever-increasing air pollution issue in India.
Dürr is committed to helping them in achieving this goal. Dürr has a wide variety of systems that allows these industries with air pollution control. One of those systems involves the use of thermal processes. This system can be easily customized according to the customers' requirements.
A thermal process treats the polluted air using a simple but effective separation technique. It involves combustion in which the pollutant is removed from the exhaust air. In all cases, if a pollutant cannot be collected for potential re-use respectively, then it is recovered, followed by which all these VOCs have to be destroyed. This system converts contaminants in the exhaust air into a non-hazardous substance at a specific temperature.
Operating Principle of the Thermal Process
The only condition on which thermal oxidation can be used is when the pollutants present in the air are flammable. During this, the impurities from the exhaust air can vary in their form. They may occur as mist, steam, or gas. A supply of energy is used to form a mixture of air and one or more flammable pollutants. After the mix is ready, the exhaust air is heated to a high temperature that the hydrocarbon molecules break down and combine with oxygen to produce steam and carbon dioxide.
Many industries prefer this air pollution control system because it involves various variants, suitable for several other applications. Dürr's thermal oxidizers are made in such a manner that they support both high and low volumes of airflow and deliver high thermal and destruction efficiencies for VOC abatement. Furthermore, the system can be modified according to the need. For example, unique compact designs or a system that can function in the auto thermal mode can be developed so that no external energy is required to clean the exhaust air.
Different system variants – Thermal Processes
Depending on the pre-heating method used, the thermal process can be divided into 2 basic groups – either recuperative or regenerative.
- Oxi.X TR – Recuperative Thermal Oxidizer
Recuperative thermal air pollution control systems (Oxi.X TR) work best with high concentrations of organic pollutants in the exhaust air. The Oxi.X TR is highly flexible as it consists of adjustable heat exchanger which helps in reducing the energy consumption by 15%.
This results in lowered capital expenditure.
- Oxi.X DF – Direct-fired Oxidizer
It is a particular variant that deals with the combustion of only a handful of critical substances, such as explosives, toxic, and carcinogenic pollutants.
- Oxi.X Regenerative Thermal Oxidizers
The Oxi.X regenerative thermal oxidation systems (RTO) do not go through the same problem. In this method, the exhaust air gets pre-heated by combustion energy. That is why no external power is consumed for the burner, thus allowing the system to operate in auto thermal mode and making the oxidizer highly efficient. The regenerative thermal oxidizer can give a purification level of over 99.8%.
- Oxi.X burner system
With a complete air pollution control system for all kinds of industries in India, Dürr also provides machinery to upgrade the existing systems. In addition, Dürr offers a whole range of Oxi.X Burner systems as each burner has a specific property and function that makes it unique.
Dürr aims to cover all the possible requirements and provide their customers with the ideal addition to their thermal oxidizer systems.
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Sorpt.X SW – Wet Scrubbers for Acid Gas Absorption
When the exhaust air connects with a medium where the contaminant dissolves more successfully than in the air, the contaminant passes into the medium, releasing the purified air from the system. This phenomenon is known as the sorptive process.
Sorptive processes comprise two parts, i.e., Absorption and Adsorption. These two processes differ significantly in the way that they operate.
The two kinds of sorptive processes are mentioned below in detail:
Absorption Process
In Absorption, a substance dissolves another substance. The contaminant or pollutant here is usually a gas, while the absorbing medium is often a liquid but can also be a solid.
Gas scrubbing is widely applied. In this process, the by-products of combustion or non-essential exhaust gas pollutants like halogens and their acids and chemicals, such as ammonia and sulfur oxides, are eliminated from exhaust gases or exhaust air. This phase works on the oxidation process and many times precedes it. Dürr Air Pollution Control System Maintenance Services in India provide a wide array of acid gas removal technologies comprising wet acid gas absorbers, dry sorbent injection, wet scrubbers and spray dryer absorbers.
Absorption separates pollutants from the exhaust air and is used for cleaning flue gases.
Adsorption process
The adsorption process helps in the concentration of pollutants. It's required when the exhaust air comprises a low to medium pollutant concentration. The pollutants here form a physical connection with the adsorbent. As a result, they are drawn out of the air and directed into the adsorbent. Activated carbons and zeolite materials are the most utilized adsorbents.
When the contaminants have been concentrated, they are moved to thermal or catalytic oxidation. At this location, concentrated pollutants are eliminated. After this, the purified air is released from the system. This procedure is an affordable and productive process for cleaning exhaust air with a low concentration of contaminants. If materials recycling is needed, systems like solvent recovery and condensation are used after the adsorption process.
The adsorbents are regenerated after a certain period to ensure pollutants do not become saturated and become unable to take in any more material. This process is known as desorption. It makes use of steam, inert gas, or hot air.
There are two kinds of adsorption processes available. The first process is fixed-bed adsorption, where many adsorbers are utilized alternately in desorption and adsorption modes. The second adsorption process is done with a substantially rotating rotor system comprising a particularly designed concentration rotor.
Sorpt.X SW
Dürr Air Pollution Control System provides certified solutions for emission control using both adsorption and absorption technologies.
Adsorption is used for concentrating the pollutants. The pollutants are separated from the exhaust air after adsorption by a sorptive system. In Absorption, contaminants are removed from the exhaust air. This process is usually used for purifying flue gases.
In India, Dürr Air Pollution Control System Maintenance Services India manufactures many Sorpt.X SW wet scrubbers, including packed tower designs, tray towers, and spray towers for industrial acid gas emission control.
Benefits of Sorpt.X SW
Minimal pressure drop
Easier operation and construction
Not susceptible to plugging
The removal efficiency is high for a range of acid gases such as HF, SOx (SO2 and SO3), and HCl.
The cost for capital equipment and installation is less
Footprint is small
Flexibility of functioning (acid gas concentration, gas volume etc.)
Functionality of Sorpt.X SW
Following the principle of acid gas removal, the acid gas is exposed to an alkaline agent, and by chemical reaction, it creates a stable salt. It can be subsequently removed with the liquid. This result is achieved in a spray chamber, like a vertical tower, where water incorporating the reagent supplies a contact surface for the chemical reaction to occur.
The reagents used often include:
Sodium carbonate (soda ash) Na2CO3
Sodium hydroxide (caustic) NaOH
Calcium hydroxide (hydrated lime) Ca(OH)2
Magnesium hydroxide Mg(OH)2
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RTO with a Rotary Valve – Oxi.X RL
The Oxi.X RL is a unique air pollution control system with a rotary distributor valve. This regenerative thermal oxidizer is capable of eliminating more than 99% of Volatile Organic Compounds (VOCs), Hazardous Air Pollutants (HAPs), and odors that emit from the exhaust gas. The Oxi.X RL depends on the thermal process for its functionality.
Working Principle of Oxi.X RL
The Oxi.X RL comes equipped with 12 separate ceramic heat exchanger beds stacked radially over a proprietary distributor valve. The beds in this air pollution control system are pre-heated before the contaminants enter the system. The incoming contaminated air enters the media bed via the system's base and is further drawn up through five of the beds.
As the air enters the system, it is heated continuously, due to which it rises to the top of the system and enters the combustion chamber. Here the burner provides the air with additional energy required to complete the oxidation process. The pollutants present inside the exhaust air are oxidized, leaving behind CO2 and H2O as the by-products of the process. Hot, clean exhaust gas is then drawn downwards through the 5 adjacent ceramic beds. Here the thermal energy is transferred to the blocks before the clean air is released into the atmosphere.
The rest 2 spare beds in the air pollution control system help prevent the cross-contamination between the inlet and the outlet sections and ensure the high efficiency of the Oxi.X RL unit. Up to 95% of the energy required to carry out the oxidation process is recovered internally. This keeps the fuel consumption by the burner to a minimum.
How is Oxi.X RL made?
The Oxi.X RL air pollution control system is available in multiple sizes. Its compact and standardized size helps create a unique airflow through a rotating distributor in a single container. This system comes with 12 different ceramic heat exchanger beds arranged radially above a rotary distributor valve. The Oxi.X RL is equipped with a state-of-the-art burner control system consisting of a burner and a patented rotor. This air pollution control system is pre-assembled on transport frames and shipped in sections to keep the installation time and cost minimum.
Advantages of using Oxi.X RL RTO over other RTOs
The Oxi.X RL RTO is one of the most compact systems of its kind in the market. It consists of a unique rotary valve system and radial ceramic heat exchanger beds. The unit comes pre-fabricated and assembled from the factory. This allows it to be shipped, installed, and commissioned in a very short period. It can run without hydraulic or pneumatic dampers, actuators, and limit switches. This is because it comes equipped with an electrical distributor valve. Hence, it helps reduce the complexity of the air pollution control system, providing a significant reduction in the maintenance requirements for the system. Every Oxi.X RL RTO comes equipped with an air-conditioned control room. This room houses the main control panel and the frequency converter required by the system. As a result, most of the wires can be easily pre-installed, and even the systems are tested before they are ready to leave the factory.
Advantages of using an Oxi.X RL RTO –
Easy installation
Small – compact design
Low Maintenance
Less operating expenditure
No hydraulic or pneumatic valve needed
Where can Oxi.X RL be used?
The Oxi.X RL system can be used in a wide variety of industries, such as – chemical, pharmaceutical, petrochemical, carbon fiber, food, and waste treatment/recycling, to name a few.
Technical Specifications of Oxi.X RL
Dürr Oxi.X RL RTO air pollution control systems are available in multiple pre-fabricated sizes, which can help treat the exhaust gas with a flow between 6000 Nm3/h to 126,000 Nm3/h. It can also treat an exhaust with a pollutant concentration level between < 1 g/Nm3 to 10 g/Nm or up to 25% LEL (Lower Explosive Limit). This particular RTO offers an efficiency level of more than 99% and can easily remove the following pollutants from the exhaust gas in industrial processes –
- Aliphatic and aromatic hydrocarbons
- Hazardous air pollutants (HAPs)
- Odors
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Control Air Pollution with Oxi.X RC (RTO)
To clean exhaust air comprising unpleasant odors and solvents, Dürr Air Pollution Control Solution created Oxi.X Air Pollution Control Systems in India. These systems are based on a highly efficacious thermal process.
The main characteristics of Oxi.X – Regenerative Thermal Oxidizers are:
• Helps in attaining a purification level of over 99.8%.
• High thermal efficiency
• Less operating expenditure
• Minimal maintenance design
What is Oxi.X RC?
Dürr Air Pollution Control Solution has developed the Oxi.X RC regenerative thermal oxidizer (RTO), which provides unmatched cost-effectiveness and clarity. The equipment has a two-chamber, single-vessel system, which ensures thermal efficiencies up to 97% and 99+% destruction of volatile organic compounds. The Oxi. X RC RTO works perfectly in odor management, VOC abatement, and controlling Hazardous Air Pollutants (HAPs). In addition, the Oxi.X RC RTO will work in a self-sustaining model with no additional fuel needed for odor and VOC control.
Benefits of Oxi.X RC RTO
• Since 2000, the device has over 300 installations and a certified and reliable design
• The VOC destruction efficiencies of 99+% aid in fulfilling strict regulatory codes
• Cost of operating fuel is lowered when thermal efficiency is up to 97%
• Oxi.X RC RTO has a non-wearing, positive sealing, and non-contacting single valve via high-pressure air and delivers trouble-free operation, leading to low maintenance costs
• Even in harsh climate conditions, Oxi.X RC RTO has an electric valve drive, which helps in providing trusted performance and quiet operation
Oxi.X RC RTO Operating principle
The Oxi.X RC RTO has a valve, which uses a double-air seal. It is the only moving part present in the unit. The easy oscillating design provides uniform air distribution, leading to a maintenance-friendly unit. Between heat recovery chambers, a smooth flow transition is enabled with the ingenious design of the Oxi.X RC RTO, along with the switch valve, which removes pressure spikes virtually. The Oxi.X RC regenerative thermal oxidizer (RTO) design is the ideal solution for pressure-sensitive processes to occur.
Design of Oxi.X RC RTO
The Oxi.X RC regenerative thermal oxidizer (RTO) gives cost-effective benefits and lowers complexity with its modular and design. For quick installation time, units up to 65,000 SCFM are manufactured skid-mounted. These units are 99% assembled by the factory for an economical and effortless installation. To easily access controls in any kind of weather, a climate-controlled, skid-mounted control room is required.
Oxi.X RC RTO Application areas
The Oxi.X RC regenerative thermal oxidizer (RTO) has a single-vessel design and supplies cost-effectiveness and clarity with a 2-chamber. To attain purified air and eliminate volatile organic compounds (VOCs) with no additional fuel, the Oxi.X RC RTO operates in a self-sustaining model. More features and advantages of Oxi.X RC RTO are:
• In harsh climatic conditions, trusted performance and quiet operation are provided by an electric valve drive
• Easy access to controls and uncomplicated installation is supplied by a climate-controlled, skid-mounted control room
• Efficient use of energy is imparted by the smooth valve switching with negligible pressure fluctuation
• To save money and time during installation and start-up, the factory is pre-wired, pre-tested and pre-assembled
• Media chambers are areas where positive separation of media beds without metal divider walls takes place
• For effortless removal of organic deposits, the ceramic media is baked out
• Electrical operating costs are minimized due to cost-effective and engineered ceramic heat exchange media beds, which provide low-pressure drop
• Secondary heat recovery by hot water, air, electricity generation or adsorption cooling, steam, the thermal oil is optional
• Natural gas, butane, propane, gaseous or liquid biofuels and fuel oils are a part of the fuel options needed for Oxi.X RC to work
• For high-solvent load applications, a hot-side bypass system can be used
Oxi.X RC RTO Technical specifications
• Single unit, low capacity: 20,000 to 90,000 SCFM
• Thermal efficiency: 95% to 97%
• VOC destruction efficiency: 99+%
• Autothermal operation: 3-4% LEL
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Oxi.X RP - Your One-stop-solution for Air Pollution Control - Durr India
Economic development in any society generates jobs and elevates the standard of living. Industrial development fulfils both these criteria and brings several adverse effects on the environment, such as air pollution.
It is imperative to ensure that the pollution emitted by these industries is minimized. That is why the industries require a highly efficient and dependable solution to control this issue of air pollution.
This is where Dürr comes in. As an international market leader, Dürr acts as a one-stop-shop for several industries and offers high-performance systems for air pollution control.
It offers a comprehensive range of air pollution control solutions specially designed to meet customers' requirements. One of the most popular ways to treat polluted air is with the help of the thermal process. This process is based on the separation principle, wherein the pollutants are removed from the exhaust air produced during the manufacturing process via combustion.
Oxi. X RP – Regenerative Thermal Oxidizer
The Oxi.X RP regenerative thermal oxidizer by Dürr was formerly known as Epsilon. It has a highly flexible design with a modularized multi-canister thermal oxidizer. This makes it suitable for varied use against Volatile Organic Compounds (VOCs) and Hazardous Air Pollutants (HAPs). It also acts as a perfect solution for odor control during a pollution control process.
Benefits of using Oxi.X RP RTO
RTOs are proven solutions for thermally efficient VOC air pollution control systems. Oxi.X RP RTO offers an innovative compact design that delivers low operating costs and is economically viable. It also ensures high efficiency during VOC destruction.
This system is also equipped with tailored heat-exchange media designed for optimized thermal efficiency, reduced pressure drop due to cost-effective operation, and application against a broad spectrum of organic/inorganic contaminants.
Here are a few advantages of using Oxi.X RP over other RTOs –
It offers broad application use over organic and inorganic contaminants, optimized thermal efficiencies due to tailored heat-exchange media, and cost-effective operations because of minimized pressure drop.
High reliable poppet valve design offers long run life and increased Return On Investment. (ROI).
Oxi.X RP meets the global standards of VOC control as it offers destruction efficiency of up to 99.8%.
It works even with high-solvent-load due to its hot-bypass system.
Its ceramic media bake-out cleaning simplifies the removal process of organic residues and offers smoke-free emission to match the broader environmental codes.
It comes equipped with optional secondary heat recovery for hot water, thermal oil, steam, electricity generation, or adsorption cooling.
Consists of multiple fuel options, including natural gas, butane, propane, and oils.
Comes with optional fuel gas injection systems.
To maintain a harmonized process, the Oxi.X RP comes equipped with the feature of temperature profile control and offering variable cycle time.
Its heavy-duty construction with independent canisters increases the operating life of the system.
The Oxi.X RP RTO provides a perfect solution for air pollution control in scenarios where a multi-canister thermal oxidizer is required. This particular system can be configured with 3, 5, or even more canisters. Furthermore, the Oxi.X RP RTO comes equipped with a modular and flexible design to meet the specified performance criteria. Thus the unit can deliver highly effective VOC destruction with low offering and capital costs.
Technical Specifications of Oxi.X RP RTO
Flow Capacity - 2,000 to 200,000 Nm³/h
VOC Destruction Efficiency - 99.8%
Thermal Efficiency - 92% to 98%
Autotherm Operation - 1 to 2 g/Nm³/h or lower
Turndown Ratios - 1:5 to 1:10 depending on the number of cans
VOC Concentration - Up to 25% LEL by using optional hot-side bypass
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