PROCESS COMBUSTION CORPORATION
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Regenerative Thermal Oxidizers (RTO)

Reduce air pollution emissions from a variety of industrial processes.

Regenerative Thermal Oxidizers (RTOs) destroy Hazardous Air Pollutants (HAPs), Volatile Organic Compounds (VOC's) and odorous emissions. PCC's systems achieve emission destruction through the process of high temperature thermal oxidation, utilizing the 3 T's of Destruction, Time, Temperature and Turbulence, at the proper oxygen level to convert the pollutants into carbon dioxide and water vapor.

PCC's RTOs are designed to repurpose the thermal energy generated during operation, reducing the energy consumption and operating costs.

By thoroughly understanding your process, our systems are engineered and designed to optimize performance, maximizing your investment.

Download and complete our Design Application Form to receive a custom review of your RTO needs.

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Years of Experience and Discovery in RTO Technology

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RTO Related Patents

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The PCC Difference

Compare the PCC RTO with any others and you'll find these distinct advantages:

Quick Switch Indexing Valve

PCC Quick Switch Indexing Valve (QSV) - PCC's Quick Switch is an air sealed indexing valve that ensures durability with high performance. The indexing valve utilizes an air seal to assure a leak-free operation with soft stoppage, reducing valve slamming. The seals are selected for resistance to process gases, temperature, longevity, and durability. 

The QSV indexing valve and control system is designed to eliminate the continuous maintenance brought about by the endless movement and slamming of poppit valves. The proven QVS indexing valve drive system operates the flow control dampers smoothly in two chamber designs. The QVS indexing valve consistently moves the valve disks seat to seat in less than 1/2 second.

  • Virtually no pressure spikes and contaminant bypass as the valves operate in unison.
  • No leaky/erratic hydraulics or compressed air that change frequency during temperature fluctuations.
  • No moisture freezing pneumatic lines and cylinders.
  • Less maintenance, more up-time operation.

Integrated Manifolding

The PCC RTO assembly incorporates the inlet and outlet exhaust manifolds into the RTO's overall shell configuration, rather than fabricating the typical network of bulky, exterior space-consuming manifolds. This eliminates external RTO ductwork and insulation, enabling the system to sit flat on a concrete pad without legs.

This streamlined assembly design decreases maintenance costs and creates a compact footprint that is cost-effective to both manufacture and installs.

Application Specific Heat Recovery Ceramic Media

Our heat recovery chambers are designed to accept all types of media (structured/random packed) including ultra low-pressure drop media specifically designed for use in PCC's RTOs. The combination of high heat recovery with low-pressure drop results in significantly lower gas and electric usage, as well as higher VOC destruction efficiency, making it one of the most environmentally responsible pollution control units available today.

How PCC's RTO Works

The premise of PCC's RTO design is as simple as 1-2-3:

  • Heat is extracted from the hot purified gas and stored in the reheat recovery chamber as it leaves the combustion chamber.
  • After a period of time, the inlet/outlet QSV indexing valve switch positions (rotates clockwise) and the contaminated process gas is redirected through the hot heat sink (ceramic media) recovery chamber, where it is preheated to within 5% of the combustion temperature before it enters the combustion chamber. The QSV indexing valve rotates on a time base depending on the hydrocarbon loading and heating value (normally every 4 minutes).
  • In the combustion chamber, the burner supplements the 5%, bringing its temperature to 1500°F, at which the VOC is converted to harmless CO2 and water vapor.

Features

Guaranteed 99% VOC destruction efficiency

Up to 97% Heat Transfer

Completely modular

State of the art controls

Seven industry patents

Benefits

Global emission regulatory compliance – now and in the future

Low Operating costs, and low CO2 and NOx emissions

Great Reliability, Low maintenance costs

Quick, 3-day installation

Operator friendly

Proven leader in pollution equipment technology

Regenerative Thermal Oxidizer (RTO) industries include:

Chemical

Technologies to treat waste streams from Basic Chemicals (organic and inorganic chemicals, plastic resins, dyes, and pigments), Specialty Chemicals (adhesives and sealants, water treatment chemicals, plastic additives, catalysts and coatings) and the Agriculture Chemical manufacturing process.

Petrochemical

Treatment of waste streams from chemical products derived from petroleum. Specializing in Acrylonitrile and Acrylic Acid processes by using multi-staged technology which results in exceptionally low NOx levels.

Refining

Systems to control the waste stream from processes where a crude or semi-finished substance (such as metal, oil, or sugar) is converted (refined) into a finished or higher-grade product.  

Automotive

PCC’s technical solutions meet all aspects of Tier I, Tier II and Tier III manufacturing processes associated with the automotive industry. Treatment areas range from Dynamometer engine test stations to spray paint booth VOC elimination.

Pharmaceutical

PCC offers alternative solutions to treat a wide range of process in the Pharmaceutical industry. Thermal and Biological Oxidation technologies, including Flameless Thermal Oxidation (FTO) are possible options.

Textile

PCC's diverse Oxidation technologies provide the end user with options specific to the treatment of dyes, flame-retardants and other chemical treatments used in the manufacturing and treatment of textiles.

Manufacturing

PCC offers several options for the treatment of off-gases and other wastes associated with manufacturing. From simple to very complex systems, PCC can provide a suitable solution.

Converting

PCC has a full range of oxidation/combustion technologies to treat off-gases for most processes associated with the conversion of raw materials into products.

Metals

Multiple combustion/oxidation technologies make-up the PCC Solution for industries that are required to treat off-gases from the manufacturing processes specific to the production of non-ferrous metals such as aluminum, copper, and zinc; and ferrous materials such as steel. 

Food

PCC’s Oxidation Systems offer both biological and thermal options for the treatment of off-gases and other waste streams associated with the processing, conversion, preparation, preservation, and packaging of foods, food by-products, additives, and beverages.  

Engineered Wood Products

PCC’s unique ability to offer technology options for the treatment of compounds, adhesives and naturally occurring compounds that are present in the off-gas waste streams from the drying and pressing applications utilized in the EWP industry.  Biological and thermal options are available to meet the control requirements of the manufacturer.

Pulp & Paper

PCC provides alternative solutions to treat a wide range of process in the Pulp & Paper industry. RTO and Biological Oxidation are the most compatible options.

PCC Integration

With more than 1,000 systems successfully operating throughout the world, we’ve custom designed systems for many Fortune 500 companies ranging from $150,000 to more than $15 million.

PCC has experience working with many systems.  With installations successfully operating in over 35 countries, PCC has the knowledge and experience to integrate a new system with your current operating platform.

International Quality Certification, LLC

PCC's Quality Management System is certified in conformance with the ISO 9001:2015 standard.

PCC's adherence to consistent and predictable systems is a cornerstone of our long-term track record of success.

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What our customers are saying...

"PCC... The best-kept secret in the industry."

— Rohm & Haas

"PCC works like a well-oiled machine."

— Louisiana Pigments Company

"We would not be where we are today without the engineering knowledge and efforts, quality of construction, professionalism, and cooperation of your first-class organization."

— Montauk Energy Capital

"PCC's commitment to safety and quality allow completion ahead of schedule, under budget, and safely."

Toray Carbon Fibers America, Inc. 

"PCC's desire to deliver a quality product was apparent throughout all phases of our project, and PCC's overall gas combustion experience resulted in a robust and reliable operating unit."

 FMC Corporation 

"We are very pleased that it was commissioned five weeks earlier than the contract completion date."

National Electrical Carbon 

"PCC was absolutely on time with delivery of our thermal oxidizer... I was quite impressed. All the units we bought from PCC run flawlessly, even after 10 years. We can't calculate a MTBF, because there have been no failures."

Ford Motor Company 

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