Thermal Oxidizer Design, Engineering & Integrated Solutions

Industry-leading expertise in thermal combustion-from fundamental principles to custom global installations.

As a premier global supplier of thermal oxidizer systems, PCC delivers end-to-end solutions tailored to your specific emission control requirements. We combine decades of proven design experience with advanced engineering to provide systems that ensure environmental compliance and operational efficiency. Whether you are seeking to understand the core mechanics of how a thermal oxidizer works, exploring our deep technical design capabilities, or ready to partner with a trusted supplier for a large-scale project, PCC provides the insight and technology to solve your most complex air pollution challenges.

Features

Guaranteed 99% VOC destruction efficiency

Up to 97% Heat Transfer

Completely modular

State of the art controls

Over 50 Years of Oxidizer experience

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.

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.

Oil & Gas

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

Asphalt

PCC has a full range of oxidation/combustion technologies to treat off-gases for most processes associated with the manufacturing of asphalt products.

Carbon

PCC offers a full range of technologies used to treat waste streams generated in the manufacture and refining of both activated carbon, carbon fibers, and carbon black.

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.

The PCC Design Advantage

Virtually every industrial manufacturing process results in waste products- cause for concern in today's environment. Thermal oxidation has proven through the years to be an effective and safe method for the disposal of a wide variety of industrial wastes if proper thermal oxidizer design practices are followed.

Thermal oxidizer design can be relatively straight forward or complex depending on the application, waste characteristics, and the air permit emission requirements. Most thermal oxidizer designs incorporate similar design principles to ensure that the desired oxidation reaction occurs and the waste stream contaminants are reduced to the levels necessary to achieve emission compliance.

How do you go about developing a thermal oxidizer design?

Step 1

An important first step in any successful thermal oxidizer design process is providing the thermal oxidizer supplier with clear and specific process design "inputs" and "outputs."

Thermal oxidation process defined.

Thermal oxidation is the effective employment of a process that provides thorough mixing of an organic substance with sufficient oxygen, at a high enough temperature, for a sufficient time, to cause the organics to oxidize to the desired degree of completion.

Here are typical thermal oxidizer design inputs and outputs.

Typical Design Inputs:

Upstream process operating conditions (batch or continuous process)
Full range of process operating conditions (Max., Min., Norm., Start-up, Upset, Design, etc.)
Waste stream design parameters (flows, pressures, and temperatures)
Waste stream composition and variability
Available utilities, site conditions, and physical equipment constraints

Typical Design Outputs:

Air emission limits (CO, NOx, VOC, SOx, HCl, PM, etc.)
Performance requirements (fuel consumption, reliability, noise, etc.)

Step 2

Begin thermal oxidizer design process.

Once these parameters are defined, the thermal oxidizer design process can begin. A basic thermal oxidizer system consists of a refractory lined vessel known as the thermal oxidizer, a burner, stack, and combustion controls.

Design inputs - Process application upstream of the thermal oxidizer and the corresponding waste stream or streams that need treated by the thermal oxidizer.

Design outputs - Typically the performance requirements and air emission limits the thermal oxidizer must be achieve.

"The Three T's" of Combustion.

These are required in order to achieve successful thermal oxidation:

Turbulence - Thorough mixing
Temperature - Oxidizing temperature (typically 1200°F - 1650°F)
Time - Combustion chamber residence time (typically 0.5 seconds - 2.0 seconds)

The Three T's of Combustion, along with sufficient oxygen, are essential and interrelated in all thermal oxidizer designs. The level of turbulence (mixing), the necessary reaction temperature, and the amount of time (residence time) is primarily dependent on the waste stream characteristics and the level of destruction required for achieving the specific air permit compliance.

PCC custom designs all of our thermal oxidizer systems. Our extensive industrial application experience coupled with our experience in handling a wide spectrum of waste streams, give us the expertise to determine how best to incorporate the Three T's of Combustion into each thermal oxidizer design.

Step 3

Determine essential design features.

As we mentioned, a basic thermal oxidizer system includes a refractory system, burner, exhaust stack, and combustion controls. More complex thermal oxidizer systems include heat recovery such as gas to gas heat exchangers and waste heat boilers, plus additional downstream pollution control equipment such as scrubbers, particulate filters, and wet ESP's. Each of these components have a variety of important design features (too extensive to discuss here), which must be considered to ensure the complete thermal oxidizer "system" is safe, reliable, and meets all performance objectives.

Other important factors to consider when evaluating a thermal oxidizer supplier:

Experience level with the specific application
Industry reputation
Process design capabilities
In-house expertise
Project execution and delivery reputation
Services (installation, start-up, training, routine maintenance, etc.)
Financial strength

Step 4

Put PCC's Thermal Oxidizer Experience To Work For You

PCC's broad range of thermal oxidizer experience includes industrial, chemical, petrochemical, refinery, automotive, pharmaceutical, food, textile, mineral, wood products, carbon products, paper applications, and tobacco. This wide spectrum of industrial applications enhances our thermal oxidizer experience and expertise by exposing PCC to a wide range of waste streams that contain components such as Acrylonitrile, Hydrogen Cyanide, Chlorinated Hydrocarbons, Halogenated Hydrocarbons, Phospine, Acrylic Acid, Ammonia, Mercaptanes, Carbon Monoxide, and many others.

Along with hundreds of engineered projects to meet your unique requirements, our thermal oxidizer experience includes:

Advanced low emission systems

Multi-staged low NOx incineration

Low BTU gas burning

Thermal destruction of nitrogen bearing compounds

Waste heat recovery

PCC's broad range of thermal oxidizer experience makes us the market leader in the design and supply of advanced, custom designed thermal oxidation systems for the destruction of industrial waste gases and liquids.

Whether the application requires a standard "off the shelf" thermal oxidizer or a custom designed fully integrated thermal oxidation system as shown below, PCC performs for you.

Complete system integration is our specialty.

PCC's team of application and design engineers understands the need for integration of equipment and accessories from you (the customer's) perspective.

We have custom designed systems for many Fortune 500 companies ranging from $150,000 to more than $15 million dollars. Our professionals bring a wide range of global experience in application/process design, project engineering, project management, material selection, procurement, fabrication, inspection, transportation, installation, commissioning, and start-up.

PCC is here to clarify how a thermal oxidizer works

Thermal Oxidizers

Have several names and sub-categories, but they all have an identical job: operate to treat pollution.

Vapor combustor
Furnace
Direct laid-off thermal oxidizer
Healthful thermal oxidizer
Regenerative thermal oxidizer
RTO
Chemical change oxidizer
TO

A well-designed oxidizer will simply exceed 99.9% destruction potency of VOCs.

The typical pollutants treated by oxidizers are Volatile Organic Compounds, commonly referred to as VOCs. VOCs plus Oxygen and heat will result in an oxidizing reaction that breaks down the VOCs to CO₂, Water, and more heat.

Major Components of a TO

The simplest thermal oxidizer could be a straight TO (aka direct laid-off TO).

thermal-oxidizer-graphic-e15553504856098

Burner
Gas Train
Oxidizer Chamber
Internal High Temperature Insulation

Instrumentation
Control Panel
System fans
Combustion Air Fan
Exhaust Stack

The Process:

A vapor stream, containing the pollutants (VOCs) is commonly sent into the oxidizer chamber by a System Fan. If there is not enough Oxygen present in the vapor stream, additional ambient air will be introduced to complete the reaction.

Quick Reminder: VOC's plus Oxygen are required to complete the reaction.

The oxidizer chamber operates at an elevated setpoint temperature ranging from 1450°F to 1650°F+. This temperature is measured by thermocouples in the chamber. The Gas Train and Burner assembly will modulate firing rates to maintain setpoint temperatures based on temperature readings. Maintaining setpoint temperature is critical to ensuring destruction efficiency of VOCs.

Compliance Note: It is commonly required to data-log this chamber temperature as proof of air permit compliance.

The 3 Ts of Combustion

A well-designed oxidizer relies on three critical factors to ensure complete destruction of pollutants.

1. TIME (RESIDENCE TIME)

This is the duration the vapor stream remains at the required elevated temperature within the chamber.

Small Chamber = Short residence time.

Large Chamber = Long residence time.

Typical Requirement: 0.5 to 1.0 seconds. Longer residence times generally result in higher destruction efficiency.

2. TURBULENCE (MIXING)

Uniformity is key. If there are "cold spots" or poorly mixed oxygen, the reaction will be incomplete.

Design Strategies: Manufacturers use specific length-to-diameter ratios, tangential entry (for a "spin" effect), internal choke points, or profile plates to ensure vapors mix thoroughly with the flame and oxygen.

3. TEMPERATURE

The oxidizer chamber must operate at a precise setpoint-typically between 1,450°F and 1,650°F+.

Control: Thermocouples measure the heat, signaling the gas train and burner to modulate firing rates to maintain the setpoint.

Compliance: Data-logging this temperature is almost always required as proof of air permit compliance.

The vapor stream that's directed into the new combustion chamber, experiences the 3 Ts within the chamber, then exits towards the exhaust stack. The exhaust stack has samples ports for compliance testing and periodic sampling to substantiate destruction of the VOCs and since this is often a straightforward straight thermal oxidizer, there's no heat recovery.

Conclusion: How do Thermal Oxidizers work?

The theory of operation of a straight thermal oxidizer is simple. A vapor stream containing VOC pollutants is directed to an oxidizer chamber, that has been well designed with the three Ts in mind: Time, Turbulence, and Temperature. The oxidizer chamber is controlled to maintain an elevated setpoint temperature by modulating the firing rate of the Gas Train and Burner assembly. In the hot chamber, the VOCs will react with Oxygen and break down to less harmful components, CO₂ and Water. Finally, the vapor stream discharges through the exhaust stack with the VOCs destroyed to meet the air permit requirements.

Thermal Oxidizer Supplier And Sales

PCC sells and installs thermal oxidizers worldwide in North and South America, China, Taiwan, Korea, Malaysia, Thailand, India, Africa, Australia, Middle East, Kazakhstan, and many other European countries. This global experience gives us valuable thermal oxidizer sales and project execution expertise to successfully handle any thermal oxidizer project regardless of installation location and culture. We support our thermal oxidizer sales channels with a highly talented, experienced, and professional in-house sales team and experienced sales representatives and agents located throughout North and South America and other countries such as China, Malaysia, and Thailand.

PCC's thermal oxidizer sales team and project engineering team offer unique benefits and added services:

Custom designed systems

Proven thermal oxidizer experience

Global thermal oxidizer sales and project execution

Financial strength through corporate ownership

Installation, commissioning, and operator training support

Spare parts and regular maintenance service

Customer-oriented culture

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.

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