Catalytic Oxidizer VS. Regenerative Thermal Oxidizer

Technical Corner
Catalytic Oxidizer VS. Regenerative Thermal Oxidizer
Energy Comparison

 

A flexographic printing company will be replacing their existing Catalytic Oxidizer with a Ship & Shore Regenerative Thermal Oxidizer (RTO):
Both systems have a flow of 12,000 SCFM and the same VOC load.
The Catalytic Oxidizer has a 72% effective heat exchanger. The RTO has 95% efficiency heat recovery.
The follow calculations are hypothetical and do not take heat losses into account.

12,000 SCFM RTO operating without VOC at 95% effectiveness requires:

12,000 x 60 x 28.24 x 0.05   → 1.01 MMBTU/H
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106

With a VOC energy contribution of 27 lbs/hr or 4.08 MMBTU/H, at 98.5% destruction efficiency, the RTO burner will be at:

1.01 – 0.408 → 0.602 MMBTU/H

Assume the 12,000 SCFM Catalytic Oxidizer with a 72% effective heat exchanger is operating at 600°F with the same VOC load as the RTO, the burner will be at:

(10.17 – 8.09) x 12,000 x 60 → 1.49 MMBTU/H
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106

Savings compared to catalytic oxidizer is:

1.49 – 0.602 → 0.888 MMBTU/H or 8.88 therms/H

At operation of 24 hours/day, 7 days/week, 50 weeks/yr

8.88 x 24 x 7 x 50 → 74,592 therms/yr
at $1.00/therm → $74,592/yr

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