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Catalysts for Improving Efficiency in Regenerative Oxidizers Presentation at 2008 Energy Conference

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Thermal reaction requires 1450-1600 F depending on residence time in combustion ... In 2006-2007 the catalyst has been applied alone in 10-15 units in board industry. ... – PowerPoint PPT presentation

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Title: Catalysts for Improving Efficiency in Regenerative Oxidizers Presentation at 2008 Energy Conference


1
Catalysts for Improving Efficiency in
Regenerative Oxidizers Presentation at 2008
Energy Conference
  • Drs. Yurii Sh. Matros and Grigori A. Bunimovich
  • Matros Technologies, Inc., St. Louis, MO

Novi, MI, May 06 2008
2
Outline
  • Regenerative oxidizers for VOC control
  • Fundamentals
  • Thermal versus catalytic
  • Catalyst retrofit efficiency
  • Catalysts
  • Case studies
  • Conclusions
  • Matros Technologies, Inc

3
Thermal and catalytic oxidizers
  • Purpose removal of volatile organic compounds
    via oxidation to more benign components
  • Examples
  • Oxidation of formaldehyde
  • CHOH O2 CO2 H2O
  • Oxidation of toluene
  • C7H8 9O2 7CO24H2O
  • Thermal reaction requires 1450-1600 ºF depending
    on residence time in combustion chamber and name
    of compound
  • Catalytic reaction occurs at 550-950ºF depending
    on type and amount of catalyst
  • Catalytic oxidation is more energy efficient for
    any type of VOC removal unit


4
RTO operation
Ceramic saddles
Ceramic saddles
Cleaned gas
250 F
200 F
5
RCO versus RTO
(mathematical modeling)
RCO
RTO
6
RCO versus RTO
  • 1. Less fuel to preheat process gas (Fuel-1)
  • 2. Less fuel to preheat air/fuel mixture to the
    burner (Fuel-2).

7
Catalytic RTO advantages
  • Fuel consumption decrease by 60-100
  • Low operating temperature
  • Pressure drop and electric consumption decrease
  • Less wear and tear in valves and other equipment
  • Longer switching cycle
  • Higher flow rate
  • Lower CO2 and NOx emission
  • Generally the catalyst is recommended at VOC
    concentration lower than 3-4 of LEL

8
Noble vs. base metal catalyst
9
Catalyst development
  • Purpose active, thermally stable and inexpensive
    catalyst for regenerative oxidizers
  • Method thermal activation
  • Aluminum and manganese oxides raw materials
  • Thermal treatment at 900-1000 ºC (1650-1800 ºF)
  • Result highly stable structure with well
    dispersed Hausmannite-like (Mn2Mn32O4) active
    component.

10
Example of commercial VOC oxidation catalyst
  • Manganese oxide (Mn3O4) over alumina, extruded
  • Moderate and high temperature VOC oxidation
  • Various size rings and cylinders, 15-mm rings are
    applied for regenerative oxidizers
  • Unique thermal stability
  • Halogens resistance
  • Low selectivity toward NOx at oxidation of
    N-containing VOCs
  • Operates in more than 100 oxidizers worldwide

11
Benefits of high thermal stability
  • 1,450 F long term operation
  • 1,650 F hours-long temperature excursions
  • regenerated from most poisons in situ
  • handles well VOC concentration spikes
  • extended operating life at normal operating
    temperatures
  • when partially deactivated can still be used at
    1000-1400 F

12
CASE STUDIES
13
RTO retrofit design
  • Analysis RTO data
  • Mathematical modeling
  • Catalyst amount
  • Temperature
  • Destruction efficiency
  • Pressure drop
  • Effect of catalyst poisons / Lifetime
  • Economic efficiency estimate

14
RTO retrofit example 1
  • Polystyrene foam manufacturing
  • Flow rate 27,000-42,000 scfm
  • Low-concentrated steam of n-pentane, i-pentane,
    c-pentane, and styrene to oxidizer inlet
  • Highly-concentrated side stream of pentane to
    oxidizer combustion chamber
  • No PM, small concentrations of contaminants Si,
    HCl
  • 3-canister RTO (Smith 1993)
  • 4.75 ft of 1 saddle
  • Bed design insures high efficiency of VOC
    reduction with side highly-concentrated stream

15
Operating results (Ex. 1)
  • Catalyst has been applied since December 2005
  • Fuel consumption reduced from 8.4 Mcfh to 2.7
    Mcfh
  • Annual fuel savings more than 300,000
  • Catalyst payback time 5 months
  • 99 destruction efficiency in initial compliance
    test
  • From lab tests catalyst retains 100 activity
    after 2 years of operation
  • Expected catalyst lifetime 10 years or longer

16
RTO retrofit example 2
  • Insulation manufacturing
  • Insulation mat curing oven
  • Formaldehyde, methanol, phenol
  • 30,000-45,000 scfm
  • Catalyst contaminants - sulfur, silicon,
    phosphorus
  • 3-canister RTO 8 ft of 1 saddle

17
Operation strategy involving catalyst
regeneration and temperature increase
18
Operating Results (Ex. 2)
  • First catalyst charge was applied from 1997 to
    2005, second has been used from 2005
  • Periodic catalyst regeneration is programmed in
    RTO controlled system
  • The catalyst has stable activity based on lab
    test results
  • Natural gas savings goes from 3-3.5 MCF/HR to 1.5
    MCF/HR during 7 years catalyst lifecycle
  • Total savings is about 1M for 7 years at price
    for NG 6/MCF. The project pay-back time is about
    12 months.

19
RTO retrofit example 3
  • Medium Density Fiberboard facility
  • Direct-fired fiber dryer (250 MMBTU/hr) and one
    board press
  • Cyclones and high temperature baghouses upstream
    the RTO (no WESP)
  • Raw materials wood fiber, resin, glue
  • Flow rate 90,000-100,000 scfm
  • Formaldehyde, methanol, phenol, acetaldehyde,
    terpenes
  • PM at 0.002-0.006 grains/ft3
  • Sodium sulfate and chloride from MDF press
  • 5 canister DÜRR RTO, 6 ft of 40x40 media in each
    canister

20
CATALYST TESTS RESULTS
  • After 5 years of operation, catalyst surface
    contained about 3 of sulfur and 0.5 of sodium

21
Operating Results (Ex. 3)
  • Catalyst installation during two days
  • Continuous operations for more than 6 years at
    880 ºF vs. 1600 ºF in the original unit
  • Catalyst stabilized its activity after 2-3 years
    of operation
  • First catalyst regeneration through thermal
    treatment was performed in March 2007
  • Natural gas savings 10 MCF/HR or about 700K
    annually at price for NG 9/MCF. The project
    pay-back time about 6-8 months.
  • In 2006-2007 the catalyst has been applied alone
    in 10-15 units in board industry.

22
Conclusions
  • Retrofit of thermal oxidizers to catalytic units
    is highly-efficient energy-saving technology
  • Fuel consumption reduction by 60-90
  • Reduction in NOx and CO2 emission
  • Short payback time
  • Commercial catalysts provide for high initial
    activity and long-term performance
  • Low-cost, highly thermally-stable manganese oxide
    catalyst
  • Hundreds of RTOs use catalysts
  • Case studies demonstrate good applicability of
    manganese oxide catalyst to various applications

23
Conclusion (continued)
  • About 800 regenerative oxidizers in various
    industries in US
  • Total volume of treated air 40 MLN scfm
  • At least 50 of these systems should be
    available for operating with catalysts
  • VOC content less than 3-4 of LEL
  • low concentrations of catalyst poisons
  • Fuels savings about 0.1 MMBTU/hr per each 1000
    scfm
  • Total potential fuel savings about 2000
    MMBTU/hr

24
THANK YOU FOR YOUR ATTENTION!
25
Additional slides
26
MATROS TECNOLOGIES, Inc.
Founded in 1993 by Dr. Yurii Sh. Matros, formerly
head of department in Institute of Catalysis,
Novosibirsk, Russia. The company teams up several
experts in the area of catalysis and catalytic
reactors
  • Process engineering
  • Heterogeneous catalytic processes, catalytic and
    thermal reactors, hydrodynamics of catalyst beds.
  • Catalyst testing, kinetics, deactivation and
    regeneration
  • Process development (modeling, simulation,
    scale-up and optimization), analysis and control
  • Technical services
  • Worldwide catalyst supplies to the U.S., Canada,
    Europe, and South-East Asia
  • Project management in catalyst installation and
    start-up
  • Engineering testing and troubleshooting of
    operating commercial reactors

27
Matros VOC Oxidation Technology
New products developed by the company
  • Manganese oxide and copper chromite catalysts
  • Manganese oxide catalyst for fluidized bed
    oxidizers
  • Pioneered regenerative catalytic oxidizer (RCO)
    technology in the US
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