technical specifications regenerative thermal oxidizer ...

TECHNICAL SPECIFICATIONS REGENERATIVE THERMAL OXIDIZER SYSTEM

Suite 400 21 Unionville Road Douglassville PA 19518 (215) 234-8188

Table of Contents

General Specifications................................................................................. 1 Operating Costs........................................................................................... 2 RTO System ................................................................................................ 3 Gastrain ....................................................................................................... 4 Manifold Specifications................................................................................ 5 Exhaust Fan ................................................................................................ 6 Hydraulic System......................................................................................... 7 Control Room .............................................................................................. 8 System Controls .......................................................................................... 9 Plan Views................................................................................................. 10

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518 215-234-8188 • www.nestecinc.com

General Specifications Conditions (Design Basis)

Design

Inlet Temperature

90°F

Inlet Static Pressure

-2°

Altitude

TBD

Specified Standard Max Volume

24,000 scfm

Specified Standard Normal Volume

21,349 scfm

Solvent Loading

164.4 lb/hr

Solvent Type

TBD

Solvent Heat Value (assumed)

15,000 btu/lb

Number of Towers

2

Purge

NA

Individual Tower Bed Area

58.5 ft²

Individual Tower Bed Velocity

410 fpm

Individual Tower Bed Gas Flow Volume

24,000 cfm (vertical)

Heat Exchange Media

Structured Packing

Heat Exchanger Bed Height

5 ft

Heat Exchanger Thermal Efficiency

93%

Heat Exchanger Free Board

0 ft

Inlet Temperature (T1)

90°F Dry Bulb

Combustion Chamber Temperature (T2)

1,550°F (min)

Exhaust Temperature (T4)

193°F (max)

Total Installed Burner Capacity

5 mmbtu/hr

Combustion Chamber Design Temperature

2,000°F

Combustion Chamber Retention Time

0.5 seconds

RTO Overall Destruction Efficiency

95%

RTO Particulate Removal Efficiency

NA

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518 215-234-8188 • www.nestecinc.com Page 1

Operating Costs

24,000 scfm with 164.4 lbs/hr solvent: Consumption Rate

Hourly Cost

Annual Cost

Fuel

0

Mmbtu/hr

$ 0 /hr

$ 0 /yr

Electricity:

70

Kw

$ 3.17 /hr

$ 12,680 /yr

$ 3.17 /hr

$ 12,680 /yr

Total Operating Costs

Operating Cost Assumptions Maximum Solvent Loading: Electricity Costs Annual Operating Hours

$

164.4

lbs/hr at 15,000 btu/lb

0.045

Kw/hr

4,000


RTO System RTO By-Pass

System Abort Path

RTO Isolation Damper

Metal Seated Butterfly

RTO Isolation Damper Construction

Aluminum painted mild steel

RTO Isolation Damper Actuator

Hydraulic Rack and Pinion

Burners

Option

Type or Manufacturer

Manufacturer

--

Eclipse (or equivalent)

Model

--

Ratiomatic

Number of Burners

1

Individual Burner Size

--

5 mmbtu/hr

NOX Output (greater than inlet)

--

Less than 0.1 lb/mmbtu

CO Output

--

60 ppmv (max)

Fuel Injection System

Optional

--

RTO Burner Enclosures

Optional

--

Side view of RTO system. One small hotspot which will be repair during installation. Recovery chambers are sized for 8’ beds allowing for various heat recovery media options. Side view of the RTO system showing bottom skid for ease of installation. All hydraulic tubing is stainless steel.

Fresh Air Inlet

Option


Fresh Air Inlet

Included

Fresh Air Inlet Damper

Included

Single Blade

Fresh Air Inlet Damper Actuator

Included

Hydraulic, Open/Close

Variable Frequency Drive

Option


Manufacturer

AB, Robicon, Emerson (or equivalent)

Size

150 hp

“Flying Start” Capability

Included

Enclosure

Included

NEMA 1 w/ Fans & Filters


Gastrain

Exhaust Stack


Diameter/Height

42”/62’

Material

Mild steel

Insulation

Per OSHA requirements

RTO Towers

Option

Materials of Construction

42” diameter/ 60’ high stack with 180° test platform and caged ladder per OSHA guidelines.

Type or Manufacturer 3/16” mild steel

External Coating

Included

Gun Metal Gray

RTO Tower Insulation

Option


Heat Exchanger Thickness, Density, Manufacturer

--

6” thick, 12 lb/cu ft. pyrobioc

Combustion Chamber Thickness, Density, Manufacturer

--

8” thick, 8 lb/cu ft, pyrobioc

Gastrain Blocking Valve Manufacturer

Option


--

Maxon (or equivalent)

Combustion Blower

Included

I.R.I Design

Included

Gastrain Enclosure

Optional

Burner/Gastrain Access Platform

Included

Platform Access Stairway

Optional

Platform Access Safety Ladder

Included

Open Grated Deck

OSHA Design


Manifold Specifications

Manifolds

--

38” / 42”

Inlet/Outlet Manifold Construction

--

12 ga aluminized

Included

Stainless steel bellows

Inlet/Outlet Manifold Velocity

--

3,500 fpm

Inlet/Outlet Manifold Insulation

--

Outlet Onl y – 4” thick, 4 lb mineral wool

Inlet/Outlet Manifold Cladding

--

Outlet Onl y – 16 ga galvanized

Inlet Manifold Valve Diameter

--

38”

Inlet Manifold Valve Type

--

Metal seated butterfly

Outlet Manifold Valve Diameter

--

42”

Outlet Manifold Valve Type

--

Metal seated butterfly

Inlet/Outlet Manifold Valve Velocity

--

4,500 fpm max

Inlet/Outlet Manifold Valve Construction

--

Aluminum plated mild steel

Inlet/Outlet Manifold Vacuum Breaker

38”Inlet/42” Outlet manifolds 12 gauge Aluminized steel. Outlet manifold insulated with 4” thick 4lb density mineral wool with 16 gauge galvanized cladding. Note the electrical conduit runs to the electrical room which will remain intact allowing for a straight forward installation.


Inlet/Outlet Manifold Diameter Inlet/Outlet Manifold Flex Connectors

Isolation and fresh air dampers with hydraulic actuators and solenoid junction boxes. This assembly is required for start-up of the RTO and connects to the process exhaust ductwork.

Option

Optional

Outlet Onl y

Purge Manifold Diameter

NA

NA

Purge Manifold Construction

NA

NA

Purge Manifold Flex Connectors

NA

NA

Purge Manifold Velocity

NA

NA

Purge Manifold Insulation

NA

NA

Purge Manifold Cladding

NA

NA

Purge Valve Diameter

NA

NA

Purge Valve Type Velocity

NA

NA

Purge Valve Construction

NA

NA


Exhaust Fan

Exhaust Fan

Option


Type

Force draft centrifugal

Quantity

1

Manufacturer

Twin Cities (or equivalent)

Volume

24,000 cfm (max)

Static Pressure

21” wc

Class

III

Arrangement

8

Inlet/Outlet Flex Connectors

Included

EPDM

Outlet Velocity

4,500 fpm

Materials of Construction

Mild steel

Fan Insulation

Included

4” thick

Fan Cladding

Included

16 ga galvanized

Lubrication System

Included

Manual

Motor Size/Type

Included

150 hp/TEFC

Motor Manufacturer

Delco

Motor Efficiency

Standard

Motor Service Factor

1.15

Spare 150HP Baldor motor (brand new and never used) included with purchase of system.

Twin City arrangement 8 Class lll main exhaust fan with 150hp motor. Maximum flow conditions are 24,000 cfm at 21” w.c. 70°F.


Hydraulic System

Hydraulic System

Option


Valve Actuator Type, Manufacturer

Included

Rack and Pinion Flo-Tork (or equivalent)

Hydraulic Pump

Included

Racine (or equivalent)

Stand by Pump

Optional

Heated Fluid Reservoir

Included

Hydraulic Line Material

--

Hydraulic Line Insulation

Stainless Steel

Optional

Flo-Tork rack and pinion hydraulic actuator similar for all dampers. Also shown are the GO proximity switches to prove position in both the open and closed positions.

One of four main diverter valves with Flo-Tork hydraulic actuator and solenoid cabinet. Each actuator has independent flow control for valve speed setting. Inlet and outlet valves are step seat construction 38” inlet, 42” outlet. Access doors and endplates for ease of inspection of all valves and cold face support grid areas. Hydraulic solenoid cabinets typical for all dampers. Each cabinet has local speed control to set damper speed base on ambient conditions.


Control Room

Control room with locked door and air conditioning system.

Control Room lighting system

Control Room


Manufacturer

Parkut (or equivalent)

Size

11’-9” wide x 6’-9” deep x 10’ high

Lighting

Fluorescent

Ventilation

Wall mounted air conditioner

Square D main disconnect and thermostat for room conditioning.

Local power center for control room.

System hydraulic skid located inside control room. Racine hydraulic pump.


System Controls

System Controls


Master Control Panel

Custom NEMA 12

Programmable Controller (PLC)

Allen-Bradley 5/03

Human Machine Interface (HMI)

Allen-Bradley 900 Series

Software, files & printouts


Automatic Sequence Start/Stop Fresh Air Stand-by Mode

Main control panel showing Honeywell Tru-Line chart recorder, Allen Bradley MMI 1000 panelview and Honeywell UDC high temperature limit controller.

Allen Bradley PowerFlex 700 150 HP VFD. Located in a NEMA 1 enclosure w/ fans and filters. Flying Start capability.

High Temperature Limit

Watlow

Chart Recorder – Circular Chart

Honeywell DR 4500A

Inlet Temperature

T/C Type K – Watlow

Outlet Temperature


Combustion Chamber Temperature


IEC Type Components

IEC Motor Startes & Relays Low Peak Fuses

(Int ernat ional E lectrotechnical Commi ssion)

Enclosure

NEMA 12 Indoors/ 3R Outdoors

Remote Operation Control Panel


MCC and power distribution for main panel and VFD.

Outside of VFD (Hoffman enclosure) VFD set-up.

cabinet MMI for

Picture of inside of main control panel showing Allen Bradley SLC 5/03 controller.


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