Speciality Thermal Oxidizers

Acid Gas

Zeeco offers both standard and customized waste disposal solutions for a variety of gas plant incineration applications, including thermal oxidation of amine treater off-gases (acid gas or tail gas), glycol dehydration vapors (BTEX), and SRU tail gas.

Zeeco's standard thermal oxidizers are available on short notice for purchase or rental, and offer the following available features:

Typical Performance:

• Destruction Efficiency (DRE) up to 99.9999%
• NOx emissions <30 ppm(vd) at 2% oxygen level
• NFPA 86-compliant Burner Management System (BMS)

Typical Applications:

• Amine Treater Acid Gas
• Glycol Dehydration System/BTEX Off Gas
• SRU Tail Gas
• Tank Vents

Design Features:

• Skid mounting is available: No extensive field wiring or plumbing between the thermal oxidizer and fuel rack
• 30' and 60' standard stack heights
• Zeeco's AR/GS-1 HEI pilot ignition system – pilot can be ignited and fired even when completely submerged underwater!
• Full color touch screen interface (HMI) with built-in diagnostics
• Cellular telephone modem for remote monitoring and assistance

recuperative

Typical Performance:

• High Destruction Efficiency (DRE): >99.9%

Typical Applications:

• Hot oil heaters
• Steam boilers
• Air and waste gas pre-heaters
• Sulfur service

Design Features:

• Direct fired
• Tolerant to upsets
• Accommodates all waste types
• No moving parts or heat-exchange media

Down-fired salt / caustic

Downfired Incineration Systems typically treat wastes containing inorganic salts (NaCl, Na2SO4, Na2S), organic salts (acetates and oxalates of alkali metals), caustic liquids, and non-combustible solid materials. Downfired Incineration Systems or Thermal Oxidizers earn their namesake from vertically-oriented burners located at the top of the incinerator that fire downwards. Zeeco's design promotes longer refractory life as well as accumulation space for any non-combustible solids contained in the waste gas. Many Zeeco downfired incineration systems employ additional equipment such as baghouses, multi-clone filters, and electrostatic precipitators to provide enhanced particulate removal capability.

Typical Performance:

• Residence time = 2.0 seconds
• Operating temperature = 1650 to 2000°F (900 to 1100°C)
• Waste Destruction Efficiency (DRE) > 99.9999%
• Particulate emissions rates = 0.005 to 0.08 grains/DSCF

Typical Applications:

• Chemical plants
• Petrochemical plants
• Spent caustic waste streams
• Organic/Inorganic salt solutions
• Wood products waste streams
• Biomass-to-Energy processes
• Catalyst applications

Design Features:

• Refractory materials selected for low porosity to minimize salt attack
• Proprietary design minimizes molten salt contact with refractory walls to promote maximum refractory life
• Proprietary design "freezes" molten salts prior to contact with downstream heat recovery/particulate removal equipment
• Particulate removal equipment may include baghouses, multi-clone filters, electrostatic precipitators, or venturi scrubber

multi-stage low nox

High temperature incineration of nitrogen-bound wastes in a traditional excess-air environment produces unacceptable levels of nitrogen oxide emissions. To limit the formation of NOx, Zeeco employs a multi-stage Low-NOx incineration process. Zeeco’s experience with nitrogen bound waste thermal oxidizers includes systems ranging in size from 1.0 MMBtu/hr (0.25 MMKcal/hr) to more than 450 MMBtu/hr (114 MMkcal/hr). The combustion chamber can range in size from 4.0' (1.0m) to 18' (5.5m) diameter.

Typical Performance:

• NOx emissions for Nitrogen Bound Waste Streams <100 ppm (vd)
• Waste Destruction Efficiency (DRE) > 99.99% (available up to 99.9999%)

Typical Applications:

• Petrochemical applications involving Amines, Nitriles, etc.
• Ammonia and/or Cyanide Vapors
• Sulfur Recovery Units: Sour Water Stripper (SWS) Gas Overhead Streams
• Carbon fiber manufacturing LT/HT Off-Gas streams
• Electronics manufacturing vent streams

Design Features:

• Guaranteed predictable emissions performance
• Proper re-ignition in oxidizing stage
• Burner combustion air is efficiently separated from waste combustion air for optimal control
• Dependable process control and long-term reliability

Carbon monoxide

Carbon Monoxide Boilers are thermal oxidizers that are used to oxidize carbon monoxide (CO)-rich waste gases that are typically generated by Fluidized Catalytic Cracking (FCC) and Residual Cracking (RCC) units in petroleum refineries. They are traditionally referred to as “CO Boilers” due to the large quantity of steam that is generated by an integral waste heat recovery system. Zeeco is an approved supplier of Carbon Monoxide Boilers for all of the world's major FCC/RCC process unit licensors.

Typical Performance:

• Residence Time = 1.0 seconds
• Operating Temperature = 1850°F (1010°C)
• Waste Destruction Efficiency (DRE) >99.9999%

Typical Applications:

• Petroleum Refineries: Fluidized Catalytic Cracking Units (FCCU)

Design Features:

• Custom engineered thermal oxidizer design guarantees optimal emissions performance
• Proven internal waste gas injection system ensures flame stability and proper ignition of carbon monoxide waste stream
• System-based approach provides dependable process control and reliability for the complete incineration and waste heat boiler package
• Refractory system design provides protection against catalyst particulate abrasion and high operating temperature

liquid wastes

Liquid Waste Incineration Systems typically treat wastes containing a wide range of water, hydrocarbons, and non-combustible solid materials. Liquid waste incineration systems or thermal oxidizers can be horizontally or vertically fired. Zeeco’s design features longer refractory life as well as proprietary liquid injection technology for any non-combustible solids contained in the waste stream. Many Zeeco liquid waste thermal oxidizers employ additional equipment such as scrubbers, baghouses, multi-clone filters, electrostatic precipitators, and SNCR / SCR systems to provide enhanced emissions reduction and particulate removal capability.

Typical Performance:

• Residence time = 1.5 – 2.0 seconds 
• Operating temperature = 1650 to 2200°F (900 to 1200°C)
• Waste Destruction Efficiency (DRE) › 99.9999%
• Meets globally recognized emission standards 

Typical Applications:

• Chemical plants
• Petrochemical plants
• Spent caustic waste streams
• Organic/Inorganic salt solutions
• Wood products waste streams
• Biomass-to-Energy processes
• Catalyst applications

Design Features:

• Refractory materials selected for low porosity to minimize salt and acid gas attack
• Proprietary design minimizes liquid contact with refractory walls to promote maximum refractory life
• Proprietary design of liquid injection nozzles prevents plugging
• Post combustion equipment may include scrubbers, baghouses, multi-clone filters, electrostatic precipitators, SNCR / SCR systems, or venturi scrubbers

Halogenated Hydrocarbon

Halogenated hydrocarbons are those containing chlorine, bromine, fluorine, iodine, etc. Chlorine is the most common halogen encountered in petrochemical plant waste. Vinyl chloride plants commonly use our incinerators, but Zeeco produces a full range of solutions for all gas and liquid halogenated hydrocarbon wastes.

Typical Performance:

• Residence time = 2.0 seconds
• Operating temperature = 1800 to 2200°F (982 to 1204°C)
• Waste Destruction Efficiency (DRE) > 99.9999%

Typical Applications:

• Vinyl Chloride Monomer (VCM) / Ethylene Dichloride (EDC)
• Carbon tetrachloride (CCl₄)
• Polyvinyl Chloride Biphenyls (PCB's)
• Brominated waste streams

Design Features:

• For small systems involving small amounts of HCl, a single stage caustic scrubber is typically sufficient for environmental compliance
• For larger systems, Zeeco recommends a two-stage absorber/scrubber, where HCl can be recovered as a liquid byproduct
• Waste heat recovery can be supplied via a firetube-style boiler integrated between the thermal oxidizer and the packed column