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Emission Control Systems

• Catalytic Recuperative Oxidizers
• Thermal Regenerative - Catalytic Regenerative Oxidizers
• Activated Carbon Recovery Systems

1. the regulatory requirements of the facility
2. the type and design of the machinery
3. the general layout of the facilities
4. the minimum amount of air flow required to achieve present and future production goals, and finally,
5. the levels and types of solvents and particulate found in the air stream.

Dec-E-Tech offers both oxidation and solvent recovery systems. Oxidation systems elevate the air streams to temperatures where the hydrocarbons and oxygen breakdown into CO² and H²O. The solvent laden air stream must be held at temperature for a certain period of time and with enough oxygen to initiate the reaction. A catalyst allows the reaction to take place at lower temperatures. Catalytic systems offer fuel efficiency and easy operation but the catalyst can be poisoned or masked. Thermal oxidizers use dwell time and temperature and are less apt to mask. They must be built to endure elevated temperatures and have reasonable fuel consumption. Finally, Activated Carbon or Zeolite beds can be used as a collector for light solvent loads in large air flows called concentrators. These systems require an oxidizer or steam to desorb the bed for reuse similar to the recovery systems. Solvent recovery systems are used for production solvent loads when the solvent recovered can be reused in the process or sold easily. Inert atmosphere systems are for specific applications only and when they fit they offer easy, clean solvent condensation for high solvent loads. Dec-E-Tech offers all of these technologies.

Catalytic Recuperative OxidizersCatalytic recuperative oxidizers have primary heat exchangers used to pre-heat the incoming solvent laden air stream from the process. They use the heat generated by the solvents in the air stream or the exothermic reaction created in the bed to elevate the incoming process air to adequate temperatures to continue the reaction. The overall fuel efficiency of any system is reliant upon the solvent loading and the primary heat exchanger effectiveness. Our precious metal or base metal catalysts allow the reaction to take place at between 550º to 650ºF. The disadvantage of a catalytic system is that contaminants or debris in the process can either poison or mask the catalyst. The newer catalysts are better able to resist poisoning and allow for a broader range of solvents and contaminants.

Dec-E-Tech Catalytic Recuperative Oxidizers

• Ideal Flow rates between 100 – 30,000 SCFM
• Destruction efficiencies available from 95% to 99%+
• Ideal for use with multiple sources and varying flow rates.
• System sits on I beam skid for easy installation

• Flexographic Printing
• Gravure Printing
• Coating and Laminating Operations
• Heatset Web Offset Printing
• Paint Spray Booths
• Sterilization Processes
• Baking Operations

• Inlet filters prevent debris from masking the catalyst and building up on the heat exchanger.
• Variable frequency driven industrial grade blower.
• Low carbon, stainless steel heat exchanger
• Heat Exchanger effectiveness - 65%-70%.
• Cold side bypass to maintain proper inlet temperatures regardless of the solvent loading or heat exchanger effectiveness.
• Fully proportional / high turndown raw gas burner for fuel efficiency during all phases of operation.
• Stainless steel reactor has dual perforated plates with offset holes to provide uniform flow and temperature presentation to the bed.
• Reactor walls are lined with high temperature fabric and plate to prevent channeling.
• Typical catalyst consists of ¼ inch spheres or monolithic structures coated with precious metal plating, or base metal spheres for low pressure drop through the bed. Catalyst selection is dictated by the process parameters.
• System delivered with pre-wired control panels.
• Turnkey installations available.

Thermal Regenerative - Catalytic Regenerative Oxidizers Dec-E-Tech offers both thermal and catalytic regenerative oxidizers: Two chamber, three chambers, or more. The system is built for long life and excellent fuel efficiency. Thermal Regenerative oxidizers are an excellent choice for applications where masking, and/or poisoning are issues, or high volumes are required. Solvent laden air travels through one chamber of ceramic, heat absorbing saddles or structured packing, and enters the combustion chamber. After combustion, the warm clean air travels over the second chamber, heating the ceramic packing. At measured time intervals, the process air is switched from one chamber to the next in order to effectively use the heat recovered from the ceramic packing to elevate the process air close to operating temperatures. The operating temperature, design of heat recovery packing and time intervals between cycles are all designed to match the application and required results. 

Thermal Regenerative Features

• Sized for flows from 20,000 to 100,000 SCFM
• Destruction efficiencies typically 95-99+%
• Heat Exchanger values typically 90-95%
• Pre-wired, easy to use control panels
• Hard wired safety circuits
• Turnkey installations available

Catalytic Regenerative OxidizersCatalytic Regenerative systems operate similarly to the thermal regenerative system except that a certain amount of ceramic packing are coated with precious metal catalyst in order to significantly reduce the operating temperature. If the catalytic system fails for any reason, the system is designed for thermal operation.

Activated Carbon Bed Solvent Recovery System Dec-E-Tech designs and manufactures solvent recovery systems for processes and applications where production levels of solvent are produced and the solvent can be reused or sold. Typically, continuous solvent recovery systems have two or more absorbers where one is used to adsorb while the second is desorbing. At relatively low inlet temperatures, the solvent laden air stream is cleaned by passing through an activated carbon or zeolite bed. Here the solvent is adsorbed by the media and clean air is exhausted. Activated carbon systems use steam to remove solvents from the bed. Steam contaminated vapors are condensed condensed so that the organics and water can be separated by gravity decantation or distillation. Three unit systems allow for one bed to cool after steam regeneration and before being placed back into service. Our multiple bed systems place the cooling bed in service downstream from the bed in the primary adsorption cycle in order to recover emissions that might otherwise escape. Activated Carbon Bed Solvent Recovery System features:

• Modular design allows for single or multiple adsorbers.
• System uses filter, fan with VFD, cooling coil, adsorber, reactor and decant system with boiler if necessary.
• System efficiency typically 98% +
• Inlet solvent saturation level up to 50% LEL.
• Fault indication system.
• Inlet filter.
• Single switch operation.
• Cooling tower and coils
• Tanks for temporary storage of solvents.
• Distillation column available.

• Recovery cost ratio is 3:1 to that of Activated Carbon Systems
• Reduction in Secondary Emissions
• Higher level of safety for high solvent loads
• No effect on product quality.
• Recovered solvent is less contaminated.