Thermal Oxidizer Systems

Meet Emission Regulations for Gas and Liquid Waste

Honeywell UOP Callidus® Thermal Oxidizer Systems help to efficiently solve your environmental challenges for gas and liquid waste. By evaluating your environmental challenges, we can use our extensive experience and cutting-edge technologies to provide custom designed solutions to meet or exceed stringent environmental regulations, including NOx standards.

Honeywell UOP Callidus Tail Gas Thermal Oxidizers, with a DRE range of 99 – 99.999, effectively destroy sulfur components found in Sulfur Recovery Unit tail gas. Callidus Thermal Oxidizer technology balances desired H2S destruction efficiencies, NOx formation and minimized CO production to meet environmental regulations.

Typical oxidizing temperatures vary from 1200˚F to 1800˚F, with residence times of 0.6 to 1.0 second. System designs for both natural or forced draft are available.

  • Typical Equipment
    • DeNOx Systems
    • SOx Removal Systems
    • Low emissions burner
    • Castable or brick refractory
    • Natural draft/ forced draft
    • Heat recovery (optional)
    • Stack
  • Typical Waste Streams
    • Sulfur plant tail gas
    • Carbon black tail gas
  • Benefits:
    • Refineries
    • Natural Gas Processing Plants
    • 20 to 150 MM BTU/hr burner
    • 1 second residence time
    • 1200˚F-1500˚F operating temperature

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Thermal oxidation of nitrogen-bearing wastes requires a specialized combustion approach. Single-stage combustion of these wastes can produce NOx emissions more than those allowed by most regulatory agencies. To maintain NOx emissions within acceptable limits, our De-NOxidizer system uses a multi-stage process to destroy wastes with a 99-99.999 DRE range.

  • The waste is burned in the first stage under substoichiometric, or reducing conditions. The high temperatures and lack of oxygen in the first stage cause the nitrogen-bearing compounds to form elemental nitrogen rather than NOx.
  • In the second stage, flue gas from the first stage is cooled to approximately 1400˚F by injection of water, steam or cooled recycled flue gas.
  • The combustion process is completed in stage three where the flue gas is oxidized at a temperature of 1700˚F to 2000˚F with excess oxygen present. NOx in the final flue gas typically ranges from 80 to 200 ppm depending on the waste composition. A destruction efficiency of 99.99 percent can be achieved for most compounds
  • Typical Equipment
    • High intensity burner
    • Brick lined furnace
    • Forced draft
    • Heat recovery equipment
    • Multi-stage process
  • Typical Waste Streams
    • Ammonia vents
    • Acrylonitrile vents
    • Nitrogen bound organic wastes
    • SWS streams
    • Carbon fiber plant wastes
  • Typical Installation
    • Petrochemical plant in India
    • 10-60 MM BTU/hr
    • 2.0 seconds residence time
    • 2200˚F/1600˚F operating temperatures

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Callidus down-fired Thermal Oxidizer systems, with a DRE range of 99 – 99.999%, routinely meet or exceed 99% destruction efficiencies for most waste components. Aqueous or organic waste streams containing inorganic or organic salts require that the Thermal Oxidizer be down-fired to prevent the accumulation of molten salts in the oxidizer furnace. Because molten salts tend to destroy refractory, our design minimizes salt contact with refractory lining, which improves refractory life.

Particulate matter emission rates may vary from as low as 10 mg/DSCM to as high as 110 mg/DSCM. The emission rate to some extent determines the type of particulate removal system necessary.

  • Typical Equipment
    • Low emission burner
    • Low porosity brick refractory
    • Forced draft
    • Adiabatic quench
    • Particulate removal
    • Acid Removal
    • Dioxin/Furan Abatement equipment
  • Typical Waste Streams
    • Ethylene plant blowdown
    • Caustic waste streams
  • Typical Installation
    • Chemical plant
    • 5 to 150 MMBTU/hr burner firing range
    • 2.0 seconds residence time
    • 1650˚F-1800˚F operating temperature

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Callidus Halogenated Waste Thermal Oxidizer Systems are capable of destruction efficiencies of 99-99.999 percent. Operating temperatures can range from 1500˚F to 2200˚F with residence times of 1.0 to 2.0 seconds depending on the destruction efficiency required.

We have extensive experience in halogenated organic waste oxidation. The most common halogen is chlorine. Thermal oxidation of chlorinated hydrocarbons produces hydrogen chloride gas (HCl) and some free chlorine, which must be removed. The quantity of HCl in the flue gas determines whether a single or two-stage HCl removal system is used. Either an HCl absorber or a caustic scrubber is used when a small quantity of HCl is present. A two-stage system is often used to reduce caustic usage when the flue gas contains a significantly large quantity of HCl.

  • Typical Equipment
    • Medium intensity burner
    • Forced draft
    • High alumina brick refractory
    • Heat recovery equipment
    • HCl recovery/scrubber
  • Typical Waste Streams
    • PVC plant vents
    • VCM waste liquids
    • Pharmaceutical vents
    • Bromine liquid wastes
  • Typical Installation
    • Chemical plant
    • 10 to 50 MM BTU/hr burner
    • 2.0 seconds residence time
    • 1800˚F operating temperature

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With destruction efficiencies typically between 99 to 99.99 percent, Callidus Fume Thermal Oxidizers thermally treat organic fumes in air or inert gas streams at temperatures between 1400˚F and 1600˚F.

Callidus Catalytic Oxidizers can be used in cases where the organic level is low and the fume stream is free from dust or substances potentially poisonous to the catalyst. Catalytic oxidation is generally carried out at 550˚F to 850˚F and requires substantially less fuel than thermal systems.

Destruction efficiencies greater than 99.99 percent may be required for some organic wastes. This is achieved by operating the oxidizer at a higher temperature with minimal auxiliary fuel. Waste heat boilers or hot oil heaters can be used downstream to recover heat for other plant operations.

  • Typical Equipment
    • Low emissions burner
    • Ceramic fiber refractory
    • Forced draft operation
    • Heat recovery equipment
    • Burner management system/Safety systems
    • Stack
    • Combustion control systems
  • Typical Waste Streams
    • VOC streams
    • Process vents
    • Pharmaceutical vents
    • Dryer exhausts
  • Typical Installation
    • 5 to 100 MM BTU/hr burner
    • 1 second residence time
    • 1500˚F operating temperature

For more information about Callidus Flares, contact us