Thermal oxidizers

Thermal oxidizers are among the most effective technologies to treat industrial waste gas streams. They reduce odor compounds, volatile organic compounds (VOCs), and other harmful emissions.

At the Callens Group, we look beyond odor control and emission reduction alone and analyze how waste gas streams, heat demand, and production processes can be optimally aligned. The result is an integrated solution that complies with the strictest emission standards, improves energy efficiency, and lowers the operating costs of your production process.

DISCUSS YOUR EMISSION REDUCTION NEEDS
Optimum TTNV Ecofrost Peruwelz 3

How do thermal oxidizers work?

Thermal oxidizers remove harmful substances from industrial waste gas streams by heating them to temperatures of between 750 °C and 1,200 °C. During this oxidation process, volatile organic compounds (VOCs), odor compounds, and other pollutants break down into less harmful compounds such as carbon dioxide and water vapor. So, thermal oxidizers help improve air quality and significantly reduce industrial emissions.

What are they used for?

Industrial odor control

Thermal oxidizers are often used to treat odors generated by production processes. Organic odor compounds are destroyed at high temperatures, significantly reducing the impact on the surrounding area. Applications include the food industry, waste processing, and the chemical industry.

Removal of volatile organic compounds (VOCs)

VOCs are generated through the use of solvents, coatings, inks, and chemical products, among other sources. Thermal oxidation is one of the most efficient technologies to reduce these emissions. The VOCs are oxidized to carbon dioxide and water vapor, while the released energy can often be reused in the production process.

Kelloggs Mechelen 2 Thermische Naverbranders Stoom 20

Key benefits of thermal oxidizers

  • Cleaner emissions: thermal oxidizers remove more than 99 % of the VOCs, solvents, odor compounds, and other harmful emissions. This makes it easier for businesses to comply with increasingly stringent emission standards and environmental regulations.
  • High energy efficiency: the heat released during oxidation can be recovered and reused for process heating, steam generation, hot water production, or thermal oil heating. This reduces the site’s energy consumption and operating costs.
  • Suitable for a wide range of applications: thermal oxidizers are used in sectors such as the chemical industry, coatings, printing, wood processing, the food industry, the pharmaceutical sector, and waste processing. They can treat a broad range of waste gas streams and pollutants.
  • Integration with existing processes: thermal oxidizers can be integrated with existing production processes, energy networks, and heating systems, maximizing the value of the available energy.
Aviko Poperinge thermische naverbrander 1

Industrial odor control

Thermal odor treatment breaks down organic odor compounds at high temperatures into harmless compounds such as carbon dioxide and water vapor. This drastically reduces odor nuisance and enables the system to comply with the applicable emission requirements.

Technical specifications:

  • Treatment capacity: from 500 Nm³/h
  • Maximum steam pressure: 30 barg
  • Thermal capacity: 7.5 MW to 22.5 MW
LEARN MORE ABOUT ODOR CONTROL
Optimum TTNV Ecofrost Peruwelz 3

VOC treatment

During oxidation, VOCs are broken down into carbon dioxide and water vapor. The released heat can then be recovered for steam generation, hot water production, or thermal oil heating.

Technical specifications:

  • Treatment capacity: 10 metric tons of steam per hour
  • Maximum steam pressure: 25 barg
  • Thermal capacity: 7,500 kW
LEARN MORE ABOUT VOC TREATMENT

Need to address odors, VOCs, or other emissions?

Our experts are here to help.

Discuss your challenge
THE CALLENS GROUP IN NUMBERS

One partner. 60 Years of expertise. Complete peace of mind.

By joining forces with the Callens Group, you get one partner who manages the entire process, from design and engineering to installation, service, and maintenance. This integrated approach combines technical expertise, project experience, and a strong service organization.

500+ projects per year

Service and support within 2 hours

400+ qualified team members

60 years of experience in EPCS projects

With 13 locations, always close to our customers

Reduce your CO₂/NOx emissions by up to 100 %

20230214 141447

Why choose thermal oxidizers instead of regenerative thermal oxidizers?

While regenerative thermal oxidation can be an attractive solution for specific applications, thermal oxidation offers greater flexibility and a wider range of applications. The technology is particularly effective for treating a broad range of both organic and inorganic pollutants.

Regenerative thermal oxidizers do have a number of limitations. Over time, their ceramic media can become contaminated by dust, silicones, or other flue gas components, affecting performance and maintenance. In addition, small amounts of untreated VOCs may pass between the ceramic chambers during valve switching which can temporarily increase emissions.

Finally, thermal oxidizers are generally easier to integrate into existing production processes and provide more heat recovery options. Thus, they combine high emission reduction with an attractive return on investment.

ASK OUR EXPERTS FOR ADVICE

Optimal integration with your production process

A thermal oxidizer delivers maximum value only when it integrates seamlessly with the rest of your production environment. That is why the Callens Group looks beyond emission treatment alone. We analyze the entire process context, from extraction and ventilation systems to heat users, energy networks, heat recovery, and the use of biogas as a supplementary fuel.

This integrated approach ensures that emission reduction is aligned with energy efficiency, operational reliability, and operating performance. During the design phase, our engineers also account for future expansions, changes in production capacity, and stricter emission requirements.

With more than 35 installations completed, the Callens Group has extensive expertise in thermal oxidation. We are a recognized market reference in the food industry, particularly in potato processing. Companies in the chemical industry and other process industries also rely on our solutions for waste gas treatment, emission reduction, and energy recovery.

Kelloggs Mechelen 2 Thermische Naverbranders Stoom 1

Heat recovery

A key benefit of thermal oxidation is that the released heat does not have to go to waste. Through heat recovery, this energy can be reused in industrial steam boilers, thermal oil boilers, hot water systems, or other industrial heating processes. This reduces both your energy consumption and operating costs.

Does the waste gas stream contain substances that could foul heat exchangers or boilers? Heat recovery is still possible. The Callens Group APCS boiler cleaning system helps the installation continue to operate safely and cost-effectively.

Higher energy efficiency

Lower operating costs

Fewer emissions

Working with the Callens Group means peace of mind, reliability, and confidence

A thermal oxidizer is an investment that will last for decades. This makes it important to choose a partner that provides both the right solution and the service required to ensure lasting performance. The Callens Group offers that combination.

At the Callens Group, you have a single point of contact for your entire steam project: from the first analysis to installation, including service and maintenance. This keeps the process clear and reduces the need for separate coordination between different parties.

The Callens Group is not tied to a single brand, manufacturer or technology. This allows us to select the solution that is technically and economically the most attractive for each project. To do so, our engineers take account of energy prices, grid capacity, water quality, emission targets, available space and total cost of ownership to provide you with a solution that integrates perfectly into your production environment.

With more than 120 service and maintenance specialists, the Callens Group has one of the largest service teams. Preventive maintenance, interventions, remote monitoring and an extensive stock of spare parts ensure that your steam installation remains maximally available and that unplanned downtime is kept to a minimum.

The Department of Technology is the Callens Group’s innovation center. Here, new developments in heat technologies are assessed for their technical feasibility and their added value for industrial applications. Only proven technologies ultimately find their way to customers.

With 13 locations across Belgium, the Netherlands and France, we combine the benefits of an international group with the proximity of local teams. This allows us to act quickly.

Thermal oxidizer projects

20200113 102758
Thermal technology Thermal oxidizers Thermal oil boilers

Steam and thermal oil are a tasty match

Capacity2 million Kcal/h
Operating pressure8 barg
Max. temperature300 °C
Steam from baking fumes:
Capacity10 tons steam/h
Operating pressure18 barg
Working pressure16 barg
Combustion efficiency96%
Callens Aviko Poperinge 8
Thermal technology Dual fuel Steam boilers +3

Steam, odor combustion, ventilation and balance of plant in one smart package

CapacityHRSG: 37 t/h 
TO: 25 t/h 
BUB: 25 t/h

Questions? We have the answers.

Thermal oxidation is a technology in which contaminated waste gas streams are heated to temperatures of between 750 °C and 1,200 °C. This breaks down volatile organic compounds (VOCs), odor compounds, and other harmful substances into less harmful compounds such as carbon dioxide and water vapor. Thermal oxidation is among the most effective emission reduction technologies for industrial applications.

Thermal oxidizers treat waste gas streams containing volatile organic compounds (VOCs), solvents, odor compounds, hydrocarbons, or other pollutants. They are widely used in sectors such as the food industry, the chemical sector, coatings, printing, the pharmaceutical sector, wood processing, and waste processing.

VOCs are carbon-containing compounds that evaporate easily and are released during production processes. They occur when solvents, coatings, inks, and chemical products, among others, are used. Thermal oxidation is one of the most efficient technologies to reduce VOC emissions.

Thermal oxidation is particularly effective in controlling odors from industrial processes. Organic odor compounds are converted into CO₂ and H₂O at high temperatures, significantly reducing their impact on the surrounding area. This technology is frequently used in the food industry, waste processing, and the chemical industry.

The heat released during oxidation can be recovered and reused in the production process. The energy can be used for steam generation, thermal oil heating, or hot water systems. This makes thermal oxidation both an environmentally and economically attractive investment.

Thermal oxidation breaks down pollutants using high temperatures. Catalytic oxidation or downstream treatment uses a catalyst, allowing similar oxidation reactions to take place at lower temperatures. The most suitable technology will depend on the composition of your waste gas stream, emission targets, and your heat recovery options. Discuss the possibilities with our experts.

Thermal oxidizers are particularly effective at removing volatile organic compounds (VOCs), solvent vapors, odor compounds, hydrocarbons, and other organic pollutants from industrial waste gas streams. During oxidation, these substances break down at high temperatures, primarily into carbon dioxide and water vapor. Depending on the application, removal efficiencies of more than 99 % can be achieved, helping companies comply with strict emission standards and significantly reduce odor nuisance.

The selection will depend on factors such as waste gas flow rate, VOC concentration, the presence of odor compounds, the required emission reduction, and heat recovery options. The Callens Group always analyzes the full process context to design the most efficient and economically feasible solution.

When the waste gas stream does not contain enough energy to sustain the oxidation process, a support fuel is used. Natural gas is the most common fuel because it is widely available, provides reliable combustion, and is easy to control.

In many cases, thermal oxidizers can also run on biogas or other combustible process gases available on site. This can help companies reduce fossil fuel consumption and further improve the system’s energy efficiency.

The most suitable fuel will depend on factors such as the composition of the waste gas stream, available energy sources, emission targets, and operational reliability. The Callens Group analyzes these parameters and recommends the most suitable configuration for each application. Wondering what is possible at your site? Ask our experts.

For a potato processing site, the Callens Group delivered a thermal oxidation system to treat 40,000 Nm³/h of cooking vapors from two French fry production lines. The system uses biogas from the site’s own processes and efficiently removes odor compounds in line with the applicable environmental standards. Heat recovery also produces 20 metric tons of steam per hour at an operating pressure of 22 barg.

Need to address odors, VOCs, or other emissions?

Our experts are here to help.

Discuss your challenge