Volatile organic compounds (VOCs) are released in many industrial processes that use solvents, coatings, inks, adhesives, or chemical products. Without proper treatment, they contribute to air pollution and may lead to stricter permit conditions.
Thermal oxidizers break down these volatile organic compounds at high temperatures, mainly into carbon dioxide and water vapor.
The Callens Group develops systems that minimize VOC emissions while maximizing heat recovery.
Volatile organic compounds are generated in a wide range of production processes such as paint and coating lines, printing plants, chemical facilities, wood processing, the pharmaceutical industry, and production environments where solvents are used.
Thermal oxidation is one of the most efficient technologies to treat these emissions. It is particularly suitable for exhaust gas streams containing organic compounds that can almost entirely be broken down through oxidation.
Reasons to choose thermal VOC treatment:
You work with solvents, coatings, inks, or chemical products.
You must comply with increasingly strict emission standards.
You want to drastically reduce VOC emissions.
You want to recover as much energy from your exhaust gas streams as possible.
Processing capacity
1 to 50,000 Nm3/h
Maximum steam pressure
up to 30 barg
Thermal output
7.5 MW to 22.5 MW
Technical specifications of a thermal oxidizer for VOC treatment
Every VOC treatment system is custom engineered. Several factors come into play, including airflow, temperature, humidity, and—above all—the composition of the exhaust gas stream.
The concentration of volatile organic compounds (VOCs), for example, plays a crucial role. If the exhaust gas does not contain enough VOCs to sustain the combustion process on its own, an auxiliary burner is added.
Depending on the composition of the exhaust gas stream, additional flue gas treatment may also be required to remove pollutants such as heavy metals, halogens, or combustion byproducts such as NOX and SOX.
Finally, we examine how the heat that is released can be recovered inasmuch as possible and be integrated into the existing steam, hot water, or thermal oil systems.
Benefits
Benefits of thermal VOC treatment
Thermal oxidation is one of the most effective ways to reduce emissions of harmful pollutants, such as volatile organic compounds (VOCs). The technology reduces emissions while putting available energy to good use. That makes it both an environmental and an economic asset.
Efficient VOC removal
Volatile organic compounds are almost completely oxidized into harmless compounds at high temperatures.
Compliance with emission requirements
The system helps businesses comply with the increasingly stringent VOC emissions legislation.
High energy efficiency
Modern burners, economizers, and heat recovery ensure optimal fuel efficiency.
Lower energy costs
By reusing recovered heat, the consumption of primary fuels decreases.
Fully customized
The thermal oxidizer is tailored to the existing production environment and energy supply.
Easy to scale
The system is designed for future capacity expansions or stricter emission standards.
How does thermal VOC treatment work?
In thermal VOC treatment, contaminated exhaust gas streams are controlled and routed to a thermal oxidizer. There, the volatile organic compounds are heated to temperatures of approximately 750 °C to 1,200 °C, causing them to oxidize into mainly carbon dioxide and water vapor.
To guarantee a high oxidation efficiency, temperature, residence time, and turbulence are carefully balanced. The heat released during this process can then be recovered through heat exchangers for steam production, hot water systems, thermal oil systems, or other industrial heating processes.
Maintenance of your thermal oxidizer and 24/7 service
The Callens Group maintenance and service team makes sure your system continues to perform at its best long after delivery. With an in-house team of more than 120 service and maintenance technicians, we schedule preventive maintenance according to the legal and technical requirements of your installation.
You can also count on fast support if an unexpected malfunction occurs. Thanks to our 24/7 availability, an extensive stock of spare parts, and the expertise of our service technicians, we carry out interventions quickly and efficiently.
Even the best-maintained system can still malfunction or unexpectedly shut down. That is why the Callens Group offers several service packages, tailored to the desired response time and level of support. So even when the unexpected happens, you can rely on specialist expertise.
One partner. 60 years of expertise. Complete peace of mind.
With the Callens Group, you choose one partner who manages the entire journey, from design to maintenance. Our integrated approach combines technical expertise, hands-on project experience, and a strong service organization.
500+ projects per year
24/7 service and support
400+ qualified team members
60 years of experience in EPCS projects
With 13 locations, always close by
Reduce your CO₂/NOₓ emissions by up to 100 %
Maximizing energy efficiency does not start with choosing a technology. It starts with mapping out your specific environment and goals.
Questions? We have the answers.
Thermal oxidation destroys VOCs by exposing them to high temperatures, typically between 750 °C and 1,200 °C. With the right combination of temperature, retention time, and turbulence, the organic compounds are almost completely oxidized into carbon dioxide and water vapor, allowing for removal efficiencies of more than 99 %.
Thermal VOC treatment is used in a wide range of industries where volatile organic compounds are released. These include the chemical industry, printing plants, coating and paint systems, wood processing, pharmaceutical companies, the food industry, and manufacturers that work with solvents or chemical products. The right solution will always depend on the composition and flow rate of the exhaust gas stream.
Discuss your project with our specialists.
The choice between thermal and catalytic oxidation will depend on the composition of the exhaust gas stream, the concentration of pollutants, and the required emission reduction. Catalytic oxidation uses a catalyst, allowing lower process temperatures. Thermal oxidation, on the other hand, offers greater flexibility and is suitable for a broader range of organic pollutants and process conditions. The Callens Group analyzes your situation and recommends the most suitable technology. Contact us.
Yes. The Callens Group takes charge of the entire process: from exhaust gas analysis and feasibility study to engineering, construction, installation, and commissioning. Our specialists look beyond the thermal oxidizer alone. They also consider extraction, ventilation, heat recovery, and integration into your existing production process. This gives you one point of contact for your complete emission reduction project.
More information about the different steps in our workflow is available here.
For a manufacturer of activated carbon filters, Optimum by Callens delivered a thermal oxidizer as part of a new production line. During the regeneration of these filters, significant pollution is generated, making an efficient and reliable solution essential. Optimum installed a two-pass low-fouling boiler combined with the APCS inline cleaning system. Thanks to this system, the heat exchangers can be cleaned automatically while the installation continues to operate, preventing production stops.
In addition, the flue gases are cooled inasmuch as possible and then routed directly to the dust filter. This enables the installation to deliver both higher operational efficiency and improved treatment of polluting emissions. The system has a capacity of 3,000 kg of steam per hour at an operating pressure of 10 bar.
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