Regenerative Thermal Oxidisers

Overview

Regenerative thermal oxidisers are widely used in refineries, chemical plants, polymer facilities and terminals to destroy volatile organic compounds and odorous or hazardous air pollutants before they reach the atmosphere. By using ceramic heat recovery beds, they can recover more than 95 percent of the heat released, which makes them very energy efficient compared with simple thermal incinerators. However, RTOs also handle flammable vapours at high temperatures, and poor design or operation can lead to fires, explosions, bed plugging, valve failures and permit violations that put plant operations at risk.

This course provides a practical understanding of the design, operation, safety and maintenance of regenerative thermal oxidisers. Participants learn VOC emission sources and regulations, combustion principles for VOC destruction, and the main RTO configurations, including two-bed, three-bed and rotary designs. The course covers ceramic media, poppet and rotary valves, burners and supplemental fuel, heat recovery and thermal efficiency, and control and monitoring systems. It also explains explosion prevention through dilution, LEL monitoring and flame arresters, start-up and shutdown, bake-out and washout procedures, troubleshooting of performance and pressure drop problems, emissions testing and compliance, and maintenance planning.

Objectives

• Explain VOC emission sources, regulations and control technology options
• Describe RTO configurations and their main components and functions
• Understand combustion principles for VOC destruction and thermal efficiency
• Operate valves, burners, media beds and control systems correctly
• Prevent fires and explosions through dilution, LEL monitoring and safeguards
• Apply start-up, shutdown, bake-out and washout procedures safely
• Troubleshoot performance problems and maintain emissions compliance

Who should attend

Training methodology

The course combines explanation of combustion and heat recovery principles with real RTO drawings, control logic and operating data. Participants calculate destruction efficiency, thermal efficiency and supplemental fuel needs, review LEL monitoring and dilution air arrangements, and analyse pressure drop and temperature trends to detect bed plugging and valve leakage. Start-up, bake-out and shutdown sequences are walked through step by step. Case studies of RTO fires and explosions are analysed in groups to identify causes and safeguards. Each day ends with a short quiz and discussion of emission control issues at participants' sites.

Programme outline

Dates and fees

Certificate

Frequently asked questions