Three-tower RTO

Regenerative Thermal Oxidizers (RTOs) are among the most mature and energy-efficient technologies for treating medium-to-high concentrations of volatile organic compounds (VOCs). The three-tower RTO is the most widely used and technologically mature classic configuration. It recovers combustion heat through a highly efficient regenerator, achieving efficient oxidation of VOCs and ultra-low energy consumption.

Core Structure

Combustion Oxidation Chamber (Core Reaction Zone)

Located in the center of the equipment, it maintains a constant high temperature (typically 760-850°C).

Equipped with the main burner for start-up preheating and replenishing system heat losses.

All VOCs are ultimately completely oxidized and decomposed into CO₂ and H₂O here.

Three Regenerator Chambers (Energy Recovery Core)

Three independent towers (Tower A, Tower B, and Tower C) are symmetrically distributed around the combustion chamber.

Each tower is filled with honeycomb ceramic regenerators, whose large surface area and heat capacity are key to achieving efficient heat recovery.

Each tower's inlet and outlet are equipped with high-performance switching valves to achieve precise airflow guidance and rapid switching.

Control System and Auxiliary Systems

Intelligent Control System: Precisely controls valve switching sequence, burner power, and fan frequency according to preset programs.

Fan System: Includes induced draft fans and purge fans, providing power for system operation.

Purge System: A key safety design ensuring purification efficiency.

Operating Principle

The three-tower RTO does not continuously heat the exhaust gas; instead, it recycles heat within the system. Its working principle can be summarized as a dynamic cycle of "heat storage-heat release," achieving near-closed-loop heat recovery through the alternating switching of the three towers.

A complete cycle includes three key processes:

Preheating Oxidation: At room temperature, exhaust gas enters the high-temperature regenerative tower, is instantly preheated to near its oxidation temperature, and then enters the combustion chamber for complete decomposition.

Heat Recovery: The high-temperature clean gas produced by oxidation enters the low-temperature regenerative tower, where its heat is stored within the ceramic body, and it is discharged after being cooled.

Safety Purging: Before tower switching, residual waste gas in the pipeline is removed with clean gas to prevent direct emission of untreated gas, ensuring a purification rate of >99%.

Energy Saving Core: After the system stabilizes, over 95% of the heat required to raise the temperature of the waste gas comes from the heat energy recovered by the ceramic regenerator. The burner only needs to compensate for less than 5% of the system heat loss, thus achieving remarkable energy savings.

Core Advantages

Ultra-High Thermal Efficiency: Heat recovery efficiency >95%, extremely low operating energy consumption.

High Purification Efficiency: Stable removal rate of >99% for multiple VOC components.

Wide Treatment Range: Suitable for medium-concentration waste gas with a concentration of 1-10 g/m³, with a wide air volume range.

Stable and Reliable Operation: High degree of automation, relatively simple maintenance.

Main Application Areas

Chemical and Pharmaceutical Industries: Breathing gas from reaction vessels and storage tanks, workshop waste gas.

Coating and Spraying: Waste gas from automotive, furniture, and metal product spraying and drying lines.

Printing and Packaging: Exhaust gases from printing presses, laminating machines, and coating machines.

Electronics Manufacturing: Solvent exhaust gases from semiconductor and circuit board production.

Others: Plastics and rubber, food processing, textile finishing, etc.

Summary

The three-tower RTO achieves efficient recycling of heat energy during VOCs treatment through advanced structural design and dynamic thermal circulation technology, striking a good balance between environmental protection and economic benefits.

With increasingly stringent environmental requirements, the three-tower RTO, with its excellent energy efficiency, will continue to be an important solution for industrial waste gas treatment. Combined with zeolite rotary concentrators and other technologies, the treatment efficiency for low-concentration, high-volume waste gases can be further optimized. We are a Chinese manufacturer of honeycomb ceramics. For more information, please contact us at annayu@169chem.net or WhatsApp +8618909016373.