Tel: +1 908 500 7500 Stephen R. Parker, Sales Engineer
Ringoes, New Jersey
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Process Furnaces With Moving Hearth



Process Furnace
6,000 SCFM Modular Thermal Oxidizer System
Designed to control vent gasses at
catalyst recycling operation
New Orleans, LA

Process Furnace Systems are designed to process low and high BTU solids using a combination of temperature and destructive distillation to breakdown the combustibles. The afterburner system will separately control the adding of the secondary combustion air and will raise the temperature of the exhaust gases to the required operating temperature, thus eliminating the smoke and vapors produced. The systems are packaged complete with burners, refractory lined chambers, and the optional moving hearth to ease loading and unloading.

The chambers shall be constructed of 0.25" carbon steel and lined with 6" of Ceramic Fibre materials rated at 2200F. The refractory shall be installed with anchors to maintain integrity. The access doors will be large enough to allow for loading of the tray racks. It will be a swing type door and will utilize hitemp gaskets and seal. The chambers shall be mounted on a channel steel skid with suitable cross bracing. Chamber shall include sight ports, thermal wells, burners, and access door.

Thermal Oxidizer
6,000 SCFM Modular Thermal Oxidizer System
Designed to control vent gasses at
catalyst recycling operation
New Orleans, LA

The gases produced in the process chambers will contain smoke and other combustibles with controlled oxygen levels. The gases exiting the process chamber will be mixed with combustion air regulated by the gas temperature in the afterburner. Once air is injected the temperature will rise. The air injection rate will increase until the gases reach the set temperature. As the run progresses, the vapor concentration will decrease, the temperature will decrease, and the air injection rate will decrease automatically. This will lower fuel costs while maintaining safe operating conditions.

Systems are designed per the customers requirements for size, orientation and process requirements. Options include extended stacks, scrubbers, fans, and controls designed to operate with existing plant systems.

Process Furnace System Quotation
This quotation describes a HiTemp Processing Furnace with a moving hearth, PLC control package, insulated stack, and scrubber system that will operate with chlorinated solvents. A typical system will include a hastalloy or 316L quencher, an FRP or 316L packaged tower scrubber, I.D. Blower and exhaust stack. The installation will require setting unit, utility connections, and bolting on the stack and customer provided supply duct. The system shall raise the temperature of the exhaust gases to the required operating temperature. This will assure maximum destruction of the VOC in the exhaust gas.

1.1 PROCESS FURNACE CHAMBER - The HiTemp Processing Furnace is proven to be one of the best units to process batch materials for volume reduction. Contaminated non-combustible materials can be heated to drive off oils and chemicals and the vapors produced are destroyed in the afterburner chamber. Materials can be segregated by loading into separate SS covered pans, loaded on racks, and the racks loaded by fork lift onto the moving refractory lined hearth. The hearth is then pushed into the furnace for processing.

The system is designed with special light weight refractory materials to minimize heatup and cooldown time. To accomplish this, we have designed the system using lightweight ceramic fiber installation which greatly reduces batch cycles. The hard refractory, typically used in a Process Kiln would have to be field installed and would not be suitable for the system design parameters. The weight of hard refractory is 160 pounds per cubic foot and the weight of typical ceramic fiber is only 8 lb/ft3.

The smoke (unconsumed particulate) and gases are drawn into a second, but stationary chamber for final thermal oxidation. A carburation section is located at the chamber outlet connection. This section contains air nozzles and a blower with actuated damper. As the combustion rate of the material increases, the damper is opened thus maintaining a proper air ratio for complete combustion of the smoke and particulate.

Systems with dual primary chambers are connected with a refractory lined Tee section placed between the chambers and the carburation section. High temperature manual dampers are used to control air flow through the chambers.

1.2 MOVING HEARTH (MH)- The entire floor of the unit is a structural frame with refractory insulation. The tray racks are placed on this refractory. The frame is supported on V-Grooved wheels riding on angle steel rails. The sides are sealed with sand troughs.

1.3 SECONDARY COMBUSTION CHAMBER (AB)- The secondary chamber or afterburner will be mounted on structural supports. The Secondary combustion chamber shall be constructed of carbon steel plate. The chamber shall be complete with the required structural supports, and flanged connections. The chamber shall be lined with a combination of both insulating and hard faced refractory materials. The refractory shall be suitably supported with stainless steel anchors for long life. The chamber shall be complete with access doors for inspection and maintenance.

The Secondary Combustion Chamber operates at a higher temperature (1,400 to 1,800oF) than the Primary Chamber and
consumes the gases, smoke, and particulate. The volatile products resulting from the thermal reduction process are drawn into the secondary combustion chamber to be further oxidized. The burner is positioned so that the incoming gases and particulate pass through the flame and are ignited. The direction of the flame assures a swirling, vortex action providing maximum turbulence and residence time.

1.4 BURNERS (G)- The System will be equipped with modulating Natural Gas burners with flame safety. The burners will be mounted to the outer shells of both chambers and are directed to assure maximum turbulence. Also included will be complete fuel trains.

1.5 PACKED TOWER SCRUBBER (PTS) - The scrubber shall include a quenching section constructed of FRP or 316L SS, venturi, circulation pump, filler valve, level sensor, liquid storage, packed tower, and demister pad. All components shall be skid mounted for ease of assembly.

The Scrubber will clean the gases of fumes before being discharged into the atmosphere. The gases contact the scrubber water to condense the fumes and wet the particles while cleaning the interior walls of the housing. A mixing section or packed tower accelerates the gas flow and maximizes the collection of the pollutants. The demister separation section removes ultra fine droplets and particles prior to being drawn to the atmosphere.

1.6 PLC CONTROL OPERATION (PLC) - The operator shall start and stop the system from the main panel or from remote inputs. Startup shall energize and prove the blower, scrubber, burner, prove set temperature, and signal to start fume injection. Blower pressure and the customer safety limits must be proven prior to burner ignition. Component failures will shut down system and alert the operator. Indicator lights will display fault.The system shall monitor and record temperatures, feed rates and cycles, external equipment conditions, and safeties. System modifications may require only simple program changes rather than extensive field modifications during system upgrades.

The controls are designed to permit the proper and safe operation of the unit and to provide the operator with various options to broaden the versatility of the unit. The control panel includes the various electrical controls to assure a safe start-up and pre-heat of the chambers and operation of the furnace.

Operating temperatures controlled by adjusting the fuel-to-air ratio according to temperature monitors in the designated flue gas flow areas. Temperature is sensed by Chromel Alumel Type K thermocouples, which are connected to the system temperature controls, which regulate the auxiliary fuel.

Typical Terms and Conditions
DELIVERY: Shall be 12 weeks after the receipt of a valid purchase order, progress payments, and all required approvals.
TERMS: 33.3% with order, 33.3% when fabrication period is half way, 33.3% when fabrication is completed prior to shipment.
Note: Costs of any and all emissions testing are extra. Any additional equipment or controls required above those stated herein shall be provided at extra charge.
INSTALLATION: Installation will require running gas and utilities to unit from source. We suggest the gas train, supply duct, and main panel are located indoors, we will provide these components loose prior to shipment of the main unit to be installed prior to delivery of main units.

1. Refractory Materials - Harbison Walker
2. System Controls, SWITCHES - Square D, Allen-Bradley, Control Concepts, RELAYS - 3PDT W\Neon indication, PANELS - Hoffman, Electromate - NEMA 4, CONTROLLERS - Honeywell, UDC-3000, DC-300, VALVE TRAIN - Asco, Honeywell
3. Burners - Midco, Haulk, Maxon
4. Catalyst Materials - Metpro Corporation
5. Heat Exchangers - Des Champs, Exothermics
FIVE-YEAR LIMITED WARRANTY: HiTemp guarantees to the original purchaser that the system described meets all pertinent emissions codes per the submitted documentation. HiTemp guarantees to the original purchaser that the equipment furnished is free of defects in material and workmanship. This warranty covers parts manufactured by HiTemp for a period of FIVE YEARS. Components and parts not manufactured by HiTemp are to be repaired or replaced per the warranty of their respective manufacturer(s), excluding any freight, handling or installation labor charges.

Documentation: HiTemp shall provide operating and maintenance manuals that include operating instructions, component data, and drawings.

1. Customer is responsible for all emission testing, rigging and field modifications, field ducting, piping and wiring, mounting and wiring of remote panels, monitoring equipment, and all starters and 3-phase electrical work. No platform is provided for stack gas sampling.
2. HiTemp can assist in the design and layout and also provide the time of an on-site Technician as may be required during system installation at no charge for labor for up to two (2) days (Per-diem travel and living expenses are extra).
3. Systems are shipped EXW unless alternate prior arrangements are made.