The systems we develop and use guarantee our customers efficient energy use and maximum process and system reliability. The environmental aspect is an increasingly important one, but for us, it is a matter of course. With our technology, you can be sure to meet even the most stringent environmental regulations.
Discover the many advantages of our modern exhaust gas scrubber system. In addition to its unsurpassed ability to clean the air of pollutants such as HF, HCl, SO2, and others, it is also revolutionizing ceramic production. The exhaust gas scrubber treats the exhaust gases from the thermal post-combustion without additional cooling air, thus maintaining the low oxygen content of the exhaust gases.
The oxygen-poor exhaust gas can then be returned to the kiln in a controlled manner.
This recirculation not only supports the efficient removal of binders from the ceramic product, preventing exothermic reactions and possible cracks in the product, but it also increases the heat transfer into the product and accelerates firing with increased temperature uniformity in the kiln chamber.
These multiple benefits ensure optimum product integrity and kiln efficiency.
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A fluorine cascade absorber is the standard solution for high fluorine and low chlorine and sulfur concentrations. The sorbent, e.g., limestone chippings, is located in a silo on top of the absorber. From this storage silo, the sorbent trickles vertically past the horizontally arranged cascades in the reaction chamber. The acidic pollutants (HCl, HF, SOx) flow through the sorbent and react with the limestone chippings. The saturated limestone chippings are collected in the system’s hopper and discharged continuously or discontinuously. A peeling drum also increases the efficiency of the system. The resulting reaction product can also be processed by a mill and transported onward by pneumatic conveying. In the heavy clay industry, the reaction product can be encapsulated. As there are no moving parts in contact with the flue gas, there are virtually no parts subject to heavy wear.
CTB continually strives to optimize the efficiency and performance of our kiln systems. One of our innovative solutions is the use of highly efficient heat exchangers to preheat the combustion air for our kiln burners during the heating phase and to supply adjacent systems such as dryers, adsorption cooling, or thermal energy storage units with hot air during both the heating and cooling phases. This technology optimizes fuel consumption and contributes to a more sustainable and environmentally friendly operation. Our kilns can be equipped with two types of state-of-the-art heat exchangers, each offering unique advantages to meet different operational requirements.
The payback period for metal heat transfer systems has been reduced from 10-15 years to 5 years in recent years, not only because of the energy aspect but also because of a complete rethink of the short life of heat exchangers. Metallic thermal expansion makes any system leaky, and you can do nothing about it. We have changed this, and many of our heat exchangers have been in use for over ten years without any maintenance.
We equip our kilns with emergency power generators to avoid production downtime or damage to the fired product. However, depending on the nature of the firing process, protection against power failure may also be required for safety reasons to prevent dangerous process conditions for people and the environment. We have extensive experience in this area and can integrate generators up to 1500 kVA into our systems. It is also possible to use a generator that is primarily used as an emergency generator in parallel with the grid to reduce peak loads, thus avoiding high grid charges and saving energy costs.
Maximum efficiency and safe post-combustion of VOCs – CTB offers cutting-edge technology for the thermal post-combustion of organic pollutants. Our thermal oxidizers are efficient and environmentally friendly.
Our specially designed burners, which cover a wide range of capacities from 40 kW to 4.6 MW and can be operated at high air/gas ratios, can be optimized for high turndown ratios, which is particularly important at high VOC concentrations. These thermal oxidizers provide efficient and thorough post-combustion of organic pollutants. Integrated oxygen and FID controls allow precise oxygen and temperature control, ensuring optimum thermal oxidation at all times.
These advanced thermal oxidizers use the heat stored in the exhaust gases, i.e., the heat recovered for the combustion process, to preheat incoming process gases loaded with pollutants. This recuperative method not only increases efficiency but also significantly reduces fuel consumption. Like the direct combustion oxidation systems, they also use oxygen and FID controls to precisely regulate oxygen levels and temperature, further optimizing fuel consumption.
These advanced thermal oxidizers use the heat stored in the exhaust gases, i.e., the heat recovered for the combustion process, to preheat incoming process gases loaded with pollutants. This recuperative method not only increases efficiency but also significantly reduces fuel consumption. Like the direct combustion oxidation systems, they also use oxygen and FID controls to precisely regulate oxygen levels and temperature, further optimizing fuel consumption.
All our thermal oxidizers are equipped with state-of-the-art oxygen and FID controls. The oxygen control ensures optimum oxygen levels for efficient combustion, while the FID control dynamically adjusts the post-combustion temperature based on real-time VOC concentrations. This dual control system ensures optimum fuel consumption, reduced operating costs, and compliance with the most stringent VOC emission standards.
CTB’s thermal oxidizers integrate state-of-the-art technology with optimum efficiency and safety
At CTB, safety is not just a buzzword but an integral part of the way we work. We understand that our customers rely on our kiln systems for both quality and safety. We are therefore proud to announce that all our kiln systems are designed and manufactured in strict accordance with EN 1539.
At CTB, debinding the products to be fired is a critical part of our customers’ manufacturing processes, requiring the highest safety and efficiency standards. This is why our kilns are equipped with state-of-the-art features that optimize the debinding process while strictly complying with the safety standards of EN 1539 for Type A and Type B kilns.
At CTB, we attach great importance to both environmental management and operational efficiency. This is why we offer an intelligent solution for optimizing thermal post-combustion: FID control!
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