Catalytic Thermal Oxidizer for the Emission Controls for Chemical Processing of Ethylene Oxide
Executive Summary
Epcon engineered and delivered a compact, high-efficiency catalytic thermal oxidizer (CTO) to abate emissions of ethylene oxide (EtO) and related VOCs from a chemical-processing plant expansion. The system was designed for rapid delivery, tight-footprint installation, and guaranteed 99% destruction removal efficiency (DRE) to meet stringent regulatory standards. With a proprietary process-stream dilution and combustion-air inlet design, the CTO ensures reliable VOC treatment with minimal impact on plant turnaround schedules — enabling compliance and operational continuity under a demanding timeline.
Project Overview
As part of a major plant expansion, a global specialty chemical producer needed a robust and energy-efficient solution to treat emissions of ethylene oxide (EtO) and related hydrocarbons from new process lines. The plant required a pollution-control system that not only meets regulatory emissions limits but can also be delivered, installed, and commissioned within a tight turnaround window. Epcon was contracted to design, build, and deliver a compact catalytic thermal oxidizer (CTO) tailored to the customer’s process emissions and timeline constraints.
The Challenge
The project presented several critical challenges:
- The process generated exhaust containing ethylene oxide and VOCs requiring efficient abatement to comply with environmental regulations.
- The plant’s expansion schedule demanded a short delivery and installation window to avoid prolonged downtime.
- The facility needed a compact footprint due to limited space for additional equipment.
- The oxidizer had to guarantee a high destruction removal efficiency (DRE) — sufficient to satisfy regulatory requirements under tight emissions-control standards.
- The design needed to integrate with the plant’s existing process-air and exhaust systems without major modifications.
Engineering Requirements
To satisfy the customer’s operational, regulatory, and scheduling constraints, Epcon defined the following requirements:
- Supply a compact CTO unit compatible with limited plant floor space
- Deliver guaranteed EtO/VOC destruction removal efficiency (DRE) of ≥ 99% to ensure regulatory compliance
- Incorporate proprietary process-stream dilution and combustion-air inlet design to safely handle solvent-laden exhaust and optimize combustion conditions
- Ensure rapid delivery, factory acceptance testing (FAT), and quick on-site commissioning for minimal process disruption
- Provide reliable, industrial-grade construction suited for continuous or batch chemical processing operations
The Solution
Epcon designed and manufactured a custom L-shaped Catalytic Thermal Oxidizer (CTO) engineered for ethylene oxide and chemical-processing exhaust streams. Key features of the solution include:
- Proprietary dilution and combustion-air inlet design to safely manage solvent-laden exhaust and maintain stable combustion conditions.
- Compact, space-saving L-shaped configuration, allowing easy integration in constrained plant layouts.
- Pre-shipment Factory Acceptance Testing (FAT) to verify performance, simplify installation, and minimize on-site commissioning.
- Full compliance with applicable emissions regulations, providing guaranteed ≥ 99% DRE per design specification.
- Modular design aimed at facilitating quick installation and startup to meet tight project schedules.
This CTO solution offered an optimized balance of performance, footprint, reliability, and delivery speed — tailored to the customer’s chemical-processing context.
Technical Specifications
System Type: Catalytic Thermal Oxidizer (CTO)
Configuration: L-shaped, compact footprint design
Pollutants Treated: Ethylene oxide (EtO), VOCs from chemical processing exhaust
Guaranteed Destruction Removal Efficiency (DRE): ≥ 99% for VOC/EtO stream
Inlet Design: Proprietary process-stream dilution and combustion-air inlet system (for safe handling of solvent-laden exhaust)
Delivery & Commissioning: Factory Acceptance Testing (FAT) completed pre-shipment, rapid on-site installation and startup
The Results
After installation and commissioning, the Epcon CTO delivered the following benefits to the customer:
- Reliable emissions abatement, meeting required regulatory DRE with no subsequent environmental compliance issues.
- Plant expansion completed without delays, thanks to on-time delivery and rapid start-up.
- Efficient use of space, with the compact L-shaped CTO fitting into existing facility layout without requiring major modifications.
- Minimal impact on operations, avoiding plant shutdown or extended downtime during installation.
- Long-term reliability and operational stability, demonstrating Epcon’s capability to deliver process-critical air pollution control systems under tight schedules.
Learn More
Epcon offers full engineering, fabrication, and installation of catalytic thermal oxidizers (CTOs), regenerative oxidizers, and VOC abatement systems designed for chemical-processing facilities, ethylene oxide operations, and other industrial emissions challenges.
Contact Epcon engineering team to discuss a custom emission-control solution tailored to your process, regulatory, and timeline requirements.
