TECHNICAL SPECIFICATIONS

REGENERATIVE THERMAL
OXIDIZER SYSTEM

Suite 400
21 Unionville Road
Douglassville PA 19518
(215) 234-8188
Table of Contents

General Specifications................................................................................. 1

Operating Costs........................................................................................... 2

RTO System ................................................................................................ 3

Gastrain ....................................................................................................... 4

Manifold Specifications................................................................................ 5

Exhaust Fan ................................................................................................ 6

Hydraulic System......................................................................................... 7

Control Room .............................................................................................. 8

System Controls .......................................................................................... 9

Plan Views................................................................................................. 10

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
General Specifications

Conditions (Design Basis) Design

Inlet Temperature 90°F

Inlet Static Pressure -2°
Altitude TBD
Specified Standard Max Volume 24,000 scfm
Specified Standard Normal Volume 21,349 scfm
Solvent Loading 164.4 lb/hr
Solvent Type TBD
Solvent Heat Value (assumed) 15,000 btu/lb
Number of Towers 2
Purge NA

Individual Tower Bed Area 58.5 ft²

Individual Tower Bed Velocity 410 fpm
Individual Tower Bed Gas Flow Volume 24,000 cfm (vertical)
Heat Exchange Media Structured Packing
Heat Exchanger Bed Height 5 ft
Heat Exchanger Thermal Efficiency 93%
Heat Exchanger Free Board 0 ft

Inlet Temperature (T1) 90°F Dry Bulb

Combustion Chamber Temperature (T2) 1,550°F (min)
Exhaust Temperature (T4) 193°F (max)

Total Installed Burner Capacity 5 mmbtu/hr

Combustion Chamber Design Temperature 2,000°F

Combustion Chamber Retention Time 0.5 seconds
RTO Overall Destruction Efficiency 95%
RTO Particulate Removal Efficiency NA

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 1
Operating Costs

24,000 scfm with 164.4 lbs/hr solvent:

Consumption Rate Hourly Cost Annual Cost

Fuel 0 Mmbtu/hr $ 0 /hr $ 0 /yr
Electricity: 70 Kw $ 3.17 /hr $ 12,680 /yr

Total Operating Costs $ 3.17 /hr $ 12,680 /yr

Operating Cost Assumptions

Maximum Solvent Loading: 164.4 lbs/hr at 15,000 btu/lb

Electricity Costs $ 0.045 Kw/hr
Annual Operating Hours 4,000

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 2
RTO System

RTO By-Pass System Abort Path

RTO Isolation Damper Metal Seated Butterfly
RTO Isolation Damper Construction Aluminum painted mild steel
RTO Isolation Damper Actuator Hydraulic Rack and Pinion

Burners Option Type or Manufacturer

Manufacturer -- Eclipse (or equivalent)
Model -- Ratiomatic
Number of Burners 1
Individual Burner Size -- 5 mmbtu/hr
NOX Output (greater than inlet) -- Less than 0.1 lb/mmbtu
CO Output -- 60 ppmv (max)
Fuel Injection System Optional --
RTO Burner Enclosures Optional --

Side view of RTO system. One small hotspot

which will be repair during installation.
Recovery chambers are sized for 8’ beds
allowing for various heat recovery media
options.

Side view of the RTO system showing

bottom skid for ease of installation. All
hydraulic tubing is stainless steel.

Fresh Air Inlet Option Type or Manufacturer

Fresh Air Inlet Included
Fresh Air Inlet Damper Included Single Blade
Fresh Air Inlet Damper Actuator Included Hydraulic, Open/Close

Variable Frequency Drive Option Type or Manufacturer

Manufacturer AB, Robicon, Emerson (or
equivalent)
Size 150 hp
“Flying Start” Capability Included
Enclosure Included NEMA 1 w/ Fans & Filters

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 3
Gastrain

Exhaust Stack Type or Manufacturer

Diameter/Height 42”/62’
Material Mild steel
Insulation Per OSHA requirements

RTO Towers Option Type or Manufacturer

Materials of Construction 3/16” mild steel
External Coating Included Gun Metal Gray

RTO Tower Insulation Option Type or Manufacturer

42” diameter/ 60’ high stack with 180°
test platform and caged ladder per OSHA Heat Exchanger -- 6” thick, 12 lb/cu ft.
guidelines. Thickness, Density, pyrobioc
Manufacturer
Combustion Chamber -- 8” thick, 8 lb/cu ft,
Thickness, Density, pyrobioc
Manufacturer

Gastrain Option Type or Manufacturer

Blocking Valve -- Maxon (or equivalent)
Manufacturer
Combustion Blower Included
I.R.I Design Included
Gastrain Enclosure Optional
Burner/Gastrain Access Included Open Grated Deck
Platform
Platform Access Stairway Optional
Platform Access Safety Included OSHA Design
Ladder

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 4
 Manifold Specifications

Manifolds Option Type or Manufacturer

Inlet/Outlet Manifold Diameter -- 38” / 42”
Inlet/Outlet Manifold Construction -- 12 ga aluminized
Inlet/Outlet Manifold Flex Connectors Included Stainless steel bellows
Inlet/Outlet Manifold Velocity -- 3,500 fpm
Inlet/Outlet Manifold Insulation -- Outlet Onl y – 4” thick,
4 lb mineral wool
Inlet/Outlet Manifold Cladding -- Outlet Onl y – 16 ga galvanized
Isolation and fresh air dampers with hydraulic Inlet Manifold Valve Diameter -- 38”
actuators and solenoid junction boxes. This
assembly is required for start-up of the RTO Inlet Manifold Valve Type -- Metal seated butterfly
and connects to the process exhaust ductwork. Outlet Manifold Valve Diameter -- 42”
Outlet Manifold Valve Type -- Metal seated butterfly
Inlet/Outlet Manifold Valve Velocity -- 4,500 fpm max
Inlet/Outlet Manifold Valve Construction -- Aluminum plated mild steel
Inlet/Outlet Manifold Vacuum Breaker Optional Outlet Onl y
Purge Manifold Diameter NA NA
Purge Manifold Construction NA NA
Purge Manifold Flex Connectors NA NA
Purge Manifold Velocity NA NA
38”Inlet/42” Outlet manifolds 12 gauge Purge Manifold Insulation NA NA
Aluminized steel. Outlet manifold insulated
with 4” thick 4lb density mineral wool with 16
Purge Manifold Cladding NA NA
gauge galvanized cladding. Note the electrical Purge Valve Diameter NA NA
conduit runs to the electrical room which will
remain intact allowing for a straight forward Purge Valve Type Velocity NA NA
installation.
Purge Valve Construction NA NA

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 5
Exhaust Fan

Exhaust Fan Option Type or Manufacturer

Type Force draft centrifugal
Quantity 1
Manufacturer Twin Cities (or equivalent)
Volume 24,000 cfm (max)
Static Pressure 21” wc
Class III
Arrangement 8
Inlet/Outlet Flex Connectors Included EPDM
Outlet Velocity 4,500 fpm
Materials of Construction Mild steel
Fan Insulation Included 4” thick
Fan Cladding Included 16 ga galvanized
Lubrication System Included Manual
Motor Size/Type Included 150 hp/TEFC
Motor Manufacturer Delco
Motor Efficiency Standard
Motor Service Factor 1.15

Spare 150HP Baldor motor (brand new and Twin City arrangement 8 Class lll main
never used) included with purchase of system. exhaust fan with 150hp motor. Maximum flow
conditions are 24,000 cfm at 21” w.c. 70°F.

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 6
Hydraulic System

Hydraulic System Option Type or Manufacturer

Valve Actuator Type, Included Rack and Pinion Flo-Tork (or
Manufacturer equivalent)
Hydraulic Pump Included Racine (or equivalent)
Stand by Pump Optional
Heated Fluid Reservoir Included
Hydraulic Line Material -- Stainless Steel
Hydraulic Line Insulation Optional

Flo-Tork rack and pinion hydraulic actuator similar for

all dampers. Also shown are the GO proximity
switches to prove position in both the open and closed
positions.

One of four main diverter valves with Flo-Tork

hydraulic actuator and solenoid cabinet. Each
actuator has independent flow control for valve
speed setting. Inlet and outlet valves are step seat
construction 38” inlet, 42” outlet. Access doors and
endplates for ease of inspection of all valves and
cold face support grid areas.
Hydraulic solenoid cabinets typical for all dampers.
Each cabinet has local speed control to set damper
speed base on ambient conditions.

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 7
Control Room

Control room with locked door and air conditioning system. Control Room lighting system

Control Room Type or Manufacturer

Manufacturer Parkut (or equivalent)
Size 11’-9” wide x 6’-9” deep x 10’ high
Lighting Fluorescent
Ventilation Wall mounted air conditioner

Square D main disconnect Local power center for control System hydraulic skid located inside control room.
and thermostat for room room. Racine hydraulic pump.
conditioning.

NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518

215-234-8188 • www.nestecinc.com
Page 8
System Controls
Main control panel showing
Honeywell Tru-Line chart
recorder, Allen Bradley MMI
1000 panelview and Honeywell
UDC high temperature limit
controller.
Allen Bradley PowerFlex 700
150 HP VFD. Located in a
NEMA 1 enclosure w/ fans and
filters. Flying Start capability.
NESTEC, Inc. • Suite 400 • 21 Unionville Road • Douglassville • Pennsylvania • 19518
215-234-8188
System Controls Type or Manufacturer
Master Control Panel Custom NEMA 12
Programmable Controller (PLC) Allen-Bradley 5/03
Human Machine Interface (HMI) Allen-Bradley 900 Series
Software, files & printouts Allen-Bradley 6200 Series
Automatic Sequence Start/Stop
Fresh Air Stand-by Mode
High Temperature Limit Watlow
Chart Recorder – Circular Chart Honeywell DR 4500A
Inlet Temperature T/C Type K – Watlow
Outlet Temperature T/C Type K – Watlow
Combustion Chamber Temperature T/C Type K – Watlow
IEC Type Components IEC Motor Startes & Relays
(Int ernat ional E lectrotechnical Commi ssion)
Low Peak Fuses
Enclosure NEMA 12 Indoors/ 3R
Outdoors
Remote Operation Control Panel Allen-Bradley 900 Series
MCC and power distribution for Outside of VFD cabinet Picture of inside of main control
main panel and VFD. (Hoffman enclosure) MMI for panel showing Allen Bradley
VFD set-up. SLC 5/03 controller.
• www.nestecinc.com
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