Thermal Oxidizer Retrofit & Rapid Deployment
    Chemical Manufacturing|WR Grace

    Thermal Oxidizer Retrofit & Rapid Deployment

    WR Grace needed a mothballed oxidizer fully refurbished and operational in 30 days. CleanCap delivered complete modernization including Hastelloy quench tower, new PLC controls, burner system, and Class 1 Div 2 hazardous area compliance.

    30 Days

    Deployment Time

    Compliant

    Class 1 Div 2

    Turnkey

    System Status

    Project At A Glance

    Challenge

    30-Day Deployment Window

    Methodology

    Intensive engineering review with parallel mechanical and electrical execution.

    Outcome

    • Deployment Time: 30 Days
    • Class 1 Div 2: Compliant
    • System Status: Turnkey

    Executive Summary

    WR Grace required a Thermal Oxidizer (TO) system to be fully refurbished, modernized, and integrated into their process within a compressed 30-day deployment window. The project included upgrading a mothballed oxidizer, adding a quench tower, installing new controls, and ensuring Class 1 Div 2 compliance. CleanCap executed a turnkey modernization that delivered rapid installation, full refurbishment, and safe operation in a hazardous environment.

    Customer Background

    WR Grace is a leading global producer of catalysts and specialty chemicals. Their production processes involve high temperatures, reactive chemicals, and organic vapors requiring thermal destruction. The facility needed a TO capable of destroying high-VOC off-gases while operating dependably in a hazardous area.

    Project Background

    The project involved a used TO vessel, an incomplete control panel, and uninstalled valves. It required engineering validation, mechanical reconstruction, electrical installation in a hazardous area, and commissioning. This was a full lifecycle modernization executed under extreme time pressure.

    The CLEAN Approach

    C

    Consult & Analyze

    • Mechanical Assessment: The vessel required refractory patching and significant cleaning.
    • Controls Assessment: Existing controls were outdated and non-compliant with Class 1 Div 2.
    • Process Review: Analyzed VOC loading and integration requirements with boiler/scrubber.
    • Root Cause: This was a reconstruction requiring engineering completion, not just assembly.
    L

    Learn & Plan

    • Control Modernization: Designed new PLC/HMI system with safety interlocks.
    • Quench Tower Integration: Configured Hastelloy tower to protect downstream equipment.
    • Valve Upgrade: Engineered specs for MODBUS flow meters and pneumatic actuators.
    • Schedule: Created a minute-by-minute execution plan to meet the 30-day deadline.
    E

    Execute with Precision

    • Mechanical Reconstruction: Restored structural components and repaired refractory.
    • Quench Tower: Installed tower and connected cooling lines.
    • Controls: Built new control panel with hazardous-rated wiring.
    • Startup: Performed dry run, safety checks, and calibrated destruction efficiency.
    A

    Assess & Document

    • Performance Validation: Achieved temperature stability and destruction efficiency.
    • Quench Performance: Reduced exhaust temperature to target levels.
    • Documentation: Provided as-built drawings, P&IDs, and operations manual.
    N

    Nurture & Maintain

    • Established support program including operator training, scheduled burner tuning, and quarterly health inspections.

    Results & Impact

    Operational Results

    • Successful commissioning under extreme time constraints
    • Fully modernized system
    • Improved process stability

    Compliance & Safety

    • Reliable VOC destruction
    • Full Class 1 Div 2 compliance
    • Improved operator safety

    "CleanCap turned a fragmented, non-operational oxidizer into a fully engineered, production-ready emissions control system in record time."