Thermal Oxidizer + Waste Heat Recovery Integration
    Renewable Natural Gas|Leading RNG Developer

    Thermal Oxidizer + Waste Heat Recovery Integration

    An RNG facility converting landfill gas needed emissions control without excessive fuel use. CleanCap designed an integrated TO + WHRU system with low pressure drop, capturing exhaust heat for glycol heating while minimizing environmental footprint.

    <30 min

    Cold Startup

    Reduced

    Carbon Intensity

    Optimized

    Heat Recovery

    Project At A Glance

    Challenge

    Fuel Efficiency & Carbon Intensity

    Methodology

    Full thermal, mechanical, and emissions evaluation for sustainability goals.

    Outcome

    • Cold Startup: <30 min
    • Carbon Intensity: Reduced
    • Heat Recovery: Optimized

    Executive Summary

    A leading Renewable Natural Gas (RNG) developer required a highly efficient emissions control solution for its processing facility. The facility needed a Thermal Oxidizer (TO) capable of destroying contaminants in the permeate stream while minimizing fuel usage. CleanCap engineered an integrated Thermal Oxidizer + Waste Heat Recovery Unit (WHRU) system that achieved major fuel savings, reduced electrical load, and rapid cold startup (<30 minutes).

    Customer Background

    The customer is a forward-thinking RNG developer converting landfill gas into pipeline-grade Renewable Natural Gas. Their mission emphasizes reducing methane emissions and delivering sustainable, low-carbon fuel alternatives. The facility requires a robust thermal oxidation system to treat VOCs and HAPs from permeate streams.

    Project Background

    The RNG upgrading process generates a permeate (off-gas) stream requiring thermal treatment. Traditional oxidizers consumed excessive fuel, delivered poor heat integration, and suffered from slow startup times. CleanCap was tasked with designing a holistic emissions and energy-efficiency solution featuring a low pressure drop TO and integrated WHRU.

    The CLEAN Approach

    C

    Consult & Analyze

    • Process & Thermal Load Characterization: Evaluated composition/flow of permeate stream and heat-load variability.
    • Energy Utilization Opportunity: Modeling showed large volumes of recoverable energy in TO exhaust with potential to heat glycol loops.
    • Mechanical Assessment: Assessed pressure drop impact on blower horsepower.
    • Root Cause: The legacy approach used a standard oxidizer design not optimized for fuel minimization or heat recovery.
    L

    Learn & Plan

    • Low Pressure Drop TO: Engineered features included optimized flow paths and ceramic fiber insulation for high heat retention.
    • WHRU Design: Designed to capture exhaust heat for glycol heating, reducing burner fuel demand facility-wide.
    • Burner Optimization: High-efficiency, low-NOx burner with modulating controls.
    • Skid-Mounted Architecture: Pre-piped, pre-wired design for rapid installation.
    E

    Execute with Precision

    • Fabrication: Constructed TO with ceramic fiber insulation and high-efficiency burner.
    • WHRU Installation: Installed downstream of oxidizer to heat glycol loops.
    • Integration: Fully assembled skid-mounted system offsite to minimize field labor.
    • Controls: Installed temperature/flow control systems and programmed startup logic.
    A

    Assess & Document

    • Fuel Savings: Burner duty cycle remained low due to WHRU preheating.
    • Pressure Drop: Measured ΔP aligned with aerodynamic modeling.
    • Emissions: Achieved required destruction efficiency with lower NOx.
    • WHRU Performance: Maintained consistent glycol loop temperatures.
    N

    Nurture & Maintain

    • CleanCap developed a long-term maintenance plan including annual burner review, WHRU inspection, and carbon-intensity tracking.

    Results & Impact

    Technical Benefits

    • Major reduction in supplemental fuel demand
    • Increased thermal stability
    • Significant heat recovery

    Financial Benefits

    • Lower natural gas costs
    • Reduced electrical cost
    • Lower maintenance downtime

    Sustainability

    • Lower carbon intensity of RNG product
    • Reduced NOx emissions

    "The result is a high-performance emissions solution that supports the customer's long-term operational, regulatory, and environmental objectives."