| RTO fuel consumption high common problem cause and treatment methods. |
| Infuencing factor | Specific reason | Inspection method | Optimization method |
| 1 | Low exhaust gas concentration | The exhaust gas is stable and its concentration is low | The concentration of imported exhaust gas is continuously measured by mobile FID | Where possible, increased thermal efficiency can reduce the fuel consumption of the system by adding ceramic bodies or replacing them with better performance ceramic bodies |
| 2 | The exhaust gas is unstable and the concentration is low for more time | The concentration of imported exhaust gas is continuously measured by mobile FID | Where possible, improve thermal efficiency by adding ceramic bodies or replacing ceramic bodies with better performance. Optimize the front-end process, reduce the time of low concentrationi exhaust gas, or design a special system for low concentration exhaust gas treatment |
| 3 | The thermal efficiency of the designed ceramic body is low | Ceramic bed height is low | Check design date and accounting,actual measurement analysis | If there is space, directly increase the ceramic body, or replace the ceramic body with better performance |
| 4 | Ceramic design wind speed is too high | Check design date and accounting,actual measurement analysis | Replace the cermaic body with better performance or reduce the operating air volume |
| 5 | The selected ceramic body has poor performance | Check the selection of ceramic date and accounting ,and actual measurement analysis. If nessary, send the sample to the ceramic body manfuacturer for profesional testing | Replace the ceramic body with better performance |
| 6 | The irregular filling of the ceramic body results in poor uniformity of the flow field of waste gas in the heat storage bed | Check the design date and calculate the actual measurement analysis if there is no problem and check the pressure difference at both ends of the ceramic bed | VOC’s governance reinstalled the usage alliance |
| 7 | Ceramic body performance degradation | Normal ceramic degradation caused by longer use time of ceramic body | Understand the type of ceramic used and the actual use time, umderstand the exhaust gas conditions and analyze the actual operatiing conditions, test and analyze the operation of the equipment, and check the appearance of the ceramic body bed. If necessary, send the sample to the ceramic body manufacturer for professional testing | Replace part or all of the cermaic body |
| 8 | Short time degradation caused by poor quality ceramic body | Replace the ceramic body with better performance |
| 9 | The degradation of ceramic by high temperature or corrosion | Replace high-temperature parts or corrosion-resistant ceramic bodies.If possible, the front end will increase the processing measures for the elements that cause corrosion. |
| 10 | The ceramic body is blocked | Blockage caused by broken ceramic body | Test and analyze the operation of the equipment,especially check the pressure difference at the both ends of the ceramic bed, and check the appearance of the ceramic body bed.If necessary, the sample will be further analyzed and tested | Replace part or all of the cermaic body |
| 11 | Particulate matter carried by the exhaust itself | Pretreatment is added to the front end to remove particulate matter |
| 12 | Clogging caused by reactioin products of exhaust gas combustion | Honeycomb ceramic body replace with saddle ceramic body |
| 13 | Ceramic bed bottom high boilling point material adhesion | Test and analyze the operation of the equipment especially check the pressure diffference between the two ends of the ceramic bed.Stop the machine to check the bottom of the ceramic bed. | Design high-temperature reburning function or artificial regular VOC’s treatment production cleaning research alliance |
| 14 | The switch valve has a large leak | Soft seal failure | The concentration of the inlet and outlet exhaust gas is continuously detected with the mobile FID, so as to evaluate the leakage situation and determaine the problem valve location | Replace the soft seal |
| 15 | Valve is damaged | Repair valve |
| 16 | Hot bypass leakage | The hot bypass is damaged | Detect RTO outlet temperature and hot bypass outlet temperature | Replace the hot bypass |
| 17 | The temperature control of the burner is unreasionable | Low burner adjustment ratio, can not reasonably control the size of the fire | Observe the operation of the regulating valve when the burner is working | Adjust the combustioin system or upgrade |
| 18 | The temperature of ceramic body sinks | The exhaust gas contains more VOCs with low boiling point | The temperature distribution of the regenerator bed was observed | Single bed temperature sinking design automatic adjustment program, twin bed sinking needs to adjust the operating air volume or adjust the exhaust gas concentration |
