VOC abatement efficiency
Thermal oxidisers installed worldwide
Years of experience in ATEX environments
In chemical and petrochemical processes, VOC emissions are often unpredictable: benzene, BTX, cumene, chlorinated hydrocarbons and mixtures that vary in concentration and flow rate. Environments are ATEX-classified, safety requirements are stringent, and the consequences of a non-compliant plant are severe. We design RTOs and SRUs for these conditions, not for ideal laboratory ones, integrating advanced control systems and also managing the revamping of existing installations that no longer comply with current limits.
The chemical and petrochemical sector requires plants capable of managing extreme variability: changing VOC composition, fluctuating flow rates, high temperatures and explosion risk. We offer regenerative and catalytic thermal oxidisers, solvent recovery plants and filtration systems designed to operate safely in ATEX zones, with integrated LEL control systems and compliance with the most stringent European directives. Every solution is developed after a thorough analysis of the real process.
For high flow rates and variable concentrations. Up to 99% abatement, thermal efficiency up to 95% and excess heat recovery.
For low-concentration VOC streams. Oxidation at 300–350°C, reduced consumption, emissions below 1 mg/Nm³.
For recoverable solvents such as BTX, toluene and hydrocarbons. Steam or nitrogen regeneration with a dedicated distillation section.
Regulatory compliance upgrade of existing third-party plants: analysis, redesign, component replacement, ATEX recertification.
In chemical and petrochemical environments, regulatory compliance is non-negotiable. Every Donau Carbon Technologies plant is designed to comply with IED, ATEX and BAT standards from day one and to continue doing so even as operating conditions change over time.
Over 350 units installed worldwide, capacity from 3,000 to 330,000 Nm³/h. Designed to manage the concentration and composition variations typical of discontinuous chemical processes.
For toluene, BTX, cumene and chlorinated hydrocarbons. Closed nitrogen circuits that eliminate explosion risk, with distillation sections for separation of complex mixtures.
Treatment systems for inorganic pollutants, HCl, Cl₂ HF, HBr and SOx, generated by chemical processes, corrosion and high-temperature resistant materials, are fully automated. Recovery of soluble-in-water solvents with high boiling point (DMF).
The chemical and petrochemical sector is among the most heavily regulated of all. Emission limits are stringent, ATEX regulations are binding, and the consequences of a non-compliant installation can be severe: legally, operationally and reputationally. We design every plant by integrating regulatory requirements from the outset: not as a final checklist, but as engineering parameters. This approach eliminates surprises and ensures compliance throughout the plant's operational life.
We design to comply with BAT-AEL values specific to the chemical sector, including diffuse and fugitive emissions often overlooked in third-party installations.
All components in classified zones are designed and ATEX-certified: adsorber, pipework, valves, instrumentation and electrical systems.
For installations outside the European Union, we design in accordation to ASME standards and applicable local regulations in the country of installation.
Every chemical process is different. The questions we receive most often in this sector concern the management of emission variability, ATEX requirements and the options for upgrading existing plants.
The RTO is sized to handle peaks without being oversized on average, often using bypass stand-by mode or storage systems to optimise energy consumption during low-emission phases.
Catalytic oxidation is preferable when VOC concentrations are low and constant, the solvents do not contain silicon, chlorine or sulphur, which could poison the catalyst, and space is limited. RTOs are better suited to high flow rates, variable concentrations and heterogeneous solvents.
Yes, but feasibility depends on mixture composition and stability. For BTX mixtures with two predominant solvents (> 80% of total) and flow rates above 500 t/year, recovery with SRS or SRN is technically and economically viable, with a dedicated distillation section for separation.
It depends on the extent of deviation from current limits and the age of the plant. In many cases, revamping is significantly less expensive than a new plant: we analyse the existing installation, identify the components to be replaced and propose the solution with the best cost-benefit ratio.
Solvent recovery on a petrochemical process. Solvents: cumene, benzene. Flow rate: 40,000 Nm³/h. Installed in 2002.
Every chemical process has its own variables. Tell us about your emissions: we will respond with a personalised technical analysis and a dedicated contact.
