Condensation-Incineration Process Vapor Recovery Unit

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The condensation + combustion Vapor recovery unit is an integrated VOCs treatment device that organically combines condensation recovery and combustion destruction technologies. At the front end, multi-stage condensation liquefies and recovers hydrocarbon components from high-concentration Vapor , achieving resource utilization. At the back end, the uncondensed, low-concentration tail gas is treated by combustion (catalytic oxidation/regenerative combustion/direct incineration), completely decomposing it into harmless carbon dioxide and water, achieving near-zero emissions.

This product complies with national standards such as the "Emission Standard of Air Pollutants for Oil Storage Depots" (GB 20950), the "Emission Standard of Pollutants for Petroleum Refining Industry" (GB 31570), and the "Technical Standard for Vapor Recovery and Treatment Facilities" (GB/T 50759-2022). The VOCs purification efficiency can reach 97%–99% or higher, and the emission concentration can be as low as below 20 mg/m³. The product is widely used in the treatment of high-concentration volatile organic waste gas in the petrochemical, chemical, and oil storage, transportation, and sales industries.

Technical Positioning Description: The combination of condensation and combustion achieves synergy between "resource recovery" and "harmless disposal"-the condensation stage converts high-value components into liquid products to generate economic benefits, while the combustion stage completely neutralizes low-concentration exhaust gases that cannot be recovered. This is one of the ultimate combined solutions for meeting stringent emission standards.

2.1 Core Technical Principles

This device adopts a two-stage, stepped treatment design:

First Stage-Condensation Recovery: Utilizing the principle of differences in saturated vapor pressure at different temperatures, the Vapor are gradually cooled through multi-stage refrigeration, causing high-boiling-point hydrocarbon components to reach a supersaturated state, condensing into a liquid for direct recovery. The condensation temperature is typically set in a three-stage gradient of 4℃→-25℃→-75℃, which can condense and separate approximately 80%–90% of the Vapor components.

The second stage-combustion and destruction: The non-condensable exhaust gas (still containing a small amount of VOCs) after condensation treatment enters the combustion system, where, under high temperature (RTO approximately 800-950℃) or catalytic action (CO approximately 300-500℃), the organic matter is completely oxidized to CO₂ and H₂O. The combustion system can be selected from different technical routes, such as catalytic oxidation (CO), regenerative thermal oxidizer (RTO), or direct incineration (CEB/VCU), depending on the composition and concentration of the exhaust gas and site conditions.

2.2 Comparison of Mainstream Process Routes

2.3 Typical Process Flow (Example: Condensation + Adsorption + Catalytic Oxidation)

Based on a technology case selected for the "National Catalogue of Pollution Prevention and Control Technologies (2025 Edition)" under the encouraged category:

Waste Gas Collection and Conveyance: Volatile vapors from the tank farm or loading rack are collected via sealed piping and fed into the main condensation unit by an explosion-proof blower; the blower operates with automatic variable-frequency control interlocked with pressure sensors.

Three-Stage Cascade Condensation: The vapors are first cooled to 4°C in a regenerative precooler, condensing out a portion of methanol and water; they then enter the first-stage condensation unit (cooled to -25°C) followed by the second-stage unit (cooled to -75°C). At this point, approximately 90% of the hydrocarbon components have been separated. The cold, lean gas stream is reheated to approximately 25°C via a regenerative heat exchanger before entering the adsorption system.

Deep Purification via Adsorption: The adsorption system utilizes two adsorption vessels that alternately undergo an "adsorption–evacuation–pressurization" cycle. When Vessel A reaches adsorption saturation, the system automatically switches to Vessel B, while Vessel A undergoes vacuum desorption to regenerate the adsorbent.

Destruction via Catalytic Oxidation: Following condensation recovery and adsorption treatment, the residual tail gas enters a gas-to-gas heat exchanger, where it absorbs heat from the high-temperature gas exiting the catalytic reactor. After further heating in a preheating chamber, the gas enters the catalytic reaction chamber, where organic compounds are completely decomposed at temperatures between 300°C and 500°C.

Compliant Discharge: The purified high-temperature gas transfers its thermal energy to the incoming cold gas stream via the heat exchanger; the cooled gas is then vented to the atmosphere.

2.4 System Components

4.1 Resource Recovery and Harmless Disposal Combined

Front-end Recovery for Efficiency: The condensation section can recover 80%–90% of Vapor resources, directly obtaining liquid oil products. 1–2 tons of light distillate oil can be recovered daily.

Back-end Thorough Purification: The combustion section completely oxidizes residual VOCs into CO₂ and H₂O, without secondary pollution.

High Overall Purification Efficiency: The combined process achieves a VOCs purification efficiency of over 97%–99%.

4.2 Multiple Combustion Technology Routes Available
This device allows for flexible selection of combustion methods based on the composition, concentration, and site conditions of the waste gas.：

4.3 Cold Energy Recovery and Energy Optimization

Regenerative Precooling: The condensation section uses a regenerative precooler to precool the inlet exhaust gas using condensed low-temperature gas, achieving cold energy recovery.

Heat Energy Recovery: The high-temperature purified gas generated by catalytic combustion preheats the incoming cold exhaust gas through a heat exchanger, reducing energy consumption.

Liquid Nitrogen Cold Energy Utilization (Liquid Nitrogen Condensation Scheme): The cold energy after liquid nitrogen vaporization can be integrated into the nitrogen pipeline network for nitrogen replenishment in storage tanks, achieving comprehensive resource utilization.

4.4 Intelligent Control and Safety Reliability

PLC/DCS Fully Automatic Control: One-button start/stop, 24/7 automatic operation, enabling unattended operation.

Explosion-proof Design: Ex d IIB T4 explosion-proof rating, suitable for flammable and explosive environments.

Multiple Safety Interlocks: Comprehensive safety measures including overpressure protection, overtemperature protection, concentration exceeding alarm, and flame arresters.

Online Monitoring: Real-time monitoring of emission concentration to ensure stable compliance.

Specific prices and delivery times are subject to actual quotation.

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