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Quench Tower Trouble

The quench tower in the picture looked good on the outside; however, when I inspected the demister I found something else entirely: it was completely plugged. Quench towers serve an important function; they reduce waste gas stream temperatures to protect downstream equipment. In this case the customer was lucky (relatively speaking). The next piece of equipment in the chain was an RTO (Regenerative Thermal Oxidizer). Which essentially turned into one very expensive lawn sprinkler. There are a number of issues here. The plugging affected source static pressures which resulted in higher fan speeds, elevated face velocities, lower residence times, and a drop in operational efficiency. The elevated velocities created a carryover effect, pulling water and product through the demister, and into the RTO. The RTO's poppet valves, and the inlet/outlet manifolds, were coated with hardened product because the product was exposed to the RTO's normal operating temperatures. Implementation of a PM schedule designed for this type of equipment would have been the best way to keep the equipment running properly. RHZ has a number PM programs created for a variety of equipment. We would be happy to work up a maintenance program tailored for the needs of your equipment.

This quench tower looks great on the outside, but the inside is another story.
The extensive plugging causes a myriad of issues.