regenerative thermal oxidation plant sautter schroeger schaefer cc353882

KLINGER Dichtungstechnik erects regenerative thermal oxidation plant

KLINGER Dichtungstechnik relies on regenerative thermal oxidation for PTFE gasket production: 150 tons of CO2 reduction

February 13, 2020

The Austrian gasket manufacturer KLINGER Dichtungstechnik produces its PTFE gaskets with filler material under the brand name KLINGER TopChem. In order to enhance its product offering and to provide customers with additional benefits, the company is now investing into a regenerative thermal oxidation plant. It will ensure that no solvent residues are emitted and that waste heat can be fed back into the process.

Visitors to the KLINGER headquarters in Gumpoldskirchen, Lower Austria, will most surely have noticed a new construction site next to the road that runs in parallel to the premises. โ€œThis is where our new regenerative thermal oxidation plant will be located,โ€ confirms Michael Sautter, Managing Director (commercial) of KLINGER Dichtungstechnik. And the plant, which has roughly the dimensions of a single-family home, is already beginning to take shape. Designed by the industrial combustion systems expert CTP-DUMAG, a next-door neighbor of the KLINGER Group, it is scheduled for completion in the first quarter of 2020.

Contacts mentioned in the article:

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Regenerative thermal oxidation plant promises efficiency gains and increased competitiveness of KLINGER TopChem

Asked about the reasons for the new plant, Mr. Sautter explains: โ€œOur regenerative thermal oxidation plant is part of a new manufacturing process for our high-performance PTFE sheets with fillers. It will allow us to increase our material efficiency as well as our annual sheet capacity. Furthermore, it will enable us to re-use our waste heat. This is in line with our โ€˜Sustainabilityโ€™ value, as it contributes to a resource conservation in our production.โ€ According to the managing director, these improvements will benefit the customer and simultaneously increase the competitiveness of KLINGER TopChem on the market.

regenerative thermal oxidation plant schรคfer

โ€œThe heat return figure provided by the regenerative thermal oxidation process is significantly higher than the one offered by thermal oxidation. In fact, we require only very low volumes of natural gas to fire the burner โ€“ the process will allow for an almost autothermic operation.โ€
โ€œNext to significant energy savings, the additional recuperator also saves a considerable amount of CO2: more than 150 tons per year.

Ernst Schรคfer, Managing Director of KLINGER Dichtungstechnik

Superior regenerative thermal oxidation

Ernst Schรคfer is KLINGER Dichtungstechnikโ€™s Managing Director (technology). He is in charge of the technical details of the project. โ€œOur new manufacturing solution includes new process technologies and we have also developed high-performance tempering and sintering ovens to achieve our goals. The reason for our regenerative thermal oxidation plant, however, is a new solvent we have introduced. Our previous version had reached its operational limits, resulting in bottlenecks and process efficiency potentials not being realized,โ€ he explains, adding: โ€œThis is why we switched.โ€ The Austrian clean air act, however, stipulates that this lubricant must be removed from the raw gas that is primarily created during tempering of the PFTE sheets. โ€œWe had two options,โ€ remembers Ernst Schรคfer, โ€œeither to opt for a thermal oxidation solution or take the path of regenerative thermal oxidation.โ€ Although both options provide the legally required results, calculation models quickly highlighted a number of advantages that spoke loudly in favor of a regenerative approach. โ€œThe investment costs were admittedly significantly higher,โ€ states Mr. Schรคfer, โ€œon the benefits-side, however, we found lower operating costs, significantly reduced CO2 emissions and less thermal energy demand.โ€ The latter, by the way, is explained by the improved waste heat recovery, meaning that more excess heat can be fed back into the process.

New process revolutionizes KLINGER TopChem production

In the course of regenerative oxidation, the scrubbed gas, which is already solvent-free, transfers its heat to a regenerator, which in turn heats the raw gas at an average temperature of approximately 180 to 200 ยฐC. The regenerators themselves consist of ceramic honeycombs, which can be used to store heat. A minor portion of the solvent removal already occurs at the regenerators. The majority of the oxidation process, however, takes place in the burner. โ€œThe heat return figure provided by the regenerative thermal oxidation process is significantly higher than the one offered by thermal oxidation. In fact, we require only very low volumes of natural gas to fire the burner โ€“ the temper process is almost autothermic,โ€ explains Mr. Schรคfer. Completing his tour of the technological highlights, Ernst Schรคfer also points out the additional recuperator, which pre-heats the primary air: โ€œFollowing its passage through the regenerator, the scrubbed gas transfers its heat to the primary air, which further reduces the energy demand of the overall drying process.โ€ Next to significant energy savings, this also saves a considerable amount of CO2: At an operating grade of 100 percent, the savings amount to more than 150 tons per year.

KLINGER TopChem offensive

Michael Sautter and Ernst Schรคfer are both satisfied with the progress of their new plant. โ€œWe are very much looking forward to showing our customers the results of our redesigned manufacturing process for the KLINGER TopChem product,โ€ explains Mr. Sautter, โ€œAs a maintenance-free gasket that does not age, it is definitely a solution for industries where absolute durability and an extremely long service life are a must: for example in district heating.โ€

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regenerative thermal oxidation plant burner station
Work in progress: the burner station up close

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