From Waste and Cost to Energy and Profit
SUPERFLOX™
Introduction
Versatile and super-efficient destruction of hazardous pollutants to help achieve the most aggressive ESG TARGETS.
SUPERFLOX™ waste gas treatment system is based on the proven German technology of Flameless Oxidation (FLOX).

The key feature of the process is the efficient and complete destruction of hazardous air pollutants (HAP) and VOC without the formation of thermal NOx.

The ability of the system to process a wide range of low heat value (LHV) gases without the need for additional fuel gas makes it a cost-saving and super efficient alternative to conventional thermal oxidizers.

The system comprises of patented FLOX burners as well patented automated gas management system.

the problem

Industrial waste gas streams are often produced at low energy content, insufficient to maintain direct combustion. To aid combustion, addition of fuel gas (natural gas, propane, etc.) is typically required. This can lead to increased operational costs and elevated levels of harmful emissions (NOx, CO2), and result in incomplete combustion of the gas.e of a div block.

Low CV Waste Gas

Waste gas of low calorific value that requires additional gas to assist combustion, increasing operational costs.

High Levels of NOx

High level of thermal NOx as a result of the need of full hydrocarbon combustion.

Incomplete Combustion

Incomplete combustion resulting in formation of contaminants such as CO, SOx, particulate matter, etc

Changing Gas Flow and Composition

Varying gas flow and composition due to e.g. frequent changes in the process requirements, treating gas from different plants, etc.

Inefficient Energy Recovery

Waste of valuable energy due to inefficient recovery on low heat value gas streams.

Operational Difficulties

Operational issues in maintaining the optimal mix of fuel gas, oxygen levels and temperature in the combustion chamber.

the solution

SUPEFLOX™ is an optimal solution for any industrial processes that struggle with the efficiencies of their waste gas treatment processes or have regulatory issues related to maintaining allowable levels of emissions.

Burns Low CV Waste Gas

Can process low calorific gases of 1.5 MJ/m3, which eliminates the need of adding valuable natural gas to ensure waste gas combustion.

Uniform Conditions

Separate introduction of waste gas and oxygen to the chamber with intensive mixing at the inlet, which ensures turbulent gas conditions across the chamber.

Low Oxygen Level

Oxygen level in combustion chamber is always maintained between 3-8%, leading to inherently safe operations without any risk of explosion.

No Thermal NOx

Combustion chamber temperature is kept at above auto-oxidation levels of most hydrocarbons, but below the temperature of formation of thermal NOx.

Flexible and Easily Scalable

The system is easily scalable and able to efficiently process waste gas flows between 5,000 and 300,000 nm3/hr, with operational range from 40% to 120% capacity.

Full Automation

Fully automated and remote gas management system.
industrial applicationS

SUPEFLOX™ is a versatile technology that can be applied across a multitude of industries

Oil & Gas Production

  • Managing CO2 Emissions associated with flaring
  • Efficient energy capture for regeneration
  • Mobile solutions

Terminals & Pipelines

  • Tank de-gassing with near-zero emissions
  • Reduces soot formation in pipelines
  • Efficient utilization of recovered vapors

Landfills

  • Extends economical life of landfills
  • Unassisted burn of low methane gas (4-6 vol%)
  • Utilization of escaping residual methane

Petrochemical Plants

  • Efficient treatment of low CV gases
  • Fully automated gas managements systems
  • Oxygen level between 3-8%

Petroleum Refining

  • Treatment of gases with inconsistent flow
  • Treatment of gases with variable compositions
  • Small footprint of installation

Ethanol Production

  • Efficient treatment of low CV waste gases
  • Recirculation of energy = improved CI Score
  • Reduced Greenhouse Gas emissions

Background

what is flameless oxidation

Superflox® is a proprietary technology, based on the well-established concept of Flameless Oxidation, discovered in Germany by Dr. Joachim Wünning in 1989.

A typical waste gas combustion cycle is associated with a number of incefficiencies:

  • High temperature combustion zone, resulting in formation of NOx;
  • Constant insertion of high-calorific gas (e.g. natural gas) is required to maintain the minimum heat content of the waste gas treated
  • Incomplete combustion resulting in formation of contaminants such as CO, SOx and particle matter (PM).
In search for a more efficient combustion technology, the phenomenon of flameless oxidation was observed, where under a certain set of conditions, full combustion of the fuel gas occurred while no flame was visible. It was also discovered in the process that the level of thermal NOx emissions remained close to zero.

This discovery was the beginning of the Flameless Oxidation (FLOX) technology as a highly efficient and low-emission alternative to the conventional flame-based combustion technologies.
Traditional Combustion with Flame Front
Flameless Combustion

Comparison

Direct Combustion

  • Additional fuel gas required
  • Pre-mixing required
  • Combustion temperature above 2700°F
  • Oxygen level between 15 and 20%
  • Energy content of fuel gas at least 20MJ/Nm3
  • NOx emissions over 200 ppmv

Flameless Combustion

  • Fuel is only required for start-up
  • No pre-mixing required
  • Combustion temperatures under 2000°F
  • Oxygen level between 3 and 10%
  • Energy content of fuel gas from 1.5 MJ/Nm3
  • NOx emissions under 25 ppmv