Case Study: Resolving Inlet Pressure Loss on a Thermal Oxidizer System

Customer Challenge

A customer operating a thermal oxidizer with a downstream scrubber was experiencing a significant decrease in inlet pressure, resulting in process instability and concerns about system performance. The issue was impacting operational efficiency and required immediate investigation to prevent further production disruptions.

The customer engaged Nitro Environmental to perform a comprehensive assessment and identify the root cause of the problem.

Assessment & Findings

Nitro Environmental conducted a detailed inspection of the thermal oxidizer inlet system and associated process equipment.

Key Findings

  • Waxy by-product accumulation was discovered throughout the inlet ductwork.
  • Elevated differential pressure (DP) was measured across the flame arrestor.
  • The flame arrestor was found to be completely plugged with waxy process contaminants, significantly restricting flow into the thermal oxidizer.
  • The existing process valve showed signs of deterioration and was not suitable for the elevated operating temperatures associated with the application.

Corrective Actions

To restore proper operation and improve long-term reliability, Nitro Environmental implemented the following corrective actions:

1. Flame Arrestor Cleaning

  • Removed the flame arrestor from service.
  • Performed a thorough solvent cleaning to eliminate accumulated wax deposits.
  • Restored unrestricted process flow through the unit.

2. Process Valve Upgrade

  • Removed the existing process valve.
  • Installed a new high-temperature-rated valve designed for the operating conditions of the system.

3. Steam Cleaning System Installation

  • Engineered and installed a steam injection connection downstream of the process valve.
  • Incorporated appropriate safety devices and controls.
  • Designed the system to allow in-place cleaning of the flame arrestor using steam without requiring removal from service.

Results

  • Inlet pressure was restored to normal operating conditions.
  • Differential pressure across the flame arrestor was significantly reduced.
  • Process reliability improved.
  • Maintenance downtime was minimized.
  • The customer gained the ability to periodically clean the flame arrestor in place, extending service life and reducing the frequency of solvent cleaning and component removal.

Customer Benefits

  • ✅ Restored system performance and process flow
  • ✅ Reduced maintenance labor and downtime
  • ✅ Extended flame arrestor service life
  • ✅ Improved safety through upgraded equipment and engineered steam cleaning provisions
  • ✅ Lower long-term operating and maintenance costs

Nitro Environmental Solution

By combining root-cause analysis, mechanical upgrades, and practical maintenance improvements, Nitro Environmental delivered a permanent solution that not only resolved the immediate restriction issue but also provided the customer with a proactive method for preventing future buildup and maintaining reliable thermal oxidizer operation.

6/7/2026