Plastic Pyrolisis Thermal Oxidizer for nrg fuels in the UK
CRA partnered with Vapor Desal to engineer and manufacture a UKCA-compliant thermal oxidizer system for NRG Fuels’ plastic pyrolysis facility in the United Kingdom. The system was designed to safely treat lean, VOC-laden pyrolysis gas streams with low hydrocarbon content, while using process-derived pyrolysis gas as fuel. Engineered for deployment in an industrial zone in Derby, the solution focused on high destruction efficiency, combustion stability, and full regulatory compliance under variable operating conditions.
Designing a High-DRE Oxidizer for Lean, Oxygen-Rich Pyrolysis Gas
NRG Fuels required a thermal oxidation systemcapable of reliably treating challenging pyrolysis off-gas streams generatedfrom plastic waste processing. The gas stream presented multiple constraintsthat demanded a highly engineered solution:
• Very low calorific value gas with poorhydrocarbon content, limiting flame stability
• High VOC loading with entrained particles requiring robust combustioncontainment
• Presence of oxygen in the inlet stream, increasing combustion controlcomplexity
• Strict UKCA compliance requirements for installation in an industrial zone
• Variable flow conditions inherent to pyrolysis plant operation
The system had to consistently achieve highdestruction efficiency while maintaining safe, stable combustion across alloperating envelopes.
UKCA-Compliant, Fully Integrated Thermal Oxidizer Engineered for Lean Gas Stability
CRA engineered and manufactured a complete thermaloxidizer package in-house, specifically tailored for lean, VOC-rich pyrolysisgas applications. The design focused on combustion stability, thermalcontainment, and compliance-driven engineering.
Core Components Delivered
• Custom-designed thermal oxidizer shell withdual-shell insulation
• Engineered burner and pilot system optimized for low-CV gas
• Dedicated air blower system for controlled combustion air supply
• Fully enclosed skid-mounted structural frame
• Integrated instrumentation, piping, and automation systems
Engineering and Validation
• Full 3D system modelling and layout engineering
• CFD simulations to validate flame stability and flow distribution
• FEA for structural and thermal integrity under operating loads
• Radiation and noise analysis to meet industrial zone limits
• Electrical, control, and interlock logic design aligned to UKCA norms
• UKCA-compliant Quality Assurance Plan covering design through testing
Fabrication and Testing
• Complete in-house fabrication of mechanical andcombustion components
• Factory assembly of the skid-mounted system with thermal containment
• Pre-dispatch functional and safety checks to validate readiness for sitedeployment
Stable, Compliant Thermal Oxidation for Complex Pyrolysis Gas Streams
• Designed to achieve greater than 99% destructionremoval efficiency
• Stable combustion maintained despite lean, low-hydrocarbon inlet gas
• Fully UKCA-aligned engineering, documentation, and compliance framework
• Compact, skid-mounted system enabling controlled installation and integration
• Validated performance through simulation, analysis, and factory testing
• Demonstrated CRA’s capability in advanced thermal treatment for pyrolysisapplications
Delivering Robust Solutions for Complex Industrial Gas Streams
This project reinforces CRA’s expertise in delivering certified thermal oxidation systems for some of the most challenging industrial gas streams. By combining advanced combustion engineering, in-house validation capabilities, and a compliance-driven design approach, CRA developed a robust solution for lean VOC-laden pyrolysis gas under stringent UK Regulatory requirements. The system highlights CRA’s ability to repeatedly engineer, validate, and manufacture complex thermal treatment solutions for emerging waste-to-energy and circular economy industries.
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