Catalytic Products International (CPI) installed a new Regenerative Thermal Oxidizer (RTO) at a Midwest USA composite automotive parts supplier for the abatement of Volatile Organic Compounds (VOCs) from a topcoat surface coating operation.
- Process Type: Automotive Parts Painting
- VOCs: Toluene, Ketones, Acetates
- Air Volume: 30,000 SCFM
- Control Type: Regenerative Thermal Oxidizer (RTO)
- Destruction Rate Efficiency (DRE): 98%
- Installation: RTO, stack, fan inlet duct skid with process by-pass T-dampers, control room.
The 30,000 SCFM TRITON-30.95 Regenerative Thermal Oxidizer (RTO) controls emissions from a spray booth, flash-off area, and drying oven that make up a new topcoat surface coating operation for plastic/fiberglass automotive parts. The RTO meets the VOC Best Available Control Technology (BACT) requirements and PSD minor source limitations specified in the facility’s operating permit.
As with all RTO applications, the system is engineered to ensure inlet VOC concentrations remain safely below applicable lower explosive limit (LEL) thresholds. The RTO is designed and permitted to destroy the VOC emissions with a destruction efficiency of at least 98%.
Thermal treatment of VOCs and other air pollutants works by a simple reaction of the harmful hydrocarbon-based air pollutants with oxygen and heat. In this environment, the VOCs are chemically oxidized to form harmless inert by-products like CO2, water vapor (H2O), and usable heat. These harmless by-products are released to the atmosphere or used within primary or secondary energy recovery techniques to further lower the operational cost.
The Regenerative Thermal Oxidizer (RTO) system incorporates specialized ceramic media in the regenerator (heat transfer bed) to allow thermal efficiencies up to 97%. RTOs operate by preheating the process air as it passes upward through the first ceramic heat exchange media. This pre-heated air then exits the heat exchange media and enters a combustion chamber where it is heated to the setpoint temperature and oxidation of the VOCs is completed at greater than 98% efficiency. The combustion chamber operating temperature is maintained at or above a three-hour average setpoint established during formal compliance testing, as required by the facilities operating permit.
Catalytic Products International (CPI) worked closely with this long-term customer and its paint system supplier to design, fabricate, and supply the Regenerative Thermal Oxidizer (RTO). The mechanical and electrical installation of the RTO included booster fan, exhaust stack, compressed air desiccant dryer, fan inlet duct skid with process by-pass T-dampers, skid mounted electrical control room, and integration into a permanent total enclosure to provide 100% capture efficiency as required by the facility’s air permit.
This approach, along with CPI start-up, commissioning, and onsite support for the formal compliance test ensured that the entire system was installed correctly, returning the customer to fully operational status with minimal downtime.
CPI has been “Enabling Clean Production™ Since 1969” and continues as a leading supplier and manufacturer of Regenerative Thermal Oxidizers (RTO) for large and small air volume VOC applications. CPI is at the forefront in providing industries including metal coating facilities with solutions to their air pollution VOC control needs.
Today, CPI partners with its customers as a trusted resource in resolving the most complex air pollution and energy conservation problems. This RTO project not only delivers high VOC and HAP reduction efficiency but is tightly aligned with the facility’s operating permit requirements and applicable VOC/HAP standards, supporting both regulatory compliance and long-term operational flexibility.
