CPI Installed RTO at EPS Foam Insulation Manufacturer

    Catalytic Products International (CPI) installed a 6,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Midwest USA expanded polystyrene (EPS) insulation manufacturer for the abatement of Volatile Organic Compounds (VOCs).

    CPI RTO 6.95 for EPS Foam ExpansionThe 6,000 SCFM TRITON-6.95 Regenerative Thermal Oxidizer (RTO) controls the emissions from two (2) foam expansion lines. The RTO will destroy VOC emissions, primarily pentane, with +98% destruction rate efficiency (DRE) and a thermal efficiency of 95% allowing for minimal gas consumption and operating costs.

    The bead expansion process uses steam which causes the process stream to be nearly saturated. A previously installed RTO from a competitor experienced significant interior and exterior deterioration as the continuous exposure to water corroded and thinned the carbon steel RTO and associated components.  The new CPI TRITON RTO, exhaust stack and fan system were fabricated with stainless steel to prevent any oxidization created by the high humidity / standing water from the process.  

    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 oxidization of the VOCs is completed at greater than 98% efficiency. The resultant hot, clean air stream is then passed downward through the second ceramic heat exchange media bed where it is cooled before being released to the atmosphere.  

    CPI worked closely with the customer to minimize the downtime associated with the installation of the Regenerative Thermal Oxidizer (RTO). CPI designed and delivered a fully skid mounted, pre-piped and pre-wired RTO with the media installed on the customer supplied concrete pad. CPI provided engineering services, drawings, and support for the complete installation of the regenerative thermal oxidizer including foundation, ductwork, and damper design and layout.  

    Established in 1969, Catalytic Products International (CPI) continues as a leading supplier of air pollution control equipment. CPI is at the forefront in providing industries including EPS insulation manufacturers with solutions to their air pollution control needs.

    Today, CPI partners with its customers as a trusted resource in resolving the most complex air pollution and energy conservation problems. We provide our customers with innovative and cost-conscious solutions to their most complex VOC, NOx, and Odor pollution challenges. Our equipment is also at work meeting energy conservation strategies and minimizing greenhouse gas (GHG) emissions.

    Topics: Air Pollution Control, Regenerative Thermal Oxidizer, Blog, Foam & Packaging Materials Case Study

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