Catalytic Products International (CPI) installed a 15,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Northeastern USA adhesive tape manufacturer for the abatement of Volatile Organic Compounds (VOCs).
- Process Type: Web Coating for Adhesive Tape
- VOC: toluene, xylene, heptane, MEK, hexanes, & ethyl acetate
- Process Air Volume: 15,000 scfm
- Control Type: Regenerative Thermal Oxidizer (RTO)
- Destruction Rate of Efficiency (DRE): 99%
- Installation: Rigging of RTO, stack, and booster fan
CPI collaborated with this valued long-time customer to replace two older competitor RTOs with a new TRITON II 15.95 RTO. The new RTO will control VOC emissions, including toluene, xylene, heptane, MEK, hexanes, and ethyl acetate, from two web coating lines. The RTO will destroy the incoming VOC emissions from the coating process with 99% destruction efficiency (DRE) at a thermal efficiency of 95%.
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 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 costs.
CPI Regenerative Thermal Oxidizers (RTOs) are engineered to provide exceptional performance and reliability. During operation of the standard two chamber RTO, the VOCs are directed into one of the system’s regenerators, an internally insulated vessel containing specialized ceramic media which allows thermal rate efficiencies up to 97%. The contaminated gases are passed through the first regenerator where energy is transferred from the ceramic media to the gas in order to elevate the temperature. This elevated temperature approaches the ignition level for most solvents and is then directed from the ceramic bed into the combustion chamber. As the stream exits the ceramic bed and travels through the internally lined combustion chamber, minimal heat is added to ensure a proper oxidation temperature and a designed dwell time is maintained providing destruction of the VOCS at greater than 99% efficiency. The resultant clean, oxidized gases are directed to the second regenerator to absorb the heat energy before being released to the atmosphere.
The installation of the RTO and related equipment included an VOC Entrapment (Polishing) Chamber, high VOC hot gas bypass system, exhaust stack, ducting material and personnel to connect the existing process duct stub outside the building to the inlet of the new RTO.
CPI was able to complete a good portion of the installation activities before the new unit arrived on site for final assembly. This approach, along with CPI start-up, commissioning and training, guaranteed 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 of air pollution control equipment. CPI is at the forefront in providing industries including web coaters 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.
