Catalytic Products International (CPI) installed a 7,000 SCFM Regenerative Thermal Oxidizer (RTO) at an Eastern USA bakery for the abatement of Volatile Organic Compounds (VOCs) from the conveyorized bread baking ovens.
Bakeries generate air pollution emissions from several different processes (including gas combustion). The primary source of emissions at a bakery is the oven, which produces Volatile Organic Compounds (VOCs) and carbon dioxide during the yeast fermentation process. The main VOC emitted from bakery operations is ethanol.
The 7,000 SCFM TRITON-7.95 Regenerative Thermal Oxidizer (RTO) will destroy the incoming VOCs in the exhaust gases emitted from a single conveyorized bakery oven with 95% destruction rate efficiency (DRE) at a thermal rate efficiency (TRE) of 97%. The high moisture, high condensable, acidic nature of the baking oven exhaust requires special materials of construction. To address the high moisture content of the exhaust streams and potential for corrosion all wetted surfaces including the exhaust stack, inlet ducting, dampers, and booster fan were constructed of stainless steel.
Thermal and Catalytic Oxidization are the most widely accepted control technologies available to control the VOC emissions from bakery processes. Thermal treatment of VOCs and other air pollutants works by a simple reaction of the harmful air pollutants with oxygen and heat. In this environment, the VOCs are converted into harmless inert byproducts, water vapor (H2O), and usable heat. These harmless by-products are typically released to the atmosphere, or in some cases use an energy recovery technique to further lower the operational costs.
CPI Regenerative Thermal Oxidizers (RTOs) are engineered to provide exceptional performance and reliability. During operation of the 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 98% efficiency. The resultant clean, oxidized gases are redirected into a second regenerator bed to continue the energy transfer and oxidation cycle before being released to the atmosphere.
CPI worked closely with the bakery oven supplier, as well as the client and their environmental consultant to define, select, and engineer the equipment best suited to safely and effectively treat emissions from the conveyorized bakery oven. CPI provided a complete engineering package including ductwork design details and layout, foundation design and layout, and utility requirements. CPI fabricated and delivered a fully skid mounted, pre-piped and pre-wired RTO with the media installed, along with booster fan and exhaust stack. Coordination with the EPC and their subcontractors as well as the final customer guaranteed that entire system was installed correctly, leading to a short start up and commissioning time frame, returning the customer to fully operational status with minimal downtime.
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 food and beverage manufacturing facilities 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.