Catalytic Products International (CPI) recently completed the installation of a new Regenerative Thermal Oxidizer (RTO) for the abatement of Volatile Organic Compounds (VOCs) at a Midwest USA coater of threaded fasteners.
Threaded fasteners are utilized in a wide variety of diverse industries, including automotive, aerospace, military and agricultural equipment. In many cases the threaded fastener will require the application of a specialty coating to enhance the bolted connection, such as to lock or seal the threads. While the base fasteners are produced in large volumes, typically the application and curing of these adhesives or sealants are performed by specialty companies with facilities dedicated to serving specific end user needs.
The new 10,000 SCFM TRITON-10.95 Regenerative Thermal Oxidizer (RTO) installed by CPI will control VOC emissions from the application and curing of these adhesives and sealants on the fasteners. The RTO system will destroy VOC emissions from the small parts coating process with 98% destruction efficiency (DRE) at a thermal efficiency of 95%.
CPI worked closely with the customer to design an RTO system, including ductwork, exhaust stack, and concrete pad, which met the needs of the new operation. The new enclosed production area, including multiple coating lines, was configured as a permanent total enclosure, with the VOC laden air collected through a floor sweep system exhausted to the new 10,000 SCFM RTO which was mounted on a customer installed concrete pad. CPI performed the rigging and installation of the RTO, working closely with the on site electrical and mechanical contractors from the customer.
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 two-tower systems 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 customer to minimize the downtime associated with the installation of the Regenerative Thermal Oxidizer (RTO). CPI was able to complete a good portion of the installation activities before the new unit arrived on site for final assembly. CPI provided on-site supervision to ensure coordination with the customer and third-party sub-contractors. This approach guaranteed that entire system was installed correctly, and the facility was back up and producing product with minimal downtime.
Since 1969 CPI has been providing industry leading coating companies 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.