Catalytic Products International (CPI) recently installed an 80,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Midwest flexible packaging manufacturer for the abatement of Volatile Organic Compounds (VOCs) and odors.
The manufacturing of the film packaging utilizes a blown-film extrusion of linear low-density polyethylene. After the packaging is formed, patterns and designs are applied to the surface of the packaging using a rotogravure printing process. When printing is complete, an adhesive laminate coating is applied to the packaging to improve barrier properties and increase its shelf life.
During the rotogravure printing and lamination process significant emissions of VOCs and odors from the solvent based inks and coatings are released to the environment. A Regenerative Thermal Oxidizer (RTO) was selected as the most effective and cost-efficient option to ensure the destruction of the VOCs and odors from the printing and laminating processes.
The new 80,000 standard cubic feet per minute (SCFM) Triton-80.95 Regenerative Thermal Oxidizer (RTO) will control the VOC emissions and odors from one (1) rotogravure printing press and two (2) laminating lines. The RTO will destroy VOC emissions with 98% destruction rate efficiency (DRE).
CPI worked closely with the customer to incorporate a VOC capture system to the overall design of the RTO system. A floor sweep system was added and the process room was configured as a permanent total enclosure (PTE) with the VOC laden air exhausted to the new 80,000 SCFM RTO. The PTE meets the U.S. EPA requirements set forth in EPA Method 204 and provides 100 % capture efficiency of the VOCs and odors.
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 VOC’s 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 provided a complete turn key installation, including engineering, design and supply of the RTO on a customer provided concrete pad. The installation of the RTO and related equipment included floor sweeps, a high VOC hot gas bypass, process exhaust ductwork and bypass T-dampers, booster fan and exhaust stack.
Established in 1969, CPI continues as a leading supplier of air pollution control solutions. CPI is at the forefront in providing industries including flexible packaging 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.