Catalytic Products International (CPI) installed a Regenerative Thermal Oxidizer (RTO) at a Midwestern USA asphalt shingle processing facility for the abatement of Volatile Organic Compounds (VOCs) from a series of tanks.
The 2,000 SCFM Triton-II-2.95 Regenerative Thermal Oxidizer (RTO) will control VOC emissions from six (6) tank vents at the facility at +99% destruction rate efficiency (DRE) of the VOCs. For this application, CPI also installed dual mist eliminators to control submicron inorganic particle emissions from the tank venting processes prior to entering the RTO.
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.
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 of 95%. 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 directed to the second regenerator to absorb the heat energy before being released to the atmosphere. As the ceramic media loads with sufficient heat, the Posi-Seal Valves switch, and the gases are reversed through the system where the heating and oxidation process continues.
For the spilt second that it takes for the valve switch to occur, a "puff" of untreated gases is released to atmosphere. This small concentration of VOC lowers the removal efficiency in standard two-regenerator systems. The addition of a specialized VOC Polishing Chamber system between the RTO and the exhaust stack allows recirculation of the “puff” of untreated gases to the RTO inlet, achieving +99% VOC destruction rate efficiency.
CPI delivered a fully skid mounted, pre-piped and pre-wired RTO with the media installed on a customer supplied concrete pad. The design and installation of the RTO included an RTO system bypass, all interconnecting ductwork and materials of construction for the cold face support grid were selected to eliminate corrosion from possible chloride contamination in the exhaust gas. CPI provided on-site supervision to minimize the downtime associated with the installation of the RTO. This approach ensured that entire system was installed correctly, and the facility was back up and producing product 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 asphalt processing 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.