As an automotive parts supplier expanded, the size of their existing RTO became a constraint, limiting the production of their paint system. Catalytic Products International (CPI) installed a 15,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Midwest automotive plastic parts surface coating facility for the abatement of Volatile Organic Compounds (VOCs).
The 15,000 SCFM Triton-15.95 Regenerative Thermal Oxidizer (RTO) replaces an existing 12,000 SCFM RTO which was not able to keep up with an increase in production volume at the facility. The new RTO system which controls a parts washer, drying oven, spray booths and an associated cure oven for controlling VOC emissions from the plastic parts coating process with 98% 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.
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 VOCs 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 turnkey installation including design, supply, and installation of the new VOC abatement system. The installation of the Regenerative Thermal Oxidizer (RTO) and related equipment included a hot gas bypass, ductwork, exhaust system and stack, and dampers. A prefilter prior to the RTO allows paint carryover buildup to occur in the filter media which can be easily changed. Insulation of the RTO housing and poppet valve section allows for bakeout of the RTO to further minimize process buildup in the RTO.
CPI delivered a fully skid mounted, pre-piped and pre-wired RTO with the media installed on a customer supplied concrete pad. CPI worked closely with the customer to minimize the downtime associated with the installation of the Regenerative Thermal Oxidizer (RTO). This approach guaranteed that entire system was installed correctly, and the facility was producing product while exceeding air compliance goals and operational requirements.
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 plastic parts 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.