RTO for VOC Control at Construction Materials Manufacturer

Catalytic Products International (CPI) installed a 22,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Northeastern USA construction materials manufacturer for the abatement of Volatile Organic Compounds (VOCs).

• Process Type:  Coating Line & Dryer
• Air Volume: 22,000 SCFM
• Control Type:  Regenerative Thermal Oxidizer (RTO)
• Destruction Rate of Efficiency (DRE): 98.5%
• Installation:  CPI installed PTE, Ductwork, and RTO.

The 22.000 SCFM TRITON-22.95 Regenerative Thermal Oxidizer (RTO) was installed to control VOC emissions from a new coating line. A key component of the overall system design was the inclusion of a VOC emission capture system.

CPI provided engineering, fabrication, and installation of a Permanent Total Enclosure (PTE) room according to US EPA Method 204 criteria to effectively capture 100% of the VOC emissions from the coating line and flash off areas. The emissions from the PTE, the coater, the spray booth, and the coating line oven are vented to the RTO. The RTO will destroy the incoming VOC emissions from the coating line with 98.5% 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.

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 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 directed to the second regenerator to absorb the heat energy before being released to the atmosphere.

CPI worked closely with the customer and oven supplier to provide a complete turn-key installation, including the design, fabrication, and installation of the RTO and Permanent Total Enclosure (PTE) room. Related RTO equipment included NGI (natural gas injection), exhaust stack, test platform, and access ladders and handrails. A process exhaust ductwork system was designed and installed to collect the exhaust from the multi-zone oven, the coater, the spray booth, and additional PTE roof locations.

CPI was able to complete a good portion of the installation activities before the new unit arrived on site for final assembly. This approach, along with CPI start-up, commissioning and training, guaranteed that the entire system was installed correctly, enabling the customer to begin operation of the processing equipment.

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 the building material industry, 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.