Catalytic Products International (CPI) installed a new 35,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Midwest USA fiberglass bathroom fixture manufacturer for the abatement of Volatile Organic Compounds (VOCs) primary consisting of styrene.
The 35,000 SCFM TRITON-35.95 Regenerative Thermal Oxidizer (RTO) controls the emissions from two (2) fiberglass resin coating booths. The RTO will destroy VOC emissions, primarily from styrene, with +98.5% destruction rate efficiency (DRE) and a thermal efficiency of >95% allowing for minimal gas consumption and operating costs. The RTO replaces an existing fluidized bed concentrator and thermal oxidizer system that was unable to achieve the required VOC removal efficiencies.
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 greater than 95%. 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 engineering, design, and supply of the RTO, process exhaust ductwork, manual balancing and bypass T-dampers, and exhaust stack. A two stage prefilter added to the inlet of the RTO prevents particulate matter from entering the oxidizer and greatly reduces maintenance frequency.
CPI worked closely with the customer to minimize the downtime associated with the installation of the Regenerative Thermal Oxidizer (RTO). The RTO was installed inside the existing building allowing for uninterrupted production during the installation and initial startup. A two-phase startup and commissioning also guaranteed minimum process downtime.
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 building products 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.