Catalytic Products International (CPI) recently completed the installation of a 2,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Midwest USA manufacturer of resins and surface coatings for the abatement of Volatile Organic Compounds (VOCs).
The new 2,000 SCFM Regenerative Thermal Oxidizer (RTO) replaces an existing Catalytic Oxidizer and will destroy the VOC emissions from two (2) existing chemical reactors and two (2) reactors to be installed in the future. The RTO will also control the VOC emissions from two (2) collection headers and from two (2) storage tank farms at the facility. The RTO will destroy VOC emissions with a destruction rate efficiency (DRE) of 98% and a thermal efficiency of 95%.
Thermal treatment of VOCs and other air pollutants works by a simple reaction of the harmful air pollutants with oxygen and heat. In this environment, the VOCs are converted into harmless inert byproducts, water vapor (H2O), and usable heat. These harmless by-products are typically released to the atmosphere, or in some cases use an energy recovery technique to further lower the operational costs.
CPI Regenerative Thermal Oxidizers (RTOs) are engineered to provide exceptional performance and reliability. During operation of the 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 redirected into a second regenerator bed to continue the energy transfer and oxidation cycle before being released to the atmosphere.
CPI choose to replace the failing catalytic oxidizer system with a Regenerative Thermal Oxidizer (RTO) because of its ability to destroy the incoming VOCs and its tolerance for small amounts of particulate carryover from the batch reactors. The RTO was designed with a high temperature bake-out that allows the RTO to “thermally clean” the cold face of potential organic particulate buildup.
To eliminate the excessive water carryover from an existing wet scrubber, an integrated stainless-steel knockout pot and mist eliminators were installed prior to the RTO. CPI constructed all wetted surfaces of the RTO, including dampers, inlet ducting and exhaust stack, with stainless steel to prevent formation of condensation and corrosion.
CPI delivered a fully skid mounted, pre-piped and pre-wired RTO with the media installed on a customer supplied concrete pad. CPI provided on-site supervision to minimize the downtime associated with the installation of the RTO and associated ductwork. 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 surface coating and resin manufacturing 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.
