Catalytic Products International installed two (2) Regenerative Thermal Oxidizers (RTOs) at a Midwest pet food manufacturing facility for the abatement of odorous Volatile Organic Compounds (VOCs) generated during the palatant manufacturing process.
The TRITON III RTOs will destroy VOC and odorous emissions including methyl mercaptan, dimethyl disulfide, and hydrogen sulfide with +98% destruction rate efficiency (DRE) and a thermal energy recovery (TER) of +95%.
4,000 scfm Three Chamber RTO to control emissions
25,000 scfm Three Chamber RTO to control emissions
Thermal treatment of VOCs and odorous compounds 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 then released to the atmosphere.
The three-tower Regenerative Thermal Oxidizer (RTO) system is designed to achieve up to +99.9% removal efficiency and incorporates specialized ceramic media in the regenerator (heat transfer bed) to allow thermal efficiencies up to 97%. The process begins as VOCs are directed into one of the systems regenerators (an internally insulated vessel containing ceramic media). 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 then is 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 for the ultimate destruction of the streams VOC's. The oxidized gases are then directed to the second regenerator to absorb the heat energy. As the ceramic media loads with sufficient heat, the Posi-Seal Valves switch, and the gases are reversed through the system where the second regenerator bed continues the energy transfer and oxidation cycle before being released to the atmosphere.
While the first and second regenerators are exchanging energy, the third regenerator is being purged with clean air. This purging of valves and regenerator prevent untreated VOCs from ever reaching the atmosphere and allows to reach +99.9% removal efficiency. The purge air is internally recirculated back through the combustion chamber and over the exhausting regenerator tower before being release to atmosphere, or to auxiliary heating systems such as secondary air to air recovery, air to water recovery, air to oil recovery, or directly back to the process in a closed loop direct recirculation process.
CPI worked closely with the customer and its EPC to minimize process downtime associated with the installation of the Regenerative Thermal Oxidizers (RTOs) and provided a complete turnkey installation including engineering, design, and installation. The RTOs and associated equipment were fabricated with stainless steel to eliminate corrosion from sulfur compounds present in the process exhaust streams.
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 pet food 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.