Catalytic Products International (CPI) recently installed a 55,000 SCFM Regenerative Thermal Oxidizer (RTO) at a Southwestern USA railcar manufacturer for the abatement of Volatile Organic Compounds (VOCs) from their paint systems.
The new 55,000 SCFM TRITON-55.95 Regenerative Thermal Oxidizer (RTO) replaces an existing 40,000 SCFM concentrator and RTO system. The larger RTO will control VOC emissions from one paint booth for exterior spraying along with VOC emissions from two interior spray lines. The RTO will control the exhaust streams containing hydrocarbon solvents including toluene, methyl ethyl ketone (MEK) and xylenes with 98.5% destruction rate efficiency (DRE) and 95% thermal efficiency.
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 this longtime customer to provide a complete turn-key installation, including engineering, design and rigging of the RTO. The installation of the RTO and related equipment included revised concrete pad design, new and modified ductwork, booster fan, exhaust stack, and control house.
The new RTO and ductwork were fully installed and commissioned while the paint booth for exterior spraying remained in operation and controlled by the existing RTO. This approach guaranteed that entire system was installed correctly, returning the customer to fully operational status 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 large surface coating operations 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.