Foundry Installs RTOs to Control VOC Emissions

Catalytic Products International (CPI) installed four (4) Regenerative Thermal Oxidizers (RTO) at a new Southeastern-based iron foundry for the abatement of Volatile Organic Compounds (VOCs) generated during the pouring, cooling and molding processes.

Each RTO will control the VOC emissions, including benzene, toluene, and phenol, with 98% destruction rate efficiency (DRE) and will achieve a thermal efficiency of 97% allowing for minimal gas consumption and operating costs.

Emissions from Pouring and Cooling processes are routed through baghouses, before being controlled by three (3) 65,000 SCFM Regenerative Thermal Oxidizers.

Emissions from the Molding process are captured and routed through a baghouse, before being controlled by a 90,000 SCFM TRITON Regenerative Thermal Oxidizer system, comprised of two (2) 45,000 SCFM RTO units operating in tandem.

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 into the atmosphere.

CPI provided on-site supervision, startup and training to minimize the downtime associated with the installation of the RTOs. This approach ensured that the entire systems were installed correctly, and the facility came online with the new production requirements.

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 foundries, 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.