Catalytic Products International (CPI) (CPI) recently installed a Regenerative Thermal Oxidizer (RTO)for the abatement of Volatile Organic Compounds (VOCs) at a Midwest USA specialty and industrial parts coating operation.
The new 35,000 SCFM TRITON-35.95 Regenerative Thermal Oxidizer (RTO) replaced an aging rotary concentrator and catalytic oxidizer system. Poor performance of the rotary concentrator and deactivation of the catalyst resulted in low VOC destruction rates and inadequate VOC emission control. To maintain compliance and stay in production, a new air pollution control system was required.
The new RTO controls VOC emissions of specialty surface coatings from multiple existing, and newly constructed spray booths, coaters, and drying ovens. The RTO destroys VOC emissions from the exhaust streams with 98.5% destruction rate efficiency (DRE) and achieves a thermal efficiency of 95%. This allows the facility to maintain compliance with Clean Air Act standards and allows for minimal gas consumption and operating costs.
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.
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 provided a complete turnkey installation of the Regenerative Thermal Oxidizer (RTO) including engineering, design, and rigging. Since the customer wanted to place the new RTO in the same location as the existing Rotary Concentrator / Catalytic Oxidizer, CPI worked closely to coordinate the construction activity to minimize downtime as much as possible. CPI was able to complete a good portion of the ductwork and site preparation activities before the new RTO arrived on site for final assembly. This approach guaranteed that entire system was installed correctly, leading to a short start up and commissioning time frame and 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 the metal parts coating industry 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.