CPI Installs RTO at Web Coater
Catalytic Products International (CPI) installed a Regenerative Thermal Oxidizer (RTO) with +99% DRE at a Northeastern USA web coater for the abatement of Volatile Organic Compounds (VOCs) and Hazardous Air Pollutants (HAPs) emitted during the manufacture of laminate flooring.
The 60,000 SCFM Triton II-60.97 Regenerative Thermal Oxidizer (RTO) will control VOC and HAP emissions from three (3) web coating lines and associated ovens at the facility. Although the exhaust streams contain relatively low VOC concentration, the State air pollution control agency required very low outlet concentrations from the proposed control device due to the presence of formaldehyde and methanol.
To achieve these requirements and provide +99% destruction rate efficiency (DRE) of the VOCs and HAPs, CPI installed the Regenerative Thermal Oxidizer (RTO) with an auxiliary VOC Polishing Chamber system.
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 chemically 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 cost.
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. As the ceramic media loads with sufficient heat, the Posi-Seal Valves switch, and the gases are reversed through the system where the heating and oxidation process continues.
For the split second that it takes for the valve switch to occur, a "puff" of untreated gases is released to atmosphere. This small concentration of VOC lowers the removal efficiency in standard two-regenerator systems. The addition of a specialized VOC Polishing Chamber system between the RTO and the exhaust stack allows recirculation of the “puff” of untreated gases to the RTO inlet, achieving +99% VOC destruction rate efficiency.
In this application, the Regenerative Thermal Oxidizer (RTO) system’s low cost of operation centers on the use of a ceramic media heat exchanger designed to provide a thermal efficiency of 97%, and a natural gas injection (NGI) system. The NGI system provides high fuel efficiency by reducing the need for combustion air and lowering gas consumption by approximately 30%. In addition, the NGI offers low NOx emissions with flameless operation and provides a more uniform temperature profile throughout the RTO.
CPI provided a turnkey installation of the RTO including engineering, design and assembly on a concrete pad, process exhaust ductwork, fresh air purge and bypass T-dampers, pressure piping, caged access ladders and access platforms. CPI also supplied engineering designs and drawings for Permanent Total Enclosures (PTEs) on six (6) coating stations. CPI provided oversight during the construction and installation of the PTEs by the customer and upon completion, tested and certified that the PTEs met the requirements of EPA Test Method 204.
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 web coating 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.