Catalytic Products International (CPI) designed and installed a high‑efficiency regenerative thermal oxidizer at a US based graphite materials manufacturing facility to control hydrocarbon-based emissions generated during graphite baking and carbonization operations.
Process Type: Drum: Graphite Baking - Pollutants: CO and Hydrocarbon based VOC
- Process Air Volume: 20,000 scfm
- Control Type: Regenerative Thermal Oxidizer (RTO)
- Destruction Rate of Efficiency (DRE): 98%
- Installation: RTO, stack, fans, and turnkey installation
Solution Provided
CPI engineered, manufactured, and installed a TRITON 20.95 Regenerative Thermal Oxidizer (RTO) to serve as the primary emissions control system for furnace exhaust streams containing hydrocarbon‑based volatile organic compounds (VOCs) and carbon monoxide. The regenerative design allows the system to achieve high destruction performance while minimizing fuel consumption through efficient heat recovery.
This solution supports the facility’s long‑term environmental objectives while maintaining the operational reliability required for continuous materials production.
RTO systems are well suited for controlling hydrocarbon emissions from high‑temperature graphite and carbon processing operations, where stable destruction efficiency and energy recovery are critical.
During operation, VOC‑laden air enters the first ceramic media heat‑exchange bed, where it is preheated before entering the combustion chamber. After oxidation occurs, the clean gas passes through a second ceramic bed, transferring heat back into the system before discharge.
This regenerative cycling enables:
- High thermal energy recovery
- Reduced natural gas usage
- Stable destruction efficiencies
- Lower operating costs compared to other oxidizer types
Project Scope
CPI delivered a complete turnkey project, providing a fully integrated and installed RTO system designed to meet the facility’s process and operational requirements.
Project scope included:
- Engineering and system design
- Fabrication and supply of a 20,000 SCFM regenerative thermal oxidizer (RTO)
- Integration with furnace exhaust ductwork serving graphite pitch baking operations
- Fans, exhaust stack, and hot gas bypass
- Control system integration
- Installation support, startup, and commissioning
The project was executed in close coordination with facility operations to minimize production disruption and ensure a smooth transition to the new emissions control system.
About CPI
CPI has extensive experience providing air pollution control solutions for graphite, carbon, and other high‑temperature industrial processes requiring reliable VOC, HAP, and CO emissions control
Since 1969, CPI has been “Enabling Clean Production™” by delivering innovative, cost‑effective solutions for VOC, HAP, NOx, and odor control.
