A fiberglass reinforced polymer rebar manufacturer selected Catalytic Products International (CPI) to design and supply a TRITON 8.95 Regenerative Thermal Oxidizer (RTO) to support a production expansion. The project was driven by the need to centralize control of styrene emissions generated during pultrusion and resin mixing operations while supporting ongoing compliance with Title V permit requirements and EPA MACT regulations for reinforced plastic composites manufacturing.
- Process Type: Dip Coating
- VOC: Isocyanate
- Process Air Volume: 4,000 scfm
- Control Type: Regenerative Thermal Oxidizer (RTO)
- Destruction Rate of Efficiency (DRE): 98%
- Installation: Title V Air Permit, MACT WWWW Compliance, Organic HAP Reduction Requirements
Solution Provided
CPI engineered, manufactured, and supplied a TRITON 8.95 RTO designed for robust VOC destruction with minimal energy consumption. The unit uses high‑performance ceramic media to capture and reuse heat to consistently achieve 98% VOC destruction efficiency and 95% thermal efficiency.
The RTO thermally oxidizes VOCs by exposing them to elevated temperatures, oxygen, and sufficient residence time. In this environment, harmful hydrocarbons convert to carbon dioxide, water vapor, and usable thermal energy. This process ensures clean, compliant exhaust while lowering fuel consumption and operating costs.
How the RTO Works
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 provided a turnkey oxidizer package that included:
- TRITON 8.95 RTO installed on a customer‑supplied concrete pad
- Inlet air filter, fans, RTO exhaust stack
- Engineering Support and Installation Supervision
- Startup and commissioning
Throughout the project, CPI worked closely with the customer’s operations team to ensure smooth integration, proper design parameters, and full regulatory compliance.
About CPI
Since 1969, CPI has been “Enabling Clean Production™” by delivering innovative, cost‑effective solutions for VOC, HAP, NOx, and odor control. CPI’s systems support customers across industries—including adhesives, coatings, chemicals, and more—in achieving air quality compliance while minimizing energy consumption and greenhouse gas emissions.
CPI partners with manufacturers 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.
