Emergency RTO for Treating Flexographic Emissions

Emergency RTO for Treating Flexographic Emissions
Summary:

Failure of a 20+ year old catalytic oxidizer required fast replacement. We brought process emissions online to a new RTO on day 20, 8 days earlier than the goal

Type of Work:
Equipment & Installation
Type of Equipment:
Regenerative Thermal Oxidizer (RTO)
Process:
Flexographic Printing

Problem

Failure of a 20+ year old catalytic oxidizer required a fast replacement to address a backlog of production.

Over the 4th of July holiday weekend, Kono Kogs was contacted by a flexographic printing plant to install an RTO. This flexographic printing company already had an RTO installed by Kono Kogs near Christmas time a few years prior on what was also a fast turnaround need. So, they knew Kono Kogs could accommodate emergency situations.

Photos: In Progess

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Approximately 40% of the cost for a new system

Solution

We had a good match in our inventory, a MEGTEC Clean Switch (rotary valve) RTO. The RTO was decommissioned and still installed a few states away from our customer’s site. Without the system are our facility, we faced some significant challenges to expedite this delivery. The sale was committed to in mid-July and we mobilized our team immediately, promising to have the RTO removed, shipped, installed and running within 4 weeks from order. Since we would not be able to refurbish the unit before installation, we prepared a large kit of spare parts to expedite RTO commissioning. Drawings were exchanged, and our customer went to work installing a new concrete pad, designing ductwork modifications, pulling electrical wires, and natural gas/compressed air piping.

Photos: After

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Equipment & Services Provided

  • Fully refurbished used Regenerative Thermal Oxidizer (RTO)
  • Performance and parts warranty
  • Low Capital Cost: Approximately 40% of the cost for a new system
  • Energy efficient: 94% heat exchanger effectiveness with structured media
  • Older model (12 year old) RTO system with another 20+ year life expectancy
  • PLC program updates to accommodate customers process and the new bypass fan
  • Mechanical assembly, ductwork guidance, permit assistance, trucking to site, start-up/commissioning service
Regenerative Thermal Oxidizer (RTO)

Results

The RTO was delivered day 14 after receipt of order (ARO), assembled completely in 3 days, and ductwork installed. Utility feeds were completed day 19, and our start-up technician arrived the same day. Our technicians worked long days through the July 4th holiday and fired the RTO up at the end of day 19. We brought the process emissions on-line to the RTO on day 20, eight days earlier than the 4 week goal. Some parts were replaced as part of the start-up protocol; also as part of start-up, PLC logic changes were made to accommodate the new process.

This was the second RTO of the same model we provided to this client. Coincidentally, it was an exact match to the first RTO, simplifying spare parts inventory planning and cost for our customer.

We structure all sales to meet our customer’s needs. For this project, with a very good condition unit, we established an as-is purchase agreement with a spare parts package, including a VOC destruction efficiency warranty. Our customer wanted to do some of the work, so we did not provide all of the trades work, but we can in most cases. We provided shipping, mechanical assembly on the customer’s concrete pad, equipment start-up and assisted with ductwork tie-in.

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