Regenerative Thermal Oxidizer Treating Coil Coating Emissions

Regenerative Thermal Oxidizer Treating Coil Coating Emissions
Summary:

Case Study: the used RTO from KKI had excellent performance numbers (99% VOC DRE) and provided significant capital cost savings compared to new equipment.

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

Problem

Established company looking for economical replacement RTO with increased capacity and lower operating costs.

This coil coating operation wanted to replace a thermal oxidizer, gain additional capacity to accommodate an increased coating line speed, increase line worker comfort by picking up air from work areas, and, if possible, reduce operating costs.

Photos: In Progess

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Used RTO provided significant capital cost savings compared to new equipment

Solution

We provided a 30,000 scfm regenerative thermal oxidizer (RTO) system designed for the high-temperature exhaust typical from coil coating oven exhaust. Although the airflow being treated by this thermal oxidizer is more than 5 times the original exhaust rate, the refurbished thermal oxidizer had lower monthly fuel usage than the original system.

This was possible because of the high thermal efficiency of the regenerative thermal oxidizer, combined with the high solvent concentrations in the coil coating oven exhaust. To handle the high solvent concentrations the RTO had a hot side heat exchanger bypass. The RTO also had a VOC entrapment (puff capture) feature, to provide the high VOC destruction efficiencies desired (98+%), and capture the visible emissions present during and RTO valve switch.

Photos: After

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Equipment & Services Provided

  • Fully Refurbished Used Regenerative Thermal Oxidizer with:
  • Heat exchanger bypass
  • Puff capture/VOC entrapment
  • Upgraded PLC w/data highway plus
  • Performance and parts warranty
  • Low Capital Cost: Approximately 40% of the cost for a new system
  • Energy efficient (95% HX) regenerative thermal oxidizer technology
  • Late model (7 year old) system w/25+ year life expectancy
  • Still running strong after 20 years with normal preventative maintenance
Regenerative Thermal Oxidizer (RTO)

Results

The RTO had excellent performance numbers (99% VOC DRE) and provided significant capital cost savings compared to new equipment. Operating cost savings were the greatest benefit, in addition to the base goal of gaining more production line speed.

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