Ceramic Media Replacement - Metal Decorating

Ceramic Media Replacement - Metal Decorating
Summary:

Case Study: Our client, a metal coater, was looking for ceramic media replacement in an Eisenmann RTO. Kono Kogs got it done with exceptionally fast turnaround.

Type of Work:
Rebuild, Repair, Retrofit
Type of Equipment:
Regenerative Thermal Oxidizer (RTO)
Process:

Problem

A metal decorator experiencing reduced airflow capacity was looking for a ceramic media replacement in their Eisenmann regenerative thermal oxidizer (RTO). A top priority for the replacement was limited downtime for their high value process. The ceramic media encasements used in this RTO had warped due to the heat typical in these ceramic media beds. The warping caused lateral pressure on the ceramic media, breaking it down and trickling media shards down into the cold face. This resulted in plugging of the cold face, reducing RTO capacity.

Photos: In Progess

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Click on a picture to enlarge

Completed in under 2 shifts of downtime

Solution

An inspection by Kono Kogs determined that a best solution might be a cold face redesign and replacement of the encasements to avoid the common media bed failures. However, due to time constraints the customer chose to maintain the encasement design.

Kono Kogs fabricated replacement encasements and designed the encasements such that we could pre-load them with ceramic media. This resulted in an exceptionally fast turnaround for the project.

Photos: After

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Click on a picture to enlarge

Equipment & Services Provided

  • Assessment and firm estimate of repair needed
  • Design of ceramic media encasements
  • Disassemble RTO for media bed access
  • Vacuum out existing ceramic media
  • Remove and scrap old encasements
  • Supply all replacement ceramic media
  • Provide all equipment and labor for repairs and ceramic media replacement
  • Reassemble RTO
  • Site cleanup
  • Assistance with restart of RTO
Regenerative Thermal Oxidizer (RTO)

Results

The fully loaded encasement plan resulted in an exceptionally fast turnaround for the project. A clever game plan was put together by our engineers and installation team- the ceramic media was vacuumed out of the old encasements, the old encasements removed, and the new encasements immediately took their place. The project from start to finish was completed in under 2 shifts of downtime.

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