Metal Can Coating: Innovative Emission Control SolutionJune 29, 2022
A metal can coating operation needed emission control for a new facility with multiple can coating lines. The emissions included two significantly different airstreams varying in both temperature and Volatile Organic Compounds (VOCs) concentration. Historically this process was treated by sending both airstreams to a single regenerative thermal oxidizer (RTO), and when needed, included a pre-heat section. The pre-heat section prevented condensation of VOCs in both the incoming ductwork and at the RTO inlet caused by mixing hot & cold airstreams typical to can coating lines. To prevent condensation, the incoming air was heated in the pre-heat section with an auxiliary burner (See related case study here for more information) to keep it above condensation temperature. This approach worked well but was costly due to the high fuel demand of the pre-heat section.
Equipment / Services provided by Kono Kogs, Inc.
Solution: VOC Concentrators Paired with Refurbished Durr Clean-Switch RTOs
- VOC Concentrator + Regenerative Thermal Oxidizer
- Three (3) new VOC Concentrators
- Two (2) refurbished Durr – MEGTEC Clean Switch RTOs
- Mechanical Installation
- Ductwork including installation
- electrical wiring
- gas/air piping
- equipment commissioning
Benefits: VOC Concentrator/RTO vs. RTO-only Solution:
- 48,000 scfm RTO capacity vs. 80,000 scfm RTO
- 2 Year Payback based on:
- 60% Fuel savings
- 40% Electric power savings
- Similar equipment footprint
Kono Kogs offered an innovative approach utilizing VOC concentrator technology paired with our refurbished RTO systems. This integrated system solves both the air mixing problem, and significantly reduces the fuel use typical with a stand-alone RTO and a pre-heat section. The design keeps the two differing airstreams segregated, eliminating condensation concerns, and also reducing the fuel use typical with a pre-heat box. In this system the cool, low VOC concentration airstream from the decorators, inside spray machines, and conveyors is routed through the VOC concentrator, and the resulting hot concentrated airstream from the VOC concentrator is sent to the RTO for final VOC destruction (see What is a VOC Concentrator? and Custom VOC Concentrators for more details). The pin oven and inside bake oven exhaust are routed directly to the RTO for treatment, and combined with the concentrated, warm airstream from the VOC concentrator. The combined airstream is routed to the RTOs for final VOC destruction.
What would have been treated by an 80,000 scfm RTO with a pre-heat section, now is treated by an integrated VOC Concentrator + RTO with a 60% fuel savings, 40% electric savings, and a similar physical footprint.
Envision it and our team can get you there
Kono Kogs – A Proven Solution Provider for Emission Control Projects
Kono Kogs fabricated and installed the VOC concentrators (3), refurbished the RTOs (2), fabricated and installed all ductwork, dampers and support structure, provided wiring, piping, and equipment commissioning- even installing our customer’s other purchased equipment. We can’t do it all, but we can do much, and strive to do it very well.
Call Us: From Full Turnkey Projects to Simple Thermal Oxidizer Maintenance
We provide everything related to regenerative thermal oxidizers including field repairs, field rebuilds/upgrades, emergency service, preventive maintenance service, relocation, trade-in, and replacement with our refurbished, warrantied long-life RTO systems. We have over 400 refurbished oxidizer units installed worldwide. Why buy new when you can buy better!
About Kono Kogs
Kono Kogs has been refurbishing used thermal oxidizers for over 25 years with over 400 installations in nearly every state in the USA and around the world. We offer full refurbishing of quality-built thermal oxidizers and stand behind them with warranties that match new equipment OEM warranties.