Coating/Hot Foil Stamping with Catalytic Recuperative Oxidizer

April 1, 2020

Problem

Start-up company needed emission control with low capital and operating costs. The founders of this start-up had extensive experience with foil coating, as well as the control of emissions from this process. Their experience prior to starting their own company had been with a thermal recuperative oxidizer that eventually was converted to a catalytic oxidizer. Their new business would be located in New Jersey, one of the most difficult regulatory environments in the country. Based on their potential to emit, they were required to achieve VOC destructions of 95% or greater and less than 50 ppmv Carbon Monoxide. Their solvent mix varied greatly, but was typically made up of toluene and MEK. The flow rate was expected to be 12,000 scfm @ 300F from 2 lines with solvent emissions of 50 lb/hr. The process initially would operate one shift per day until production ramped up to 24/7. They also may have to locate the oxidizer indoors if the new facility they were seeking had aesthetic restrictions.

Before

After

Equipment

Catalytic Recuperative Oxidizer
12,000 scfm capacity (1994 vintage)

Installed
Fall 2003

Location
New Jersey

Solution

Kono Kogs was recommended to them by a consultant, whom we had worked with recently on a successful project in New Jersey. The founders were familiar with oxidizers and were confident in the ability of a catalytic system to treat their emissions. They had investigated new equipment suppliers but could not justify this amount of capital on a system that does nothing to increase the bottom line, and would negatively affect their cash flow.

Kono Kogs analyzed the process, solvent levels, initial operating schedule, future operating schedule, size limitations, and most importantly the performance requirements.

We recommended a 12,000 scfm catalytic recuperative oxidizer with bead catalyst. Although their previous experience had been with monolith catalyst, a bead catalyst can provide from 10-20 times the poison resistance of monolith style catalyst. This is important with varying mixes of solvents. The bead catalyst utilized in this system would provide greater then 20 times the poison resistance of monolith, and was designed to provide greater than 5 years of catalyst life. Although it had the capacity for 12,000 scfm the catalytic system was small enough to fit into most facility overhead doors. The system also was projected to run at minimum burner firing rate or actually turn the burner off during operation due to the high energy release from the combustion of VOC’s in the exhaust stream. Most importantly the system would provide 97% VOC destruction guaranteed, at a cost of less than half that of new equipment.

Result

The catalytic oxidizer provided by Kono Kogs included performance and parts warranties rivaling new equipment. The equipment cost was less than half of the cost of a new catalytic system. It achieved well over 95% VOC destruction and is a trouble free system for this coater.

Equipment / Services provided by Kono Kogs, Inc.
  • Refurbished, warranted Used Catalytic Recuperative oxidizer
  • Performance and parts warranty
  • Capacity of 12,000 scfm
  • Low cost, high-quality oxidizer at less than 50% of new equipment cost
  • Energy efficient (70% HX) low temp (600F) operation
  • Low maintenance, long life bead catalyst
  • Guaranteed 97% VOC destruction; Actual Results: 99.9% VOC destruction

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About Kono Kogs

Kono Kogs has been refurbishing used thermal oxidizers for over 20+ years with over 350 installations in nearly every state in the USA and every continent (we are only waiting for an opportunity in Antarctica). We offer full refurbishing of quality-built thermal oxidizers and stand behind them with warranties that match new equipment OEM warranties.