Coil Coating with Regenerative Thermal OxidizerApril 1, 2020
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.
The existing thermal oxidizer had a typical heat exchanger effectiveness for this industry and this oxidizer vintage. However, with today’s fuel prices, the fuel costs to run the thermal oxidizer exceeded $15,000/month. With increased airflow from the process and additional air pick-up points from work areas, this coil coater wanted to investigate new technologies that will allow them to increase exhaust rates, with little to no additional fuel cost.
Regenerative Thermal Oxidizer
30,000 scfm capacity (1997 vintage)
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.
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
Equipment / Services provided by Kono Kogs, Inc.
- 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 in 2016 with only preventative maintenance over its life
About Kono Kogs
Kono Kogs has been refurbishing used thermal oxidizers for over 25 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.