RTO Air Pollution Control Requirements Made Easy
July 21, 2021Regenerative thermal oxidizer (RTO) requirements and regulations can be hard to navigate, especially for first-time buyers. Kono Kogs is a recognized industry leader providing cost-effective pollution control solutions meeting the challenging air pollution control needs of diverse companies.
While we’re capable of supplying the most complicated reconfiguration work to meet specific applications, we also enjoy solving simpler needs for customers new to the RTO requirements maze.
In this case study, Kono Kogs provided:
- Turnkey installation of two refurbished RTO systems
- Mechanical assembly of both systems
- Ductwork
- Process dampers
- Electrical wiring
- Natural gas & compressed air tie-in
Before & After: Two Turnkey Refurbished RTO Systems Installed by Kono Kogs
Starting with the right RTO design
The process started with two well-built systems from our used RTO inventory featuring one of the best rotary valve designs on the market. Rotary valves significantly reduce pressure spikes caused by valve switches back to the process, which was important for this manufacturing process (and any other pressure-sensitive application).
Challenge: VOC condensation buildup
This can coating application has highly condensable volatile organic compounds (VOC), which tend to build up on the fan wheel in a typical forced-draft RTO system. This causes fan imbalances and requires housekeeping to keep the wheel clean.
Solution: Relocate RTO Fan
The solution was to move the fan to the exhaust side of the RTO where the higher temperature on the outlet of the RTO prevents build up on the fan and fan wheel.
Challenge: Two airstream temperatures
This application has both cold (inside spray) and hot (inside bake oven & pin oven) airstreams that combine just prior to the RTO.
Solution: Install inlet Mixing Box
Kono Kogs added an inlet mixing box before the two RTOs to control air temperature entering the RTO. This prevents condensate buildup on duct walls and the RTO valve.
Challenge: Industrial NOx emissions
Nitrogen oxide (NOx) emissions are poisonous and highly reactive, and many regions have adopted regulations requiring reduced NOx emissions from industrial facilities.
Solution: Gas train overhaul, natural gas injection
Natural gas injection was added, which provides exceptionally low operating costs and low NOx conditions. Kono Kogs also added a low NOx burner so the client would meet local codes.
We also completely overhauled the gas train and performed needed upgrades for proper control of the new low NOx burner.
Challenge: Protecting equipment and productivity
Preventive regenerative thermal oxidizer maintenance is essential. Because RTOs are exposed to harsh chemicals and high temperatures, small problems can quickly escalate to major issues without following a consistent maintenance plan. Our customer needed to keep up routine maintenance while minimizing operational downtime.
Solution: Tandem RTO Arrangement
For process operating flexibility, an innovative tandem operation was provided by adding:
- Priority logic
- Additional isolation dampers for each RTO
- A common ductwork header design
The result is all eight processes exhausting to this tandem RTO arrangement can be directed to either RTO or both RTOs, facilitating routine maintenance. The tandem RTOs share one common 60-ft. exhaust stack with an OSHA approved access platform, including handrails and continuous tie-off system up the side of the access ladder.
Kono Kogs also added a fully redesigned and UL-rated control room featuring an Allen Bradley ControlLogix PLC (programmable logic controller) and PanelView HMI (human-machine interface).
Extensive RTO Refurbishments
In addition to the application-specific updates detailed above, Kono Kogs also performed the extensive refurbishing we are known for.
The RTOs were stripped down to their main components: the rotary valve, ceramic media chamber and combustion chamber. Kono Kogs provided new ceramic media designed specifically for this application, to mitigate plugging.
Nearly all auxiliary components, including the fans, blowers, exhaust stacks, burners, and most of the gas train were replaced.
On the remaining sub-systems, Kono Kogs:
- Refurbished the rotary valves (including new seals)
- Fully rebuilt the air cylinders
- Replaced the solenoid actuating valves
- Inspected and repaired any cold face issues, combustion chamber & media bed insulation
- Tested and replaced all instrumentation as needed
Because of our confidence in these refurbished thermal oxidizer systems, we provided an extended warranty well over and above our standard 180-day warranty on performance and parts.
Ready for your own RTO installation before & after?
With an installed base of over 400 oxidizers stretching across 5 continents, plus our extensive, readily available inventory, Kono Kogs is a recognized industry leader and provider of cost-effective pollution control solutions for the most challenging applications.
Established in 1996, we’re proud of our 25 years of excellence in purchasing and refurbishing thermal oxidizers, regenerative thermal oxidizers, and catalytic recuperative oxidizers.
Reach out to the Kono Kogs team today to learn about your options. We’ll leverage our expertise and resources to help you arrive at a value proposition best suited to your facility.
Contact us with your questions or to request service and support for your RTO system. Request a quote for an estimate tailored to your specific process conditions.
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 almost every continent. We offer full refurbishing of quality-built thermal oxidizers and stand behind them with warranties that match new equipment OEM warranties.