RTO Ceramic Media Plugging: Paint Spray Booth

April 14, 2022

Completed Ceramic Media Replacement

RTO ceramic media installation site three months after job completion

Equipment: Regenerative Thermal Oxidizer: 25,000 scfm capacity

Process: Automotive Paint Spray Booth

Plugging Issue: Siloxane solids

Problem/Opportunity

Automotive paint line emissions were plugging the ceramic media beds in a regenerative thermal oxidizer (RTO). Frequent and costly ceramic media cleanings and replacements were harming production schedules and profitability. Paint emissions containing siloxanes were the source of the plugging. When the siloxanes are exposed to the high temperatures in an RTO ceramic media bed they form SiO₂ which adheres to the ceramic media surface. Over time, the particulate will fill what is referred to as the ‘void volume’ of the media and begin to plug the bed leading to increased pressure drop throughout the unit. To maintain the desired airflow draw from the spray booths the RTO fan speed increases to overcome the additional system airflow resistance due to plugging. The result is increased operating costs (fan horsepower) and decreased thermal efficiency (higher burner firing). Also, additional wear and tear on the RTO due to pressure spikes during valve switches.

Solution

Kono Kogs was hired to analyze the plugging and develop a solution to extend ceramic media life. With proper ceramic media bed design, the bed life can be extended significantly and sometimes plugging can be alleviated completely. However with siloxanes, the plugging cannot be eliminated. In these cases understanding at what temperatures the creation of solid SiO₂ occurs determines the best solution. The bed design that offers the combined longest life and highest fuel efficiency was proposed. Kono Kogs worked with local contractors hired by our customer to facilitate COVID travel/work rules in 2021. Additional plugging was found in the cold face upon removal of the ceramic media, which was unexpected. Cleaning and cold face repairs were made to allow the desired 1 day media replacement to hold schedule. Kono Kogs left an extremely clean job site, and also re-started and confirmed proper RTO operation prior to leaving.

Click images to zoom enlarge
RTO ceramic media installation site three months after job completion

Media condition 3 months after installation #1

RTO ceramic media installation site three months after job completion

Media condition 3 months after installation #2

Kono Kogs installed RTO ceramic media at automotive manufacturer

Media Installation Complete

RTO ceramic media installation job

Media installation in progress #1

RTO ceramic media installation job

Media installation in progress #2

RTO ceramic media installation job

Media installation in progress #3

RTO ceramic media installation job

Media installation in progress #4

RTO ceramic media installation by Kono Kogs

Media installation in progress #5

ceramic media removed, except for fines, from Kono Kogs jobsite

Media Removed; Media "fines" still to be cleaned up from under cold face

cold face plugging found while removing ceramic media at Kono Kogs jobsite

Media Removed: Cold face plugging shown prior to clean up

ceramic media removal at automotive manufacturer by Kono Kogs

Media Removal under way

Equipment / Services provided by Kono Kogs, Inc.
  • Assess media plugging characteristics
  • Design media bed optimizing life and thermal efficiency
  • Provide ceramic media and oversight for replacement
  • Ensure clean work site before leaving

Contact Us

  • This field is for validation purposes and should be left unchanged.

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 around the world. We offer full refurbishing of quality-built thermal oxidizers and stand behind them with warranties that match new equipment OEM warranties.

Kono Kogs has experience refurbishing nearly every major RTO model on the market, even obsolete models from OEMs that are no longer in business.

We provide every component or service related to regenerative thermal oxidizers including relocation, trade-in, field repairs, field rebuilds/upgrades, emergency service, preventive maintenance service, and replacement with our refurbished, warrantied long-life RTO systems. We have over 350 refurbished oxidizer units installed worldwide. Why buy new when you can buy better!