Ceramic Media Replacement for Regenerative Thermal Oxidizers (RTOs)

Our Ceramic Media Solutions

We offer a full range of ceramic media types to meet the specific needs of your Regenerative Thermal Oxidizer (RTO) system:

Structured Ceramic Media

Typically arranged in blocks containing ceramic materials configured in a specific geometric design, like a corrugated or honeycomb structure, and often placed in several layers, this style of ceramic media offers a range of benefits for pollution control systems, including:

• Low Pressure Drop: Engineered channels allow for smooth airflow, reducing energy consumption.
• High Thermal Efficiency: Maximizes heat recovery, improving overall system performance.
• Ideal For: Systems requiring high throughput and minimal maintenance.

Installation Requirements: Structured media must be installed in a specific orientation (e.g. vertical or horizontal flow) to ensure proper airflow and thermal performance. It often requires custom support structures to hold the media in place and prevent shifting during operation. This media must be placed on a flat, debris free surface to avoid cracking or misalignment. Structured blocks are more fragile than random media and must be handles carefully to avoid breakage.

Tools/Skills Needed: Lifting equipment (for large blocks), alignment tools or templates, trained personnel familiar with structured media installation

Random-Packed Ceramic Saddles

In order to create a large surface area for efficient heat transfer, these randomly-placed ceramic pieces are slightly U-shaped or saddle-shaped (hyperbolic paraboloid) with additional ridges incorporated on one side. This shape also offers low resistance to air flow. Sometimes used in conjunction with structured ceramic media types, these ceramic media types offer several unique benefits, including: 

• Cost-Effective: A proven, economical solution for many RTO designs.
• Versatile: Available in multiple sizes and materials to match your system's specs.
• Easy to Install: Simplifies replacement and maintenance procedures.

Installation Requirements: This type of media must be poured and leveled evenly across the bed to avoid channeling or uneven flow. Some systems require different sizes or types of media layered in specific zones. Mesh or grating may be required to prevent media from escaping into the ductwork.

Tools/Skills Needed: Basic PPE, shovels or buckets for pouring, rakes or leveling tools, less specialized labor compared to structured media

Custom Media Configurations

The experts a Kono Kogs, Inc. can work with you to develop custom ceramic media configurations to best fit the heat transfer requirements of your RTO or RCO. These solutions are specifically designed for exhaust streams that contain or have the ability to create particulate and condensable and acidic airstreams. Benefits of working with our team of engineers include: 

• Tailored Solutions: We analyze your system's design and operating conditions to recommend the optimal media type and layout.
• Hybrid Media Beds: Combine structured and random media for the best of both worlds—efficiency and cost savings.
• Retrofit Expertise: Upgrade older systems with modern media for improved performance.

Installation Requirements: Requires careful planning to install structured media in one zone and random media in another. Proper containment or separation between media types is essential to prevent mixing. Often requires engineering input to determine the optimal layout and media types.

Tools/Skills Needed: Combination of tools and skills from both structured and random media installations, detailed installation plan or guidance from the media supplier

Read more about Ceramic Media Replacement in RTOs.

Case Study: See our case study for a ceramic media upgrade for an automotive paint line.