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Rebuild, Repair, or Upgrade

Oxidizer Rebuild, Repair, & Upgrade Services

thermal oxidizer repair services

Kono Kogs helps businesses achieve environmental compliance at a reasonably low cost while also lowering operating costs. Often this goal can be achieved by repairing, rebuilding, retrofitting, or upgrading your existing oxidizer, whether it's a regenerative thermal oxidizer (RTO), regenerative catalytic oxidizer (RCO), thermal oxidizer, or catalytic oxidizer, from nearly any OEM.

Save costs & achieve compliance

Rebuild or Relocate

RTOs have life spans of 30-40 years. A field or shop rebuild restores worn components and modernizes your oxidizer for a fraction of the replacement cost.

Case Study:
RTO Relocation & Tie-In
north_east
A Fortune 500 packaging customer reused a surplus RTO by relocating it from the East Coast to the Midwest to replace an aging catalytic oxidizer, instead of buying a new system
thermal oxidizer relocation

Repair

Get your oxidizer back in operation quickly with our experienced crews, available 24/7/365 for emergency repair and troubleshooting.

Case Study: 
Roof Insulation Repair
north_east
A custom pre-insulated roof section replaced a failed one on a packaging printer's RTO, which was back online in under 12 hours.
repairing the roof insulation on a regenerative thermal oxidizer

Retrofit or Upgrade

Selective retrofits and upgrades can improve your system's reliability, lower energy demand, adapt it to process changes, and extend its life.

Case Study: 
Pneumatic to Electric Rotary Valve Drive Upgrade
north_east
Replacing a wear-prone pneumatic valve drive on a 25,000 SCFM RTO with an electric drive removed hard-to-source parts and winter freeze-up risk that threatened downtime.
upgrading the ductwork on a regenerative thermal oxidizer

Repair, Rebuild & Retrofit Services from the Oxidizer Pros

Kono Kogs repairs, rebuilds, retrofits and upgrades regenerative thermal oxidizers (RTOs), regenerative catalytic oxidizers (RCOs), thermal oxidizers (TOX), catalytic oxidizers (CATOX) and VOC rotary concentrators. We work on equipment from nearly every OEM, including obsolete models from manufacturers no longer in business. Our technicians do this work both in the field and in our Green Bay, Wisconsin shop.

Thermal oxidizer repair

Our oxidizer repair services address a specific failed or failing component so your system can get back to running reliably and in compliance. Common repairs include hot spot and insulation repair, hot-side bypass damper repair or replacement, poppet valve and rotary valve troubleshooting, cold face repair, burner and combustion troubleshooting, heat exchanger repairs on recuperative thermal oxidizers, and stack test failure troubleshooting.

Repair goes hand-in-hand with maintenance. Part failure is the number one cause of oxidizer downtime, and our KONOCare preventive maintenance program focuses on finding at-risk parts before they fail. KONOConnect remote monitoring alerts your team and ours to faults and trends early, and lets our technicians troubleshoot remotely. When something does break, our service team is on call 24/7/365 for emergency oxidizer repair at 920-615-8804.

What's the difference between repairing and rebuilding an oxidizer?

A repair addresses one problem. A rebuild restores the whole system: our team evaluates every subsystem and refurbishes the oxidizer mechanically and electrically, often adding upgrades along the way. A rebuild makes sense when the oxidizer has "good bones" (sound metal and insulation) but several components are worn or outdated. It can be done on site or in our shop. When planned well it takes surprisingly little downtime.

Common oxidizer rebuild services include switching valve rebuild or replacement, ceramic media replacement, combustion chamber insulation repair or replacement, PLC and controls replacement, and burner, fan and drive work. We also rebuild oxidizers as part of a relocation to a new site. Not sure whether to rebuild or replace? We have a guide to RTO replacement or refurbishment.

Why retrofit an oxidizer?

An oxidizer retrofit adds or swaps components on your existing system to solve a recurring problem, lower operating costs, or meet a new requirement, without buying a new oxidizer. Common thermal oxidizer retrofits include:

  • Pneumatic-to-electric valve drives to eliminate wear and winter freeze-ups in pneumatic lines
  • Custom ceramic media mixes to lower pressure drop, fuel and electric use, and to resist plugging
  • Low NOx burners to meet stricter local NOx emission limits
  • Fuel/air ratio control systems for added fuel savings
  • Catalyst added to an RTO, converting it to an RCO that runs at lower temperatures, when the airstream is free of catalyst poisons
  • Process tee dampers and ductwork to tie in new process lines
  • PLC/controls upgrades and remote monitoring to replace obsolete, hard-to-support controls

See Industrial Oxidizer Advances Worth the Investment for about on oxidizer upgrades that pay off.

What to look for in an oxidizer service provider

When your oxidizer needs repair, a rebuild or a retrofit, look for a partner with:

  • Multi-OEM experience. Kono Kogs has rebuilt more than 200 RTOs and worked on virtually all makes and models.
  • Self-performed work. Our team handles engineering, fabrication, PLC programming and installation, which gives us tight control of both cost and timeline.
  • Parts on hand. We stock long-lead parts like ceramic media, insulation, fans, burners and actuators, so repairs aren't stalled waiting on parts.
  • Fast response. Our service team is available 24/7/365.
  • Honest repair-vs-replace guidance. Because we also build new oxidizers and sell refurbished ones, we'll tell you when a repair or rebuild makes sense and when replacement offers better long-term value.
  • A strong safety record. Kono Kogs is ISN certified and our crews are OSHA 10 trained.

Request service or call 920-615-8804 to talk with our team about your oxidizer.