Regenerative Thermal Oxidizers (RTO)

An installed regenerative thermal oxidizer unit

A regenerative thermal oxidizer (RTO) is an air pollution control device that destroys VOCs and hazardous air pollutants (HAPs) in industrial exhaust air. By using regenerative heat recovery, it achieves high fuel efficiency, often operating with 95% heat recovery.

Regenerative Thermal Oxidizers (RTO) are the technology of choice for most applications due to its high VOC destruction efficiency, low fuel use and long system life.
How do we know if our existing oxidizer has enough capacity when adding a new process line?

We can evaluate your current oxidizer’s capacity alongside the new process requirements to recommend the best upgrade approach. Options may include adding new heat exchanger media, installing a larger fan, or modifying the burner and combustion chamber to meet destruction needs. For some cases, using a VOC concentrator to reduce pollutant levels before the oxidizer can be an effective solution. Please note that existing equipment may not be sufficient, even with changes or upgrades.

What is the role of turbulence in a thermal oxidizer?

VOCs (Volatile Organic Compounds) must combine with oxygen and heat to trigger the chemical reaction that breaks them down into CO2 and H2O. There are many successful thermal oxidizer designs that ensure sufficient turbulence, such as introducing the process air at an angle to induce spin or creating internal choke points. The better the mixing and heat distribution, the higher the VOC destruction.

How do I choose between RCOs and recuperative units?

RCOs offer greater fuel economy, while recuperative units may be best for high VOC concentration airstreams (or an RTO can be considered). Contact KKI for guidance in choosing the right oxidizer for your application.

Can the flow capacity of ceramic media be increased?

It depends on some design factors that need to be scrutinized but typically, no. Advancements in new structured media designs can sometimes increase the thermal efficiency and reducing pressure drops through the media beds. This can sometimes can provide a couple percentage points of capacity increases over RTOs that utilize saddle ceramic media.

Our process shifted to more water-based and less solvent-based, and now the oxidizer uses much more gas. Can this be improved?

We can evaluate your heat exchanger, whether metal recuperative or ceramic regenerative, to see if upgrading to a more efficient type is possible. Adding a catalyst might also help reduce gas usage. In some cases, replacing the oxidizer with a more efficient system is the best option. We can check our inventory for suitable units or design a custom system tailored to your needs.

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You can also call Buster at 920-309-0725 or send us an email.