RTO System Videos

Tour of Regenerative Thermal Oxidizer Combustion Chamber and Ceramic Media Bed ; 15,000 scfm capacity RTO, Ceramic fiber insulation modules line the chamber walls constructed of 1/4" mild steel plate.  Includes a hot side bypass damper utilized to dissipate heat from high VOC emission streams.

Poppet valves are cycled open closed to show how flow direction changes occur in a regenerative thermal oxidizer configured with poppet valves. Overview of the main combustion chamber and ceramic media beds is given along with actual cycling of poppet valves.

Its not complicated... but it is.  Kono Kogs, Inc. is available to answer your in-depth questions about RTO operation and its advantages.   Call us for more in depth understanding of RTOs, yours or one you are considering for your facility.

‍A regenerative thermal oxidizer (RTO) is a type of air pollution control equipment that destroys hazardous air pollutants (HAP), volatile organic compounds (VOC) and odorous emissions created during industrial processes. RTOs are the most common air pollution control technology in use today.

RTO technology uses combustion at high temperatures to oxidize air pollutants from industrial exhaust streams, which turns them into CO2 and H2O before they’re released into the atmosphere. The term “regenerative” in regenerative thermal oxidizer comes from the ceramic media heat exchanger, which retains heat from the prior combustion cycle to preheat (and partially oxidize) the pollutant-filled airstream for the next cycle.

Trying to understand how a VOC rotary concentrator works, what it does, what one looks like, and why it is an innovative technology for air pollution control of light concentration, ambient temperature airstreams?

A VOC Rotary Concentrator is an air pollution control technology used in applications with a combination of high volume of air with low concentration of solvents or VOCs -Volatile Organic Compounds. Practically speaking, it is a front-end, pre-conditioning unit placed upstream of a thermal oxidizer or RTO. By concentrating the VOCs from a large airstream into a small airstream, it allows the use of a smaller thermal oxidizer or RTO.

The main benefit of using rotary VOC concentrators is reduced fuel and electric consumption compared to an oxidizer only. Processes with a large airflow, light VOC concentrations less than 500 ppmv, and temperatures below 100F are ideal applications for a VOC concentrator.

Internal tour of a 40,00 scfm regenerative thermal oxidizer (RTO), including the ceramic fiber insulated walls and ceiling, cold face support, and ceramic media beds (media removed).  Unit was designed with ceramic saddle media, a nozzle mix burner (not shown).

This 25,000 scfm capacity Durr Reeco RL RTO had a drive air cylinder and a pinning air cylinder each with its own solenoid actuating valve.  Freezing air lines in winter or lack of available spare parts puts the RTO at risk of extended downtime and production schedule upsets. Retrofit of an electric drive to replace the pneumatic drive system is a wise solution.

Simple explanation of a cold face support design on a regenerative thermal oxidizer. Steel tube support is shown in this design. Other regenerative thermal oxidizer cold face designs use structural angle, channel, or bar grating as the support base and top that base with perforated metal or expanded metal. The type of ceramic medias can dictate the type of cold face floor.

In-House Ductwork Design and Fabrication:  Kono Kogs has been designing and installing ductwork since our inception, but in late 2020 we began ductwork fabrication in-house.  We now design, fabricate and install our ductwork projects and do it exceptionally well. Whether it is ductwork needed for an installation of one of our quality, refurbished regenerative thermal oxidizers (RTO), relocation of an RTO that includes ductwork, or like this project, which was ductwork only, we can be competitive nationwide.  

Know-How Leads to Efficiency and Savings: Familiarity with thermal oxidizers, the many manufacturing processes that exhaust to the oxidizer, and decades of installation experience allows us to craft a plan of attack that eases installation challenges while providing a quality ductwork installation. This particular installation required a significant duct support stand.  Erecting it in the field and then securing the duct inside of the support would have been a challenge for even our experienced field crew.  So our crew and designers addressed the issue by designing the duct to ship nested in the support stand (see below).  This is one of many examples of our crew's foresight and creativity that are put into practice on every one of our ductwork projects. The advantage for our customers? Less downtime, no surprises, and confidence that we can-and-will protect what we have been entrusted with- our customer's precious capital investment.

Installation Details: In 2 days our crews had installed a T-damper, exhaust hood and 150' of custom ductwork (dark gray ductwork), and were ready for the main header and support stand.  The next few days saw the installation of the custom duct stand, main header and isolation damper, the remaining connecting ductwork, plus the installation of 4 more T-dampers. All dampers were designed and fabricated in-house at Kono Kogs.

Kono Kogs Inc recently installed this rotary valve regenerative thermal oxidizer (RTO) to treat emissions from a rotogravure printing press.

The project scope of supply included a 25,000 scfm RTO, fully refurbished with a parts ad performance (VOC destruction) warranty, shipping and mechanical assembly of the RTO, printing press interconnecting ductwork and installation, as well as all collection ductwork from the press through the roof, across the roof and to the RTO main fan inlet.

Through difficult weather conditions, soft ground due to heavy rains, and the normal winter weather challenges our crew completed the installation successfully.All ductwork was fabricated in-house which allows Kono Kogs to offer very cost-competitive turn-key installations.  

Our crew also started up the RTO, set airflow rates to match the printing press OEM design rates, and trained our customer's personnel.

Another successful, cost-effective air pollution control project by Kono Kogs, Inc. Becoming another customer's favorite Thermal Oxidizer Specialist.

Example of an installation of two refurbished RTO systems, including ductwork and process dampers provided by Kono Kogs. Mechanical assembly of the two systems, electrical wiring, and tie-in of the natural gas and compressed air were also provided as part of the turnkey project.