High-Efficiency RTO for Chemical Manufacturing

A chemical manufacturing facility faced increasing regulatory pressure to reduce Hazardous Air Pollutant (HAP) emissions from their solvent-based coating lines under EPA NESHAP 40 CFR Part 63. Their existing carbon adsorption system was reaching end-of-life and was no longer cost-effective due to high media replacement costs, limited capacity, and an inability to handle peak solvent loads of Toluene, Xylene, and MEK exceeding 500 lbs/hr.

Our team designed and commissioned a 45,000 SCFM three-chamber Regenerative Thermal Oxidizer (RTO). The three-chamber design eliminates the 'puff' of untreated air during valve switching cycles, ensuring maximum DRE at all times. We utilized high-density structured ceramic media for superior Thermal Energy Recovery (TER). The system was integrated with the facility's DCS for real-time monitoring and automated load balancing across the three chambers. Combustion temperature is maintained at 1,600°F with a 0.5-second residence time.

• Achieved 99.3% DRE for complex solvent mixtures including Toluene, Xylene, and MEK.
• Thermal Energy Recovery (TER) reached 95%, enabling auto-thermal operation at low LEL concentrations.
• Eliminated the need for expensive carbon media replacement, saving $180,000 annually.
• Reduced facility carbon footprint by an estimated 2,500 tons of CO₂ equivalent per year.