Catalytic Products International (CPI) recently completed the installation of a 60,000 SCFM Regenerative Thermal Oxidizer at a Midwest USA steel drum reconditioning facility for the abatement of Volatile Organic Compounds (VOCs) and Odor emissions.
The reconditioning process includes the cleaning, restoring, testing, and certifying of industrial containers which may have previously contained materials such as paints, resins, tars, adhesives, oils, soaps, solvents, cleaners, or related materials. The interiors and exteriors of the drums are cleaned and reconditioned to prevent contamination of materials from one cargo shipment to the next and to ensure the integrity of the containers. The output streams from the water and acid cleaning processes are typically controlled by a packed tower scrubber. However, while these wet scrubbers may eliminate some of VOCs, they do not destroy the non-water-soluble VOCs and odors. One of the final steps in the refurbishing process involves painting and coating of the drums to improve the aesthetic and reduce the corrosion of the drums.
During the cleaning and coating processes significant emissions of VOCs and odors are released into the environment. While odor issues related to industrial processes are not uncommon and the compounds creating the offensive odors may not be in sufficient concentrations to present a health risk, they can diminish the quality of life for the community surrounding the manufacturing or reconditioning process.
The new CPI 60,000 SCFM Regenerative Thermal Oxidizer (RTO) will control VOC emissions and odor from the Packed Tower Scrubber used to control the wash process, as well as the Paint Booth and Drying Oven. The RTO system will destroy VOC emissions with 98.5% destruction efficiency (DRE).
Thermal treatment of VOCs and other air pollutants works by a simple reaction of the harmful air pollutants with oxygen and heat. In this environment, the VOCs are converted into harmless inert byproducts, water vapor (H2O), and usable heat. These harmless by-products are typically released to the atmosphere, or in some cases use an energy recovery technique to further lower the operational costs.
CPI Regenerative Thermal Oxidizers (RTOs) are engineered to provide exceptional performance and reliability. During operation of the RTO the VOCs are directed into one of the system’s regenerators, an internally insulated vessel containing specialized ceramic media which allows thermal rate efficiencies up to 97%. The contaminated gases are passed through the first regenerator where energy is transferred from the ceramic media to the gas in order to elevate the temperature. This elevated temperature approaches the ignition level for most solvents and is then directed from the ceramic bed into the combustion chamber. As the stream exits the ceramic bed and travels through the internally lined combustion chamber, minimal heat is added to ensure a proper oxidation temperature and a designed dwell time is maintained providing destruction of the VOCS at greater than 98% efficiency. The resultant clean, oxidized gases are redirected into a second regenerator bed to continue the energy transfer and oxidation cycle before being released to the atmosphere.
CPI provided a complete turn key installation, including engineering, design and supply of the Regenerative Thermal Oxidizer (RTO), concrete pad, electrical work, compressed air piping, ductwork, exhaust stack and system startup. Due to the high moisture content and alkali carryover from the wet exhaust streams, all wetted surfaces including the RTO, ductwork, dampers and exhaust stack were constructed of stainless steel to minimize any water condensation.
CPI worked closely with the customer to minimize the downtime associated with the installation of the Regenerative Thermal Oxidizer (RTO). CPI was able to complete a good portion of the installation activities before the new unit arrived on site and delivered the RTO for final assembly and loading of the media on site. CPI also provided on-site supervision to ensure coordination with third-party sub-contractors. This approach guaranteed that entire system was installed correctly, and the facility was back up and producing product with minimal downtime.
Established in 1969, Catalytic Products International (CPI) continues as a leading supplier of air pollution control equipment. CPI is at the forefront in providing industries including drum refurbishing facilities with solutions to their air pollution control needs.
Today, CPI partners with its customers as a trusted resource in resolving the most complex air pollution and energy conservation problems. We provide our customers with innovative and cost-conscious solutions to their most complex VOC, NOx, and Odor pollution challenges. Our equipment is also at work meeting energy conservation strategies and minimizing greenhouse gas (GHG) emissions.