The Benefits of Using Damper for RTO

The Regenerative Thermal Oxidizer Process

The Simple RTO Process

An RTO uses six basic steps for each cycle to heat the incoming dirty air, burn off pollutants and cool the exhausted clean air.

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1. Polluted air is drawn into the RTO fan
2. Polluted air is pushed through a valve system into one (of two) beds of ceramic media
3. Air is pushed through heated ceramic media; heating the air while cooling the ceramic media
4. Heated air is pushed into a combustion chamber where pollutants are burned off
5. Clean, hot air is pushed into second (of two) beds of ceramic media; giving off heat to the ceramic media, cooling the air
6. Clean, cooled air is pushed through open valve and exhausted into the atmosphere

LEARN MORE – How an RTO Works

Types of Regenerative Thermal Oxidizers

While RTOs can come in a few different configurations and layouts depending on the system’s requirements, the number of heat chambers used is the most common differentiator between types of RTOs. Also, there are variations in the types of valves used to reverse airflow direction. Some RTO technologies may not incorporate a traditional combustion chamber at all.

Essential differentiators between types of RTOs are:

• Chamber Configurations
• Heating Techniques
• Air Flow Valves

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Applications of Regenerative Thermal Oxidizers

RTOs are used by manufacturers in a wide range of industries and applications. The Kono Kogs team has experience with practically every possible oxidizer application across many industries around the globe.

Industry Processes Using RTOs to Treat Emissions

• Printing
• Industrial Painting
• Electronics Fabrication
• Material Coating
• Chemical Processing
• Lamination
• Can Production

LEARN MORE – RTO Industry Applications

How much does a regenerative thermal oxidizer (RTO) cost?

RTOs are sized and priced based on airflow volume that the system will treat. Total Cost of Ownership (TCO) is the initial capital investment in the equipment, plus installation costs, plus operating costs (fuel, electricity, and compressed air).

• RTOs have the lowest operating cost compared to other types of thermal oxidizers.
• Lower cost units often have higher operating costs and lower reliability due to inferior components, and a design operating on its outer limits.
• Fully refurbished RTO systems from Kono Kogs can save you 40% or more in capital costs compared to buying new – with comparable guarantees and warranties

LEARN MORE – RTO Costs

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‍Contact the KKI team for help selecting the most cost-effective RTO system for your application. We can turn quotes around within 24 hours for common applications. When special features are required, like hot gas bypass, puff capture, special metals, etc. a little more time will be needed to complete the quote.

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Regenerative Thermal Oxidizer Design Factors

Certain RTO design factors can make a significant difference in both capital and operating costs:

• Process air volume flowrate affects the size of the RTO unit, dampers and ductwork you’ll need.
• Process air exhaust temperature determines the need for ductwork insulation, fan sizing, and affects expected operating costs.
• Type & concentration of pollutants affects material of construction, heat exchanger efficiency, and greatly determines operating costs of electricity and fuel.
• Complexity of RTO design affects how much RTO maintenance will be required. RTOs come in different designs, sizes and configurations.
• Projected growth could make it smarter to install a higher-capacity system right away, rather than adding a second RTO in the future.

RTOs Compared to Other Pollution Abatement Systems

Regenerative thermal oxidizers have many advantages over other oxidizer designs, but application in a specific process must be evaluated to determine whether it is a good match for your emission control needs.

Regenerative Thermal Oxidizer vs Thermal Oxidizer

In thermal oxidizers, air flows only one direction through the system. RTOs however create airflow reversals using dampers and control logic, which makes them much more thermally efficient.

Compared to other thermal oxidizer systems, regenerative thermal oxidizers are more efficient and reliable, and have a longer service life. However RTOs have a more complex build and are heavier, which can affect shipping, installation and commissioning costs.

RTOs are the best option for most industrial processes, however when 99.99% destruction of VOCs is a requirement, a thermal recuperative oxidizer may be the better solution.

LEARN MORE – Regenerative Thermal Oxidizers vs. Thermal Oxidizers

If you want to learn more, please visit our website SASTAR.

Regenerative Thermal Oxidizer vs Recuperative Thermal Oxidizer

The main difference between regenerative and recuperative thermal oxidizers is how each one recovers heat while operating. Recuperative thermal oxidizers use metal as the heat exchange material, while regenerative thermal oxidizers use ceramic media.

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Regenerative Thermal Oxidizer Components

In many cases, KKI can help businesses comply with environmental regulations and reduce operating costs by repairing, rebuilding, or upgrading their existing regenerative thermal oxidizer. We have an extensive inventory of RTO parts including ceramic media, fans, burners, and much more, plus an in-house fabrication shop.

When the cost of regenerative thermal oxidizer repair outweighs the benefit, KKI can facilitate RTO replacement. We offer fully refurbished systems with parts and performance warranties.

Available RTO components from Kono Kogs

• Exhaust stacks
• Combustion chambers
• Media chambers
• Media cold face support
• Gas trains
• Process ductwork/supports
• Process T dampers
• Hot bypass valves
• Access platforms
• PLC cabinets
• Actuators
• Insulation & cladding
• Pneumatic controls

Kono Kogs RTO upgrades/services

• Ceramic media change outs & upgrades
• Fan balancing/rebuilds/relocation
• Damper replacement
• PLC programming & upgrades
• Burner/gas train upgrades
• Turnkey capture systems
• Exhaust stack reconfiguration
• Fan motor rebuilds
• Preventive RTO maintenance programs
• Remote monitoring hardware/software
• Full turnkey installation

The components and services above are by no means comprehensive. KKI can handle any RTO rebuild or replacement project you are facing. We invite you to send us your trickiest projects; we look forward to the challenge!

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Regenerative Thermal Oxidizer Manufacturers

The best-built RTOs make the best used RTOs. KKI selects only the best pre-owned regenerative thermal oxidizers and stands behind them with warranties that match new equipment Original Equipment Manufacturer (OEM) warranties. Check out our current RTO inventory from manufacturers including:

• CECO ADWEST Technologies
• Dürr MEGTEC Systems
• CMM Group
• REECO (Dürr)
• TANN Corp.
• Alstom

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Adding a Concentrator to a Regenerative Thermal Oxidizer

Sometimes air volumes are so high – as in many painting and coating applications – they would require a huge, cost-prohibitive RTO system. In these cases, when the airflow is at or near ambient temperatures, a Zeolite Concentrator can be added upstream of the oxidizer to condense fuel-abundant VOCs and reduce air volumes, allowing for a smaller, less expensive RTO.

How a Zeolite Concentrator Works

When the dirty waste stream enters the spinning concentrator wheel, its pollutants are attracted to the Zeolite and stick to its surface. The Concentrator’s blowers then push the heated, lower-volume air stream with its condensed VOCs into the RTO.

Concentrators feature a heat exchanger and require blowers and a separate burner – all of which need to be properly maintained to sustain reliable system performance and prevent damage to both the Concentrator and the oxidizer. The addition of a Concentrator also necessitates a much more complex control system.

Is an RTO Right for Your Industry and Application

RTO systems work especially well for industries including:

• Paint booths

• Coating processes

• Automotive

• Ethanol production

• Pharmaceuticals

• Various other manufacturing processes

Could your team benefit from an RTO refresher course? Learn more about our training services.

If you want to learn more, please visit our website Damper for RTO(ar,ru,es).

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