While your existing RTO system may have been designed for optimum thermal efficiency at the time it was manufactured, new advances in media and catalysts now give us more options for many exhaust streams that lend themselves to catalytic technology. Catalyst (either precious metal or base metal) promotes the oxidation process to occur at a reduced temperature as opposed to using heat only to thermally oxidize VOCs at greatly reduced temperatures. Often, our customers can recognize a 50% reduction in fuel usage. Many actually achieve and operating condition (self-sustain) with no additional fuel required for oxidation.
The RTO to RCO conversion is a relatively simple conversion and often works in combination with your existing ceramic media and can typically be accomplished with only a few days of equipment down-time.
By reducing the operating temperature, in many applications, fuel usage can be greatly reduced. Many processes may achieve self-sustain (oxidizer burner off) without supplemental fuel.
Reducing energy usage also reduces your carbon footprint. MEGTEC can help estimate your reduction in emissions.
CO and NOX Reduction
Catalytic oxidation usage virtually eliminates CO and reduces other products of combustion. Catalyst allows combustion at lower operating temperatures, reducing fuel consumption, which results in lower NOx emissions.
With reducing operating temperatures, your equipment is less prone to thermal expansion, hot spots and temperature related issues typically due to thermal stress. Start-up from cold time is also reduced due to operation at a lower set-point. This often adds flexibility to your plant RTO/RCO operating schedule.
Valve cycle time may be substantially increased (resulting in less valve switches) reducing wear and valve maintenance requirements as the valve system is critical to achieving DRE.
Catalyst can provide up to 98+% DRE at reduced operating temperatures.
Catalyst Life Expectancy
Modern catalysts can withstand elevated temperatures, abrasion and are resistant to many poisons.
The correct type of catalyst is matched with your process.
Often there is potential for capacity increase by upgrading to a ceramic media mix that meets your needs, eliminating the capital costs, down time and real estate required for new equipment. Reducing system pressure drop by reducing operating temperature also substantially lowers electrical costs.
MEGTEC Systems can provide test samples that can be installed in your existing RTO to ensure there are no poisons or contaminants that can be harmful to the catalyst. The samples can be easily installed and removed by positioning them on the media during routine maintenance interventions and sent back to MEGTEC for testing. We suggest a 3-6 month testing period to get an accurate snapshot of your process constituents. There is no cost for this testing program.
MEGTEC will review your system and work with you to determine the best overall media and catalyst solution.
With the new operating temperatures, re-permitting or testing may be required by local, state or federal agencies. This is typically a readily accepted retrofit and the overall benefits outweigh any permitting costs that may be incurred.
Return on Investment
The RCO conversion can provide an attractive return on investment. MEGTEC can review your system and process to estimate your return on investment.
You may also qualify for local, state or Federal incentives, grants, or tax programs for this type of energy savings project.
Call a MEGTEC representative today to discuss the feasibility and Return on Investment analysis we can perform, that will show you how you can reduce your energy costs.
These links can be helpful to find incentives available in your specific area: