Case Study - Coating / Hot Foil Stamping

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Courtesy of Kono Kogs, Inc.

Problem: Start-up company needed emission control with low capital and operating costs. 
Equipment: Catalytic Recuperative Oxidizer
                   12,000 scfm capacity (1994 vintage)
                   Installed: Fall 2003
                   Location: New Jersey


Project Details:
The founders of this start-up had extensive experience with foil coating, as well as, the control of emissions from this process. Their experience prior to starting their own company had been with a thermal recuperative oxidizer that eventually was converted to a catalytic oxidizer. Their new business would be located in New Jersey, one of the most difficult regulatory environments in the country. Based on their potential to emit, they were required to achieve VOC destructions of 95% or greater and less than 50 ppmv Carbon Monoxide. Their solvent mix varied greatly, but was typically made up of toluene and MEK. The flow rate was expected to be 12,000 scfm @ 300F from 2 lines with solvent emissions of 50 lb/hr. The process initially would operate one shift per day until production ramped up to 24/7. They also may have to locate the oxidizer indoors if the new facility they were seeking had aesthetic restrictions.

Kono Kogs was recommended to them by a consultant, whom we had worked with recently on a successful project in New Jersey. The founders were familiar with oxidizers, and were confident in the ability of a catalytic system to treat their emissions. They had investigated new equipment suppliers but could not justify this amount of capital on a system that does nothing to increase the bottom line, and would negatively affect their cash flow.

Solution Provided by Kono Kogs, Inc.
Kono Kogs analyzed the process, solvent levels, initial operating schedule, future operating schedule, size limitations, and most importantly the performance requirements.

We recommended a 12,000 scfm catalytic recuperative oxidizer with bead catalyst. Although their previous experience had been with monolith catalyst, a bead catalyst can provide from 10-20 times the poison resistance of monolith style catalyst. This is important with varying mixes of solvents. The bead catalyst utilized in this system would provide greater then 20 times the poison resistance of monolith, and was designed to provide greater than 5 years of catalyst life. Although it had the capacity for 12,000 scfm the catalytic system was small enough to fit into most facility overhead doors. The system also was projected to run at minimum burner firing rate or actually turn the burner off during operation due to the high energy release from the combustion of VOC?s in the exhaust stream. Most importantly the system would provide 97% VOC destruction guaranteed, at a cost of less than half that of new equipment.

Equipment / Services Provided by Kono Kogs, Inc.:

  • Refurbished, warranted Catalytic Recuperative oxidizer
  • Capacity of 12,000 scfm
  • Low cost, high quality oxidizer at less than 50% of new equipment cost
  • Energy efficient (70% HX) low temp (600F) operation
  • Low maintenance, long life bead catalyst
  • Guaranteed 97% VOC destruction; Actual Results: 99.9% VOC destruction !!

Customer Testimonial:
'We have been running our catalytic system for approximately 9 months and we just recently performed our stack test. Kono Kog's refurbished oxidizer provided 99.9% VOC destruction efficiency, greatly exceed their warranty of 97% and our NJ regulations of 95%. We would highly recommend Kono Kogs'.


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