Process: Coil Coating
Problem: Established Company Looking for Economical Replacement Oxidizer with increased capacity and lower operating costs
Equipment: Regenerative Thermal Oxidizer
30,000 scfm capacity (1997 vintage)
This coil coating operation wanted to replace a thermal oxidizer, gain additional capacity to accommodate an increase coating line speed, increase line worker comfort by picking up air from work areas, and, if possible, reduce operating costs.
Solution Provided by Kono Kogs, Inc.
The existing thermal oxidizer had a typical heat exchanger effectiveness for this industry and this oxidizer vintage. However, with today’s fuel costs the fuel costs to run the thermal oxidizer exceeded $15,000/month. With increased airflow from the process, and additional air pick-up points from work areas, this coil coater wanted to investigate new technologies that will allow them to increase exhaust rates, with little to no additional fuel cost.
We provided a 30,000 scfm regenerative thermal oxidizer (RTO) system designed for the high temperature exhaust typical from coil coating oven exhaust. Although the airflow being treated by the thermal oxidizer is more than 5 times the original exhaust rate, the refurbished thermal oxidizer had lower monthly fuel usage than the original system. This was possible because of the high thermal efficiency of the regenerative thermal oxidizer, combined with the high solvent concentrations in the coil coating oven exhaust. To handle the high solvent concentrations the RTO had a hot side heat exchanger bypass. The RTO also had a VOC entrapment (puff capture) feature, to provide the high VOC destruction efficiencies desired (98+%), and capture the visible emissions present during and RTO valve switch.
Equipment / Services Provided by Kono Kogs, Inc.:
• Refurbished Regenerative thermal oxidizer with:
o Heat exchanger bypass
o Puff capture/VOC entrapment
o Upgraded PLC w/data highway plus
• Low Capital Cost: Approximately 40% of the cost for new equipment
• Energy efficient (95% HX) regenerative thermal oxidizer technology
• Late model (7 year old) system w/25+ year life expectancy