Catalytic Products International (CPI)

CPI Installs RTO at Automotive Paint Shop

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Catalytic Products International (CPI) recently completed the installation of a new Regenerative Thermal Oxidizer (RTO) in the paint shop at a Midwest automobile manufacturer for the control of Volatile Organic Compounds (VOCs).

The 65,000 SCFM Silicone Series Regenerative Thermal Oxidizer (RTO) will control VOC emissions from a new solvent based 2K clear coat spray paint booth. The RTO destroys VOC emissions from the paint solvent vapors with 98% destruction rate efficiency (DRE) allowing the facility to maintain compliance with Clean Air Act standards. The RTO will achieve a thermal efficiency of 95% allowing for minimal gas consumption and operating costs.

CPI worked closely with the Engineering, Procurement, and Construction (EPC) firm as well as the end user customer to define, select, and engineer the equipment best suited to safely and effectively treat emissions from the paint spray booth.  In this application the paint spray booth exhaust contains VOCs including siloxanes, methanol, ethanol, acetone, and formaldehyde. When oxidized, the siloxanes present in the 2K clear coat solvents will form an inorganic particulate, silicone dioxide (SiO2), which clings to hot, metallic surfaces and forms a destructive and efficiency robbing barrier layer in the exhaust system and thermal oxidizer.  The Silicone Series Regenerative Thermal Oxidizer includes a special media designed to handle the light particulate loading while providing reduced pressure drops and the highest thermal efficiency.  This Silicone Series design extends the duration between media changes. 

Thermal treatment of VOCs and other air pollutants works by a simple reaction of the harmful hydrocarbon-based air pollutants with oxygen and heat. In this environment, the VOCs are oxidized to form harmless inert by-products like CO2, water vapor (H2O), and usable heat. These harmless by-products are released to the atmosphere or used within primary or secondary energy recovery techniques to further lower the operational costs.

CPI Regenerative Thermal Oxidizers (RTOs) are engineered to provide exceptional performance and reliability.  During operation of the standard two chamber 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 directed to the second regenerator to absorb the heat energy before being released to the atmosphere. 

CPI provided on-site supervision to ensure coordination with the EPC and their subcontractors as well as the final customer.  This approach guaranteed that entire system was installed correctly, leading to a short start up and commissioning time frame, returning the customer to fully operational status with minimal downtime. 

CPI has been “Enabling Clean Production Since 1969” and continues as a leading supplier of air pollution control equipment. CPI is at the forefront in providing industries including the automobile industry 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.

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