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Over the years, production-driven companies have focused mainly on new process technologies to streamline production and increase profits. It was not until recently that newer, more efficient technologies were designed to meet the varying process emissions found in many manufacturing facilities. The Regenerative Thermal Oxidizer (RTO) is an abatement technology widely used on industrial air pollution control applications because of its ability to reuse up to 97% of the thermal energy from combustion to preheat incoming, untreated pollutants. Early RTO designs were established for process exhaust gases containing very low emission concentrations but current designs have evolved to handle much higher concentrations.
Likewise, new features enable the RTO to handle challenging conditions such as emission spikes by incorporating a Hot Gas Bypass (HGB). Since most RTOs do not have catalysts incorporated into the design, there are significant savings in maintenance and replacement parts. And the VOC/HAP performance efficiency stays consistently high over the operational life since there is no catalyst present that can degrade with time. RTOs have a distinct advantage over catalytic systems as the auxiliary fuel usage is lower during low process exhaust concentrations. When concentrations are above 3% LEL (lower explosive limit) the RTO is generally self-sufficient, meaning no supplemental fuel is required for combustion. This has a direct correlation on greenhouse gas emissions from the auxiliary fuel combustion process, mainly CO2 and NOX are also reduced compared to older emission control designs with higher fuel usage. For example, the high thermal efficiency of the RTO can reduce the auxiliary fuel consumption by hundreds of dollars per hour for larger-scale chemical plants.