A Midwest-based manufacturer of expanded polystyrene (EPS) insulation installed a regenerative thermal oxidizer (RTO) for the abatement of volatile organic compounds.

The 6,000 scfm oxidizer, designed and supplied by Catalytic Products International (CPI), controls the emissions from two foam expansion lines. It will destroy VOC emissions, primarily pentane, with more than 98 percent destruction rate efficiency (DRE) and a thermal efficiency of 95 percent, according to the manufactuer. CPI says the oxidizer design allows for minimal gas consumption and operating costs.

During insulation manufacturing, the bead-expansion process uses steam, which causes the process stream to be nearly saturated. A previously installed RTO experienced significant interior and exterior deterioration because the continuous exposure to water corroded and thinned the carbon steel oxidizer and associated components.

The new RTO’s exhaust stack and fan system were fabricated with stainless steel to prevent any oxidization created by the high humidity and standing water from the process. CPI delivered a skid-mounted, prepiped and prewired RTO with the media installed to the customer-supplied concrete pad for installation. CPI worked closely with the customer to minimize the downtime associated with installation.