RTO with Energy Recovery and Dust Collection

Manufacturer Reduces Heating Costs and Eliminates Air Pollutants

A worldwide picture frame manufacturer was building a brand new facility to increase production and office space at their headquarters. Located in the scenic North woods of the Midwest meant environmental concerns were top priority when selecting the air pollution control system provider. Even though the Environmental Protection Agency did not require them to treat the 96 tons of Volatile Organic Compounds produced each year, the president insisted the pollution be controlled. When the picture frames are coated, the process omits lacquers and varnishes that might affect the environment around the plant, damaging the relationship between the manufacturer and its’ neighbors. The goal was to find an air pollution control system that would eliminate the VOC’s, particulate and odors at an affordable cost.

Controlled Environment Equipment was asked to provide a cost-effective air pollution control system and they did. Not only did the system that CES designed and installed control pollutants but the heat generated was used to heat the plant, significantly reducing energy costs.

The new production line consists of eight spray booths and six dryers. The spray booths are ducted to a Farr GS32 dust collector that removes particulate. From the collector, the polluted air is sent to a 35,000 scfm Retox© Regenerative Incinerator that burns the hydrocarbons with 99% efficiency. To make the system cost-effective, CEE knew that cascading the exhaust would be necessary so the system was designed to re-circulate air from the dryers to the spray booths. In addition to the cascading, a glycol heat recovery system was utilized to recover waste heat generated by the oxidizer in the final exhaust stack. A heat recovery coil in the make-up air unit uses this heat for the facility in the winter months. By cascading and re-circulating the exhaust air the total system cfm dropped from 60,000 to 35,000cfm. This directly correlated into a large reduction in equipment and operating costs.

All together the picture frame manufacturer saved $500,000 initially in equipment costs and $200,000 annually in utility costs. The system is not only cost-effective and efficient but user friendly as well. The entire air pollution control and heat recovery system is controlled by a CEE control panel that has a telemetry system to monitor the performance via telephone. Should the system have problems, CEE can monitor and troubleshoot quickly from a remote location.

Article By: David Swinehart VP of Engr