The Challenge

A 25-year old three-chamber Regenerative Thermal Oxidizer (RTO) originally manufactured by Smith Engineering was showing its age. To keep it running strong for a major wall covering manufacturer, Anguil Environmental Systems was brought in to modernize and optimize the equipment.

The Solution

The goal of the project was to extend the life of the unit while cutting operating costs.

The oxidizer’s aging ceramic media was replaced with high-performance extruded monolith block media, instantly boosting thermal energy recovery (TER) while maintaining top-tier VOC destruction. This change resulted in over $250,000 in annual energy savings.

To improve efficiency further, Anguil optimized the airflow distribution through the media using perforated stainless steel sheets in the cold face. This ensures uniform air distribution, improved thermal performance, and consistent VOC destruction. Insulation repairs and replacements eliminated exterior hot spots for safer, more stable operation.

Recognizing that the old control system was becoming a maintenance nightmare, Anguil installed a state-of-the-art control panel featuring a new PLC, HMI, VFDs, and Ethernet-based remote access. This upgrade provided operators real-time visibility, smarter control, and easier troubleshooting.

The Result

The upgraded RTO now runs smoother, cleaner, and cheaper. The new media reduced operating costs while the modern control panel gives the customer modern components and complete control of their equipment.