THE CHALLENGE
A 25-year-old three-chamber regenerative thermal oxidizer (RTO), originally manufactured by Smith Engineering, was beginning to show its age to its major wall manufacturing owner. Anguil Environmental Systems was brought in to optimize and modernize the equipment.
It was discovered the media was not working as well as it could, and the electronic control system was starting to be difficult to maintain. The customer’s goal was to extend the life of the unit, increase VOC destruction, and cut back on increasing operating costs.
THE SOLUTION
The first repair was to replace the oxidizer’s aging ceramic media with high-performance extruded monolith block media. This simple change instantly boosted thermal energy recovery (TER) while maintaining top-tier volatile organic compound (VOC) destruction. This easy change resulted in over $250,000 in annual energy savings.
To further improve efficiency, Anguil optimized airflow distribution through the media using perforated stainless-steel sheets in the cold face. This change ensured 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Recognizing that the old control system was becoming a maintenance nightmare, and out of date with current technology, Anguil installed a state-of-the-art control panel featuring a new PLC, HMI, VFDs, and Ethernet-based remote access.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. Remote access is a gamechanger in the industry as it allows experts to execute repairs without the associated costs of an on-site visit.
THE RESULT
With these optimizations, the 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.
