Feel free to check our RTO Inventory and get in contact with our sales and applications engineers to ensure that the system meets your needs. Quality-built refurbished regenerative thermal oxidizer (RTO) systems offer a long service life, can save you up to 40% compared to new units, and come with performance and parts warranties comparable to those of new systems.
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Perhaps. The retrofit typically involves catalyst somewhere in the media bed, allowing the unit to operate as Regenerative Catalytic Oxidizer (RCO).The result is reduced operating temperatures and energy savings. However, the conversion may be more complex or not possible if the unit is older, heavily customized, or in poor condition. Please contact KKI for a detailed review of the process.
Yes, we can assist in evaluating your system to identify issues such as leaking valves, heat exchanger problems, poor airflow distribution, or catalyst performance. We provide thorough assessments and turnkey solutions to help you stay operational. For regenerative thermal oxidizers (RTOs), see our blog post about stack test failures for more troubleshooting guidance.
Yes, we can support both turnkey projects and specific needs like ductwork and damper sizing and supply or other fabrication needs. Through our Complete Air Fab division, we offer extensive fabrication capabilities and can provide or install ductwork as part of a full turnkey solution—or handle any portion of the project you prefer. Check out our case studies to see examples of our work.
It depends. Regenerative thermal oxidizers (RTOs), depending on age, may be good candidates for repair, rebuild, or upgrade, which is often more cost-effective than full replacement. Upgrades may include PLC modernization and energy-saving features. Thermal recuperative oxidizers are usually less cost-effective to repair long-term, though minor fixes can extend their life temporarily. Catalytic recuperative oxidizers can be repaired, but costly catalyst replacements may justify system replacement if contamination is frequent. Contact us for an evaluation, and we can provide honest guidance to help you choose the best long-term option.
Yes, the type of ceramic media in an RTO can be optimized for an exhaust airstream. Using the right type of ceramic media can maximize thermal efficiency, minimize pressure drop, and better handle organic and inorganic particulates that may be present. Check out this case study for more information.
Note: Regular preventative maintenance and understanding your airstream's composition are cruical for determining the appropriate timing for media replacement.
It depends on your location. Some local and state regulations require low NOx emissions, especially in non-attainment or ozone-sensitive areas. To find out what applies to your facility, contact your local air permitting authority or environmental regulatory agency. If needed, low NOx burners can be retrofitted to your system to meet these requirements.
Catalyst utilized in a regenerative catalytic oxidizer (RCO) allows chemical reactions to occur at lower temperatures (700-800F) than they occur in a thermal oxidizer (typical -F) or an RTO (typical F).
Read more in Comparison: RTOs and RCOs.
We can evaluate your current oxidizer’s capacity alongside the new process requirements to recommend the best upgrade approach. Options may include adding new heat exchanger media, installing a larger fan, or modifying the burner and combustion chamber to meet destruction needs. For some cases, using a VOC concentrator to reduce pollutant levels before the oxidizer can be an effective solution. Please note that existing equipment may not be sufficient, even with changes or upgrades.
Regenerative thermal oxidizers (RTOs) have a heat recovery (efficiency) of 95% typically. This technology has the lowest operating cost of all thermal oxidizer systems – not to mention the longest service life and highest reliability. It’s even possible for an RTO to operate with no auxiliary fuel use whatsoever if process VOC concentration levels are >3-4% lower flammability limit (LFL).
Yes, RTOs can be designed to match your specific exhaust airstream characteristics. They are typically optimized for airstreams with solvent concentrations in the 0–10% Lower Explosive Limit (LEL) range. For higher concentrations up to 25% LEL, additional features such as hot gas bypass systems may be needed to ensure safe and efficient operation.
We can evaluate your heat exchanger, whether metal recuperative or ceramic regenerative, to see if upgrading to a more efficient type is possible. Adding a catalyst might also help reduce gas usage. In some cases, replacing the oxidizer with a more efficient system is the best option. We can check our inventory for suitable units or design a custom system tailored to your needs.
We can evaluate your system by measuring airflow and emissions at key points to assess its current performance. If it’s not optimized, we’ll recommend improvements such as adjusting system settings or adding capture hoods and enclosures. We can also provide these solutions as part of a new system if needed.
TOX with heat exchangers typically have a shorter life span than CATOX systems or RTO systems. This is due to the elevated operating temperatures that the heat exchanger is exposed to. Especially detrimental to the system are repeated on/off cycling that imposes significant thermal stress on the heat exchanger. It is best to apply these systems in applications that run 24/7/365.
The term “regenerative” in regenerative thermal oxidizer (RTO) is drawn from the type of ceramic media heat exchanger used in these systems. It is unique in that it captures heat from the exhausting, clean airstream during one cycle and releases the heat to the incoming, dirty airstream in the next cycle. The heat is captured (and released) from beds of ceramic media. The RTO incorporates switching valves to cycle the direction of the airflow through the RTO heat exchanger beds to enable regenerative heat recovery.
For more information, please visit SASTAR.
Applications with fairly clean process airstreams with low to medium air flow, and medium to high VOC concentrations (>10% LFL) are best for thermal oxidizers. TOX systems can be custom designed to handle high VOC concentrations as compared to CATOX and RTO systems. Typical applications are petrochemical, and chemical airstreams. Special applications are best served by TOX, such as silicone containing airstreams, or processes where secondary heat recovery allows the TOX to operate as efficiently as RTO systems or CATOAX systems because of the heat returned to the process.
Catalytic Recuperative Oxidizers destroy pollutants discharged in the exhaust air of industrial processes. They achieve high VOC destruction efficiency by heating and maintaining a polluted airstream at temperature (typically 600 to 650F) for a set “dwell” time as it passes through catalyst material. The lower operating temperature of a catalytic oxidizer results in much lower fuel use than thermal recuperative oxidizers. VOC destruction efficiency can reach 99+%. Catalytic oxidizers can operate with an integral heat exchanger for fuel savings, or for a lower capital cost, without a heat exchanger. Learn more here.
VOCs (Volatile Organic Compounds) must combine with oxygen and heat to trigger the chemical reaction that breaks them down into CO2 and H2O. There are many successful thermal oxidizer designs that ensure sufficient turbulence, such as introducing the process air at an angle to induce spin or creating internal choke points. The better the mixing and heat distribution, the higher the VOC destruction.
Kono Kogs stands behind every refurbished RTO with warranties that match or exceed those of new equipment OEMs. We have a proven track record of meeting warranty commitments for parts and system performance across a wide range of customers from startups to Fortune 500 companies. Our experienced team provides ongoing technical and maintenance support both on-site, and remotely via KONOConnect to ensure your system operates reliably over the long term.
To ensure quality, we use only top-tier components, conduct thorough inspections, and upgrade parts as needed. Our collaborative planning and extensive oxidizer expertise help deliver flawless projects that our customers trust and recommend.
Fuel gas injection systems are ideal for applications requiring low NOx and CO emissions and where variable fuel demand exists, such as processes with fluctuating exhaust temperatures or flow rates. They can provide significant fuel savings by precisely controlling fuel input, improving combustion efficiency, and reducing overall energy costs.
Sometimes air volumes are so high – as in many painting and coating applications – they would require a huge, cost-prohibitive RTO system. In these cases, when the airflow is at or near ambient temperatures, a Zeolite Concentrator can be added upstream of the oxidizer to condense fuel-abundant VOCs and reduce air volumes, allowing for a smaller, less expensive RTO.
When the dirty waste stream enters the spinning concentrator wheel, its pollutants are attracted to the Zeolite and stick to its surface. The Concentrator’s blowers then push the heated, lower-volume air stream with its condensed VOCs into the RTO.
Concentrators feature a heat exchanger and require blowers and a separate burner – all of which need to be properly maintained to sustain reliable system performance and prevent damage to both the Concentrator and the oxidizer. The addition of a Concentrator also necessitates a much more complex control system.
RTO systems work especially well for industries including:
• Paint booths
• Coating processes
• Automotive
• Ethanol production
• Pharmaceuticals
• Various other manufacturing processes
Could your team benefit from an RTO refresher course? Learn more about our training services.
For more information, please visit Damper for RTO.