Regenerative Thermal Oxidizers (RTOs) are vital in reducing industrial air pollution through the thermal destruction of volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). As industries face growing pressure to optimize operations in response to tightening environmental regulations and fluctuating energy costs, enhancing the efficiency of RTOs has become a priority. One key optimization strategy lies in choosing the right ceramic packing media. This guide explores how structured ceramic media, like FLEXERAMIC® from Knight Material Technologies, can improve energy efficiency, reduce operational costs, and extend uptime by reducing repacking and maintenance needs.

Priorities driving RTO optimization

RTOs are favored for VOC and HAP abatement due to their energy recovery capabilities and continuous operation without cool-down periods. However, a variety of industry priorities are pushing RTO manufacturers to improve their operating efficiencies:

Structured packing vs. random packing media for RTOs

Structured packing, such as the corrugated FLEXERAMIC structured media, offers several advantages compared to random packing, like ceramic saddles. One example is that random packing is prone to uneven gas distribution and deposit buildup, causing hot spots and clogging. In contrast, FLEXERAMIC’s engineered design ensures uniform gas flow and minimizes fouling. Its corrugated structure increases surface area and turbulence, promoting better particulate disengagement and reducing pressure drop, leading to extended service intervals and lower maintenance costs.

Benefits of FLEXERAMIC structured media

FLEXERAMIC structured packing provides substantial improvements in energy efficiency and operational performance compared to traditional ceramic saddles:

how to increase RTO efficiency The right heat transfer packing will save energy costs.The right heat transfer packing will save energy costs.

Real-world case studies of savings from FLEXERAMIC structured media

The switch to structured ceramic media in regenerative thermal oxidizers (RTOs) has delivered significant operational and financial benefits across various industries. Several real-world examples highlight the impact of this switch that demonstrate the impressive cost reductions and efficiency gains achieved by adopting structured media:

Structured Media for Long-Term Savings

Switching to structured ceramic media like FLEXERAMIC in RTOs can significantly reduce energy costs, maintenance frequency and unplanned shutdowns. These real-world examples highlight how structured media improves efficiency, enhances sustainability and boosts profitability. For industries facing rising energy costs and tightening regulations, investing in structured media is a strategic move that provides immediate and long-term benefits.

Read the full Regenerative Thermal Oxidizer Efficiency Guide to learn how to cut down on repacks, energy costs and unplanned shutdowns.

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