Proven Results Across Industries

    Real engineering challenges solved with the CLEAN methodology. Measurable outcomes you can trust.

    Restoring RTO Performance Through Advanced Troubleshooting & Field Service
    Industrial Processing

    a leading rendering company

    Restoring RTO Performance Through Advanced Troubleshooting & Field Service

    Challenge: Process Buildup, Fan Repairs, & Pressure-Control Issues

    Successful Ceramic Media Cleaning

    Full bakeout programming installed and tested

    High Performance Damper Operation Restored

    Supply of new dampers and actuation

    Pressure Instruments Replaced and Calibrated

    More Efficient Control Implemented

    CleanCap restored critical RTO functionality through comprehensive field repairs involving advanced burner troubleshooting, plugged heat recovery media, fan vibration, and pressure-control system restoration, addressing multiple reliability concerns for an industrial processing facility.

    Comprehensive mechanical and electrical repairs, systematic fault isolation, component replacement, controls verification, and calibration to restore critical RTO functionality.
    RTO Reliability Upgrade Restores 24/7 Operations
    Municipal Wastewater

    Encina Wastewater Authority

    RTO Reliability Upgrade Restores 24/7 Operations

    Challenge: Silica Buildup & Chronic Shutdowns

    20%+

    Downtime Reduction

    3x Longer

    Maintenance Intervals

    Significant

    Fuel Savings

    A 6,400 SCFM RTO serving 400,000+ residents was shutting down every 4-5 weeks due to silica-induced media blinding. CleanCap engineered silica-resistant structured ceramic media, upsized heat-recovery canisters, and Supplemental Fuel Injection (SFI) to restore predictable performance.

    CLEAN Methodology applied for root cause analysis and targeted system redesign.
    Thermal Oxidizer + Waste Heat Recovery Integration
    Renewable Natural Gas

    Leading RNG Developer

    Thermal Oxidizer + Waste Heat Recovery Integration

    Challenge: Fuel Efficiency & Carbon Intensity

    <30 min

    Cold Startup

    Reduced

    Carbon Intensity

    Optimized

    Heat Recovery

    An RNG facility converting landfill gas needed emissions control without excessive fuel use. CleanCap designed an integrated TO + WHRU system with low pressure drop, capturing exhaust heat for glycol heating while minimizing environmental footprint.

    Full thermal, mechanical, and emissions evaluation for sustainability goals.
    Thermal Oxidizer Retrofit & Rapid Deployment
    Chemical Manufacturing

    WR Grace

    Thermal Oxidizer Retrofit & Rapid Deployment

    Challenge: 30-Day Deployment Window

    30 Days

    Deployment Time

    Compliant

    Class 1 Div 2

    Turnkey

    System Status

    WR Grace needed a mothballed oxidizer fully refurbished and operational in 30 days. CleanCap delivered complete modernization including Hastelloy quench tower, new PLC controls, burner system, and Class 1 Div 2 hazardous area compliance.

    Intensive engineering review with parallel mechanical and electrical execution.
    Industrial Oven Insulation Rehabilitation
    Automotive Manufacturing

    Automotive Components Manufacturer

    Industrial Oven Insulation Rehabilitation

    Challenge: Energy Waste & Quality Issues

    25%

    Energy Reduction

    Restored

    Temp Uniformity

    Faster

    Warm-up Time

    A critical curing oven was consuming excessive energy with ±10-15°F temperature deviations causing scrap. CleanCap's thermal imaging revealed collapsed ceramic fiber and thinned firebrick. Complete multilayer insulation rehabilitation transformed the failing asset.

    Advanced infrared diagnostics and heat-loss modeling for root cause identification.
    Wet Scrubber Conversion & Ammonium Sulfate Recovery
    Semiconductor Manufacturing

    Fortune 500 Lighting Manufacturer

    Wet Scrubber Conversion & Ammonium Sulfate Recovery

    Challenge: Wastewater Surcharges & Compliance

    Reduced

    Surcharges

    Sellable

    Byproduct

    Eliminated

    ANS Operation

    35,000 SCFM scrubbers producing dilute ammonium hydroxide faced costly neutralization and discharge penalties. CleanCap's feasibility study enabled conversion to sulfuric acid injection, creating concentrated ammonium sulfate suitable as fertilizer feedstock.

    Process modeling, pH control logic, and economic analysis for ROI validation.
    High-Temperature Vessel Insulation Relining
    Industrial Manufacturing

    ET Industrial Manufacturing

    High-Temperature Vessel Insulation Relining

    Challenge: Thermal Performance Degradation

    Minimized

    Heat Loss

    Safe

    Shell Temps

    Extended

    System Life

    A high-temperature processing vessel showed exterior hot spots, performance drift, and rising energy costs. CleanCap's inspection revealed cracked refractory and deteriorated fiber blanket. Full relining with modern materials restored thermal stability and operator safety.

    Top-to-bottom thermal system assessment with engineered material selection.

    Every project follows our proven CLEAN methodology for consistent, measurable results.