A process or piece of equipment could require an upgrade for any number of reasons. CleanCap can assist and if we are not a good fit, we always have recommendations.
Retrofits we commonly perform:
Regenerative Thermal Oxidizer – Media Replacement
Regenerative Thermal Oxidizers (RTOs) will experience over years of operation reduced air flow capacity, channeling or voids in the media bed, thermal imbalances in the chambers, non-efficient energy use, and extended startup times. These are all signs of a Regenerative Thermal Oxidizer (RTO) that should be evaluated for media replacement. Monolithic structured media beds clog when particulate loading occurs in the process stream, improper ceramic media selection, and improper media installation or arrangement can increase the potential of clogging or channeling. A properly functioning RTO supports ongoing manufacturing efficiently and maintains state and federal environmental compliance. Improperly operating RTOs can negatively impact production volume, increase operating costs, and can lead to expensive environmental fines. CleanCap provides extensive knowledge and experience with all types of oxidizer equipment and can provide a corrective solution. CleanCap’s aftermarket service team offers full-service corrective and preventive actions plans. We specialize in bake-outs, partial and full media removal/change-outs and include insulation and packing repairs or replacement.
Thermal Oxidizer Rebuilds and Relocation
CleanCap’s aftermarket service team specializes in extending equipment life, therefore creating more uptime and saving your facility money. With costs of a new thermal oxidizer system and associated equipment on the rise, the opportunity to purchase a previously owned, rebuild an existing unit, or the relocation of a unit may be an attractive option for many businesses. Some of the advantages include lower energy costs, improved volatile organic compound (VOC) destruction efficiencies, and reduced emissions of other pollutants (e.g. NOx, CO2). Within the U.S. there are thousands of installed thermal oxidizers that are more than ten years old. These units are likely underperforming and costing facilities countless headaches, downtime, and excess emissions liabilities. If this is your equipment and maybe you have reached your limit resulting in contemplating the cost of replacement, let CleanCap help! This scenario creates an opportunity for your facility to improve the performance of existing oxidizers by having a qualified aftermarket team come in to evaluate and inspect the equipment for improvement solutions and put together a comprehensive plan for rebuilding or replacing faulty system components including larger, seemingly expensive, critical items like burners and fans. Various options are available and typical projects include installing a higher efficiency heat exchanger, adding variable frequency drives to the fans, improving process flow and distribution, integrating secondary heat recovery, adding a concentrator, and recovering waste heat. Additional projects include the use of a lower temperature oxidation catalyst to reduce energy usage or replacement of the burner with a more efficient low NOx version.
Although environmental regulations require the initial installation of your VOC oxidation equipment, the primary factor today is economics. An upgrade or replacement abatement project should involve a financial return analysis to determine its financial feasibility. Most retrofit packages see a financial return between 24 to 48 months through reduced operating costs. In some cases, cost sharing funds are available through utilities and other state and federal agencies for upgrading or replacing energy intensive equipment with energy efficient systems. In addition, some areas may qualify to market carbon credits earned by the reduction of VOCs. CleanCap focuses on ensuring that your equipment is operating at optimum efficiency and productivity, so that you can focus on consistently producing products.
Burner Management System Upgrades to Improves Performance and Save Energy
To maintain reliability and proper operation, burner management systems need to be inspected periodically. A malfunctioning flame detection system can lead to heat processing equipment shutdowns and have an adverse effect on plant productivity. Many burner alarms and flame loss alarms may conceal the ineffectiveness of the burner management system for years and cause unnecessary natural gas consumption.
Many combustion customers require their burners and combustion systems to be maintained for optimal performance. CleanCap provides qualified personnel to adjust combustion systems for optimum performance, maximum efficiency, and the lowest emissions. Our highly trained and experienced staff knows what it takes to offer quality combustion tuning. Because we manufacture and design combustion systems, we have the advantage of knowing how to make your industrial burner or combustion system work to the original specifications.
Although there are many places to buy a panel, a combustion control system requires detailed process knowledge of the combustion operation and interaction with the burner system. With today’s demands for high efficiency, low emissions (NOx), and maximum productivity, a well designed and engineered control system can pay for itself quickly. CleanCap provides complete combustion control solutions from concept through design and build, commissioning, training, and follow-up support. A wide variety of standard and custom-designed combustion control systems can be furnished to suit your requirements.