A large, industrial wastewater treatment facility with around-the-clock operations needed a solution to improve the on-stream reliability of two Regenerative Thermal Oxidizers (RTOs). Their systems were often shutting down multiple times a week – causing major operating and environmental compliance issues.
A recycling facility that processes waste bakery products experienced significant reductions in airflow capacity, negatively impacting production rates. The bottleneck was a two-chamber RTO (Regenerative Thermal Oxidizer) system that had prolonged startup times, suffered significant chamber temperature imbalances, and contained ineffective ceramic media.
When a Fortune 100 engine manufacturing facility in the Southwest brought in PolSys for routine RTO and Zeolite Concentrator training, our field engineer uncovered critical system failures—including a plugged pressure transmitter and degraded components—that had gone unnoticed for months. This case study reveals how expert insight prevented costly downtime and restored regulatory compliance.
A metal container manufacturer operating a 40,000 SCFM Regenerative Thermal Oxidizer (RTO) was facing serious operational challenges. High system pressure drop, temperature imbalances, and frequent media bake-outs were disrupting production and raising concerns about passing an upcoming air compliance test. Read how we delivered a turnkey solution—resolving system inefficiencies, restoring flow balance, and reducing downtime.
A global Fortune 100 automotive manufacturer faced major operational challenges due to outdated PLC and HMI hardware in their 4 Regenerative Thermal Oxidizers (RTOs). These legacy systems not only risked future manufacturer support but also contributed to unplanned downtime and inefficiencies. Read how our turnkey control system upgrade delivered robust, reliable performance—minimizing downtime, improving responsiveness, and streamlining operations.
A major chemical manufacturer operating 24/7 faced frequent shutdowns due to a failing legacy control system on their Regenerative Thermal Oxidizer (RTO). These disruptions led to costly permit violations and production losses. To address these critical issues, we delivered a fast, customized control system upgrade that significantly improved reliability, compliance, and overall operational efficiency.
This expert article — written by us and featured in Process Heating magazine — highlights five common but often overlooked issues with industrial control systems on air pollution control equipment. Drawing from real-world experience that includes a case study, it explains why these “hidden” problems can lead to costly downtime or compliance risks—and why an upgrade may be the smartest next step.
Read how we successfully completed two different media changes and other RTO repairs in suddenly challenging conditions, on time and on budget.