Epcon Industrial Systems has announced the launch of a patented process heating and emissions control system tailored to the demanding requirements of the composites manufacturing industry. The innovative solution integrates a Regenerative Thermal Oxidizer (RTO) with Secondary and Tertiary Heat Exchangers, offering unmatched energy efficiency and VOC destruction performance. 

At the core of the system is a multi-chamber RTO designed with airflow reversal through ceramic media beds, enabling more than 95% heat recovery efficiency and greater than 99% VOC removal. Engineered for a residence time of at least one second and operating temperatures up to 1600°F, the system ensures complete oxidation of volatile organic compounds commonly released during curing processes. 

Epcon’s engineering team custom-designed each RTO system based on flue gas volume, VOC concentration, and explosive limits. A key feature is the inclusion of burners with more than a 20:1 turndown ratio and combustion air fans controlled via variable frequency drive (VFD). These components maintain precise combustion chamber temperatures and fuel-to-air ratios across dynamic process conditions.

Downstream of the RTO, treated exhaust enters a Secondary Heat Exchanger that transfers energy to a fresh air stream feeding curing ovens. Real-time adjustments via VFDs ensure both temperature and pressure requirements are met efficiently. To further optimize thermal efficiency, a bypass hot stream mixing system reduces the load on burners while maintaining curing consistency. An auxiliary booster burner downstream provides final temperature regulation when needed.

In the final stage, the system’s Tertiary Heat Exchanger transfers residual heat from the treated air stream to water via an economizer coil. This preheated water, reaching temperatures around 160°F, is ideal for indirect heating of phenol-formaldehyde adhesives and sealants, further reducing plant utility costs. 

Also, the custom PLC-based control architecture supports remote operation and programmable process steps. This allows manufacturers to predefine setpoints for each phase of the curing cycle, ensuring fast response times and steady-state performance with minimal manual intervention.