CASE STUDY: Reality-Ready RTOs: Why Real-World Thermal Load Matters

6.25.25

CASE STUDY: Reality-Ready RTOs: Why Real-World Thermal Load Matters

Introduction

We were brought into a California facility facing sustained high-temperature emissions, a failing oxidizer, and increasing compliance pressure. This is where Ship & Shore shines — where others offered off-the-shelf replacements, we engineered a solution that could actually survive the process.

The Problem

Some oxidizer failures happen fast. Others collapse slowly. This plant was headed for the latter — and fast.

Their emissions profile had changed:
– New raw materials
– Mid-process shifts
– Stricter limits from AQMD

The result: sustained inlet temperatures above 600°F — far beyond what their aging system was built to handle.

What we saw:
– Refractory failure every six months
– Burner cycling under heat stress
– Inconsistent destruction efficiency
– Manual throttling to avoid temperature spikes

Most vendors proposed a “replacement in kind.” Same footprint. Same limitations. Still not built for the actual heat.

We didn’t take that bait. We waited. We listened. Then we re-engineered the whole thing.

The Solution

• Step 1: Process Mapping & Thermal Profiling

We installed portable sensors and collected 14 days of real-world production data — capturing not just temperatures, but rate-of-rise, dwell time, and BTU distribution across duct zones. That became our baseline — not theory, but facts.

• Step 2: Refractory Redesign

We scrapped the cast-in-place model and built a two-tier system:
– Primary hot face: 60% alumina brick, mechanically anchored
– Backup insulation: 3” of 8-lb ceramic fiber + castable lining

This wasn’t just heat resistance. It was engineered thermal memory — designed to reduce cycling fatigue and hot spots.

• Step 3: Media Selection

We specified a custom mix:
– Structured high-alumina ceramic
– Random-packed saddle media

Most firms would’ve defaulted to a single media type. That would’ve killed efficiency under these thermal loads. Ours didn’t.

• Step 4: Burner & Controls

We installed a low-NOx modulating burner with:
– Dual thermocouple feedback
– PLC control with manual override
– Auto shutdown and remote alerts

The system is now stable, responsive, and audit-ready.

• Step 5: Install + Commissioning

In a 72-hour window:
– We dismantled the compromised unit
– Rebuilt duct tie-ins with high-temp expansion joints
– Completed final refractory and insulation
– Ran full test cycles at load and tuned burner modulation until spec was exceeded

No prefab. No assumptions. Just field-engineered performance.

The Results

– 99.95% VOC destruction efficiency
– Zero unplanned shutdowns in the first six months
– 19% reduction in fuel use, via downstream heat recovery
– Refractory life extended from 6 months to 36+ months
– Full AQMD compliance, with automated logs and remote alerting

The Real Result

Operators don’t babysit the system anymore.
Compliance reports go out without stress.
The plant runs. The system runs.
And nobody’s waiting for it to fail.

Request a Technical Assessment

[shortcode alias=”cta_tech_assessment_green”]

Categorised in: Achievements, Case Study & White Papers, Industry news, News, News, RTO, Ship & Shore, VOC Abatement