CASE STUDY – VOC Abatement & Energy Recovery for EPS Manufacturing
November 6, 2025 7:39 am
CASE STUDY: VOC Abatement & Energy Recovery for EPS Manufacturing
November 5, 2025
Client Overview
A U.S. Expanded Polystyrene (EPS) producer needed a customized VOC control solution to meet strict air-quality regulations. High pentane emissions during bead expansion, molding, and storage triggered EPA and regional compliance pressure. The system had to achieve high destruction efficiency, reduce fuel use, and support future production increases.
Challenge
EPS beads contain 3.5–6.5% pentane by weight. As the beads expand, pentane vapor is released through multiple exhaust points, creating high VOC loading and fugitive emissions. The facility required a solution that would:
• Reach ≥98% VOC destruction
• Capture emissions at all critical process stages
• Lower operating fuel cost
• Handle variable production loads
• Meet evolving air-district rules
Solution – Custom 10,000 SCFM RTO
Ship & Shore Environmental engineered and supplied a regenerative thermal oxidizer (RTO) tailored to the plant’s airflow and pentane emission profile. Key features:
• 1,500°F operating temperature for 98%+ VOC destruction
• Dual ceramic media beds with ~95% thermal efficiency
• Precision poppet-valve switching for maximum heat recovery
• Integrated heat exchanger capturing stack heat for drying room and building heat
• Ducting strategy designed to collect both process and fugitive emissions
• Capable of self-sustaining operation when pentane BTUs replace natural gas
Performance & Results
• VOC destruction verified above 98%
• Natural gas use reduced up to 70% due to recovered heat
• Regulatory compliance achieved and permit risk eliminated
• Energy captured from stack reused inside the facility
• System designed for future production expansion
| Metric | Before | After |
| VOC Control | Non-compliant | 98%+ compliant |
| Fuel Cost | High | Reduced through heat recovery |
| Pentane Emissions | Uncontrolled | Fully captured & oxidized |
| Facility Risk | High | Cleared & certified |
Why Ship & Shore
• 20+ years of VOC engineering experience
• 85% of U.S. EPS industry served
• In-house design, fabrication, installation, and startup
• Solutions based on process needs, not pre-built units
• Focus on safety, performance, and long-term ROI
Conclusion
With a properly designed RTO and heat-recovery strategy, EPS facilities can meet strict VOC limits while reducing operating cost. This project demonstrated that emissions compliance and energy efficiency can be achieved in one engineered solution.
📞 Contact us at +1 (562) 997-0233
📧 Email: service@shipandshore.com
Categorised in: Case Study & White Papers, News, News, VOC Abatement