01
The Challenge
Fuel per gallon and VOC emissions were both above target on the drying system.
02
What Was Applied
Emisshield on the combustion-facing surfaces of the dryer system. Gas consumption and yield were recorded pre- and post-coating for the RTO, Dryer A, Dryer B, and the combined system.
03
Why It Worked
Coated combustion surfaces re-radiate burner energy into the drying air stream rather than the shell, so the dryer reaches the same drying duty on less gas per gallon and burns more completely, which lowers VOCs. See Energy Savings.
04
Summary of Results
| Unit | Gas yield before (BTU/gal) | Gas yield after (BTU/gal) | Improvement |
|---|---|---|---|
| RTO | 953.69 | 809.50 | 15.1% |
| Dryer A | 4,999.95 | 4,604.48 | 7.9% |
| Dryer B | 4,199.53 | 3,987.26 | 5.1% |
| RTO + Dryer A + Dryer B | 10,166.79 | 9,389.75 | 7.6% |
| Unit | Gas consumption before (MMBtu/day) | After | Change |
|---|---|---|---|
| RTO | 198.06 | 184.25 | −7.0% |
| Dryer A | 1,059.48 | 1,049.47 | −0.9% |
| Dryer B | 890.42 | 907.04 | +1.9% |
| System | 2,147.96 | 2,140.77 | −0.3% |
| Temperature | Before | After |
|---|---|---|
| RTO temperature | 1,629.7°F | 1,637.9°F |
| RTO outlet | 374.3°F | 372.4°F |
| Dryer A inlet | 993.4°F | 900.6°F (−9.4%) |
| Dryer B inlet | 889.2°F | 870.6°F (−2.1%) |
Yield improved on all units while consumption held roughly flat, meaning more gallons dried per MMBtu. Combustion chamber temperatures rose, shell temperatures fell, and cross-zone temperature control improved.