Case Study · Ethanol
RTO High Emissivity Coating: 1,209 BTU per Gallon Better Gas Efficiency at a Midwest Ethanol Plant
| Industry | Ethanol |
|---|---|
| Asset | Regenerative thermal oxidizer |
| Customer or location | Midwest USA |
| Products used | Emisshield on ceramic fiber, chambers, burner tile, and brick walkway |
| Headline metric | +1,209 BTU/gal gas efficiency |
| Secondary metric | ΔT +46°F |
| Also measured | Retention time 2× |
| Also measured | Excess air and NOx −5.2% |
An ethanol plant's RTO for VOC destruction had insulation degradation and VOC breakthrough from temperature imbalance. Emisshield was installed across the entire interior: ceramic fiber, upper and lower chambers, burner tile, and the brick walkway. Natural gas efficiency improved by 1,209 BTU per gallon, the temperature differential rose 46°F with better destruction removal efficiency, retention time in the combustion chamber doubled, excess air and NOx fell 5.2%, and ceramic fiber module life extended.
01
What was the challenge?
Temperature imbalance was degrading insulation and letting VOCs break through.
02
What was applied?
Emisshield on the entire interior surface of the RTO.
03
What were the results?
| Metric | Before | After |
|---|---|---|
| Natural gas efficiency | Baseline | +1,209 BTU/gal |
| Temperature differential (ΔT) | Baseline | +46°F, better DRE |
| Retention time in combustion chamber | Baseline | 2× |
| Excess air | Baseline | −5.2% |
| NOx | Baseline | −5.2% |
| Ceramic fiber module life | Baseline | Extended |
| Maintenance | Baseline | Reduced |
04
Why did it work?
A uniform high emissivity chamber holds destruction temperature with less firing and less excess air, and the sealed fiber surface resists the cycling that degrades modules. See Energy Savings.
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