Kono Kogs Completes Thermal Oxidizer Installation With Unique Challenges

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Industry-leading thermal oxidizer supplier Kono Kogs expertly handles unusual installation and commissioning circumstances to complete a special upgrade of environmental pollution control equipment, reducing operating costs by over 40% for a carpet manufacturing process.

The customer was extremely pleased with the equipment, the support from Kono Kogs, and the performance of the thermal oxidizer.

A failing recuperative thermal oxidizer used in a carpet manufacturing process was located on a remote rooftop platform. Due to the nature of the solvents in the process, and the extreme crane reach required to set the system on the roof, a decision was made to upgrade the existing recuperative style oxidizer rather than replacing it with a regenerative thermal oxidizer.

Extensive knowledge of different available oxidizer brands and their individual technologies, the ability to install extremely heavy equipment in an unusually difficult-to-reach location, tight project management and ability to meet budgetary constraints were essential to project success.

The heart of any thermal recuperative oxidizer is the heat exchanger. In this case, the heat exchanger, a MEGTEC / Katec thermal recuperative oxidizer was in excellent condition and was not replaced; even though this oxidizer was fairly old, it was lightly used and was of a bent heat exchanger tubes design that extends heat exchanger life, by reducing thermal expansion stress on tubes and tube sheets when operating at temperatures of 1450F.

Kono Kogs provided a new burner assembly and coordinated control logic changes with the customer to integrate the controls into their facility-wide control platform. They met with the installation contractor to review the installation, and provided on-site support.

The crane reach was so long that a 750-ton crane was required to place the 32,000-pound main piece. Reducing time with the costly crane was the critical cost consideration for installation planning. The Kono Kogs team coordinated with the installation contractor to identify possible installation difficulties. They implemented design changes to the interconnecting ductwork and removed unneeded features to expedite actual installation time.

The Kono Kogs customer team installed the oxidizer on a Sunday to reduce the impact on production and had the unit running within a week—meeting a tight production deadline. The customer was extremely pleased with the equipment, the support from Kono Kogs, and the performance of the thermal oxidizer.

The new oxidizer will use approximately half of the gas of the previous unit.

About Kono Kogs:

Since 1996, the engineers at Kono Kogs have advised companies about thermal, regenerative thermal, catalytic and VOC type oxidizers. The services they offer include refurbishing existing systems, preventative maintenance, emergency repair and new unit replacement alternatives. In addition, the company maintains the largest inventory of oxidizers in the US which typically cuts delivery times by over 50%.

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Chris Heikkila
Kono Kogs
(920) 309-0725
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