Integrated System with Prime and Finish Ovens, Thermal Oxidizer and Heat Recovery for a Coil Coating Application​

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Project No 1480

Integrated System with Prime and Finish Ovens, Thermal Oxidizer and Heat Recovery for a Coil Coating Application

The Challenge

Meeting current federal and state regulations can often compromise fuel costs and operational efficiency, leaving companies spending more money and time than necessary to fix a specific problem. One recent Epcon customer in the metal processing industry was looking to replace a coating line Ovens & standalone Thermal Oxidizer system.

The Solution

A viable solution we have found to this particular problem is custom engineering Air Pollution Control equipment to work in conjunction with Heat Processing equipment. For example, coupling a multi-zone Oven with one or two Heat Exchangers and a standalone Oxidizer to maximize operational cost and productivity. When engineered properly, these custom systems have proven fuel reduction by as much as 50% while simultaneously maintaining compliance with air emissions regulations.

After extensive evaluation and consideration of the existing system operation, we implemented the use of a combination system layout, consisting of a 3-Zone Prime Oven & 4-Zone Finish Oven with a single standalone Thermal Oxidizer system, along with the secondary heat recovery system.

The Results

The new system ultimately resulted in total savings of $320,000 per year on fuel cost alone. This allowed the facility to pay off their investment in less than a 5-year period, thus earning an even higher ROI on their combination system than anticipated.

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