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RCO - Pacific Wood Laminates plywood mill in Brookings, OR, USA

Regenerative Catalytic Oxidizer (RCO)

Catalytic oxidizers work like thermal oxidizers to destroy Volatile Organic Compounds (VOCs), Hazardous Air Pollutants (HAPs), Carbon Monoxide (CO), and odors, while using a catalyst to achieve oxidation at lower temperatures.

Regenerative Catalytic Oxidizers (RCOs) – Use ceramic heat exchange beds to store and release energy by reversing process gas flow.

Geoenergy® GeoCat® RCO - Pacific Wood Laminates plywood mill in Brookings, OR, USA

Performance & Efficiency

  • Destruction Removal Efficiency (DRE): Up to 99%
  • Thermal Energy Recovery (TER): 96–97%
  • Energy Use: Less than half of a comparable thermal oxidizer

Catalyst selection is tailored to the application to maximize efficiency and service life. However, catalysts can be deactivated (“poisoned”) by certain compounds or masked by particulates. Gas streams should be free of catalyst poisons and excessive particulates to ensure 5+ years of effective operation.

Suitable Applications

RCOs are ideal for processes with simple solvent VOCs and minimal particulate matter, such as:

  • Printing & packaging (alcohols, xylene, toluene)
  • Wood products without combustion ash (e.g., steam/gas-heated veneer dryers)

Maintenance Considerations

Unlike RTOs, RCO performance depends on both temperature and catalyst activity. Even in clean applications, catalyst efficiency decreases over time. Catalyst sampling and analysis are recommended every 3–5 years. 

How an RCO works

  • Inlet Preheat: Pollutant-laden air passes through the inlet heat recovery chamber, preheating close to catalyst temperature.
  • Catalyst Oxidation: A natural gas burner maintains about 450°C (~800°F) for complete oxidation on the surface of the catalyst layer.
  • Outlet Heat Recovery:  The cleaned gas transfers heat to the outlet ceramic bed before exiting.
  • Flow Reversal: Typical discharge temperatures are about 20°C (~35°F) above inlet temperature. Finally, the emission stream exits the RCO system through the outlet diverter valve and is transferred to the stack via the induced draft fan.
     

Process

RCO systems are very similar to RTO systems, with the exception that they have an additional top layer of catalytic material. The catalyst makes the oxidation occur at lower temperatures, reducing the operation temperature to around 450°C (~800°F), reducing thermal wear and energy consumption.

RCO Advantages

Our RCO systems feature the proven Geoenergy® Single-Blade, Dual-Seat Poppet Valve, installed on over 110 RTO/RCO units handling about 17 million m³/h (~10+ million CFM) of process gas.

The key features of RCO include:

  • Up to 99% DRE (Destruction Efficiency) and 97% TER (Thermal Efficiency).
  • Catalyst selected to match application requirements.
  • Fast-Acting Single Blade Poppet Valves – Located at ground level for easy maintenance and long service life.
  • Only one poppet valve per heat recovery chamber (minimal moving parts).
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