Case Study: RTO Industrial Burner Retrofit for Denver Media Film Production
At a manufacturing facility near Denver, in Windsor, CO, producing thermal media for photo printers and coated paper for photographs, aging burner equipment in their regenerative thermal oxidizer (RTO) was threatening uptime and compliance. The RTO is critical to meeting environmental VOC destruction requirements, but the existing 18 MM BTU/hr burner had been obsoleted by the manufacturer, and frequent repairs were becoming costly and disruptive.
The facility needed a fast, reliable replacement that would minimize downtime while ensuring the RTO could continue operating efficiently at 5,600 feet elevation.
About the Customer: A Leader in Media Film and Coated Paper Production
The Windsor plant manufactures specialty thermal media and coated paper products used in photo printing worldwide. To meet environmental regulations, their processes rely on a robust thermal oxidizer to destroy volatile organic compounds (VOCs) from coating operations. Unplanned RTO downtime directly impacts both compliance and production throughput, making system reliability essential.
The Challenge: Obsolete Burner Causing Rising Downtime
The plant’s existing obsolete burner had reached the end of its serviceable life. As repairs became more frequent, the risk of extended downtime grew. Replacement parts were no longer available, and the plant needed a solution that would:
- Match the firing capacity of the original burner despite high-altitude conditions
- Integrate with the existing RTO controls and fuel train
- Be installed with minimal disruption to production
- Support ongoing VOC destruction requirements for regulatory compliance
The Solution: A Custom-Engineered Burner Replacement and System Optimization
We engineered and delivered a complete retrofit solution that replaced the obsolete burner and optimized the supporting systems for long-term reliability.
Key upgrades included:
- New Burner: A modern burner matched to the original firing capacity, engineered for reliable operation at 5,600 feet elevation.
- Combustion Air System: New combustion air fan, relocated for optimal geometry and easier access to the fuel train.
- Control Integration: Modification of existing control panel wiring and PLC I/O to support the new equipment.
- Fuel Train Adjustments: Rerouted and welded gas piping to integrate the new burner with the existing system.
- Prefabricated ductwork, fabricated a custom burner mounting flange, and coordinated demolition of the old components to keep installation on schedule.
Implementation: Minimizing Downtime Through Pre-Fabrication and Coordination
To keep the RTO offline for as little time as possible, we:
- Rough-installed the new combustion blower and pre-fabricated air ductwork
- Completed all welding, piping, and wiring in coordination with plant personnel
- Assisted with PLC programming and controls testing
- Performed full commissioning, system testing, and operator training
- This approach reduced disruption to production and ensured the RTO was back online quickly
Results: Restored Reliability and Extended System Life
The retrofit delivered immediate benefits for the Windsor facility:
- Reduced Downtime: Obsolete components were eliminated, cutting unplanned maintenance events.
- Improved Accessibility: Relocated blower and reworked piping made maintenance easier.
- Continued Compliance: The RTO is now prepared to meet VOC destruction and emissions requirements without interruption.
- Extended Equipment Life: The retrofit defers the need for a costly full RTO replacement while ensuring reliable operation.
Why BDC: The Trusted Partner for High-Stakes Thermal System Retrofits
The Windsor facility chose BDC for our specialized expertise in industrial combustion and our ability to deliver fast, engineered solutions for mission-critical systems. With decades of experience in burner retrofits, VOC compliance systems, and NFPA86 adherence, we help plants avoid costly downtime while extending the life of their thermal equipment.
For facilities facing obsolete combustion equipment or increasing downtime on critical oxidizers, we provide the knowledge and hands-on support to keep production and compliance on track.
Looking to extend the life of your thermal systems and avoid costly production interruptions?
Connect with our team today to schedule a consultation and see how we can keep your operation running at peak performance.
