In industrial facilities, where a number of different processes occur containing different types of material, harmful emissions are released causing a need for environmental cleaning devices to be integrated into the facility. Environmental cleaning devices play an important role in protecting workers’ health and safety, ensuring compliance with environmental regulations, and reducing harmful emissions into the air and environment surrounding the facility. Understanding the pollutants in your facility will help determine the best type of device needed to reduce emissions.

What Are Emissions?

According to Merriam-Webster, emissions are something that is sent forth by emitting, such as substances, and especially pollutants discharged into the air. In industrial processes, harmful emissions could be that of nitrogen oxide, ammonia, mercury, carbon dioxide, particulate matter (PM), sulfur dioxide, volatile organic compounds (VOCs), and heavy metals. Because there are different types of pollutants, emission standards can vary depending on the industry.

Compliance Regulations

The Environmental Protection Agency’s (EPA) mission is to protect human health and the environment, and works to ensure Americans have clean air, land and water. In order to fulfill their mission, they are responsible for writing regulations, enforcing those regulations and helping companies understand the requirements. The EPA breaks down the regulations by sectors, including agriculture, mining, paper, pulp and lumber manufacturing, oil and gas, plastics, food processing, electric power generation, transmission and distribution and many others. Under the Clean Air Act, the EPA sets limits on certain air pollutants, including setting limits on how much can be in the air anywhere in the United States. Because of this, facilities integrate different environmental cleaning devices into their facility based on their processes to help regulate and reduce emissions into the atmosphere, protecting the environment and workers.

Types of Environmental Cleaning Devices

Depending on the type of industry and process, the environmental cleaning device differs based on that facility’s need. While there may be similar qualities within industries involving the same type of device, it’s important to understand your facility’s specific pollutant and ensure the right device is in place.

RTOs & RCOs

Both Regenerative Thermal Oxidizers (RTOs) and Regenerative Catalytic Oxidizers (RCOs) play a crucial role in controlling volatile organic compounds (VOCs) that are emitted in various processes. While they are similar in their purpose, it’s important to understand each device’s unique characteristics and the type of VOC they can handle.

Regenerative Thermal Oxidizers (RTOs) are an efficient air pollution control device that destroys volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) through thermal oxidation, achieving high thermal recovery and destruction effectiveness. RTOs are ideal for facilities with high-volume exhaust streams and variable VOC concentrations, such as refineries, wood processing, and chemical plants, where durability and high destruction efficiency are critical.

Regenerative Catalytic Oxidizers (RCOs) are also an advanced air pollution controls system that efficiently reduces VOCs and other pollutants while minimizing energy consumption. RCOs are better suited for clean, consistent airstreams with lower VOC loads, such as those in printing, electronics, coatings, and pharmaceutical manufacturing, offering the added benefit of lower energy use due to catalytic operation.

Both devices have a high VOC destruction efficiency, that turn VOCs into CO₂ and water vapor, greatly reducing the facility’s environmental footprint and maintaining clear emissions.

• • RTOs typically destroy over 98-99% of VOCs and other pollutants.
  • RCOs typically achieve >95-98% destruction efficiency for VOCs and odors.

While RCOs tend to have lower energy costs overall, both RTOs and RCOs prove to be energy efficient and significantly help lower the amount of fuel required, especially in continuous operations.

• RTOs recover up to 95% of heat, due to their regenerative heat exchange design.
• RCOs use a catalyst to enable oxidation at 482-932°F compared to the ~1472-1832°F at which RTOs operate.

Both RTOs and RCOs provide excellent reliability when used for the right process, and are designed for long term, low maintenance operation with automated controls.

• RTOs are well-suited for industries with high-volume continuous exhaust streams and variable VOC concentrations.
• RCOs work best with continuous or semi-continuous processes, low to moderate VOC loading and stable flow rates and temperatures.

Wet and Dry Electrostatic Precipitators (ESPs)

Wet and Dry Electrostatic Precipitators (ESPs) are other types of air pollution control devices that manage fine particulate emissions. These systems are essential for achieving high-efficiency dust and mist collection, especially in processes where traditional filtration isn’t enough to meet environmental or safety standards.

Dry ESPs are ideal for high temperature processes such as those in power generation, mining, pulp and paper, and wood processing, where collecting dry particulate is critical for emissions control. They are well-suited for large-scale applications like boilers, kilns, and incinerators.

Wet ESPs are better suited for applications with sticky, corrosive, or submicron particles such as in sulfuric acid plants, refineries, food processing, and chemical manufacturing, where moisture is used to enhance collection and prevent re-entrainment.

Both dry and wet ESPs have a high collection efficiency, and can remove 99%+ of fine particles, including PM2.5, submicron aerosols, and mists. Additionally, ESPs offer minimal resistance to airflow, resulting in lower energy costs for fans compared to traditional baghouses or filters.

The Importance of Environmental Cleaning Devices

At JBW we know that EPA compliance and operational safety go hand-in-hand when it comes to environmental cleaning devices in industrial facilities. Whether it’s controlling volatile organic compounds (VOCs), particulate matter (PM), or hazardous air pollutants (HAPs), staying ahead of regulations not only protects your people and equipment, but it also protects your business.

Some key tips to remember when it comes to your facility and air quality are knowing the applicable regulations.

• Identify which federal (EPA, MACT, NSPS) and state/local air quality rules apply to your facility.
• Focus on key pollutants: PM, VOCs, HAPs, NO_x, SO₂, and opacity limits.

Conducting a baseline emissions assessment at your facility and keeping documentation and reporting up to date are key to keeping your operations running smoothly.

• Measure emissions before and after pollution control to demonstrate compliance.
• Use EPA approved testing methods.
• Keep detailed records for audits and compliance certification.
• Maintain calibration records, stack test results, maintenance logs, and deviation reports as required by your air permit.
• File timely reports (semiannual, annual compliance, excess emissions) to regulators.

Remember to choose the right cleaning device for your facility by matching the device to your pollutant type, load, and temperature.

• RTOs are excellent for high-volume VOC destruction.
• RCOs are efficient for lower-temp, cleaner VOC streams.
• Dry ESPs are great for dry particulate matter at high temperatures.
• Wet ESPs are best for acid mist, sticky or fine aerosols.
• Scrubbers are good for soluble gases, mist, and odor control.

Just as important as it is to remain compliant with regulations, it’s just as important to prioritize operator safety and training.

• Ensure operators are trained in lockout/tagout (LOTO), confined space entry, high-voltage safety, and handling of corrosive or hot gases.
• Maintain clear SOPs for inspection, startup, and shutdown.
• Monitor and ventilate areas where cleaning agents or gases may accumulate.

Finally, maintaining and monitoring equipment proactively helps to reduce additional costs and unplanned shutdowns.

• Perform regular preventative maintenance to avoid breakdowns that lead to permit violations.
• Monitor key indicators like:
  • Pressure drop (baghouses, scrubbers).
  • Burner temp (RTO/RCO).
  • Opacity readings (ESPs).
  • Fan speed, flow rates, and pH (scrubbers).

No matter what the device or process is, our team at JBW provides tailored solutions to help facilities select, design, and maintain the right environmental cleaning device, from ESPs to RTOs and scrubbers. We work closely with clients to ensure their systems meet regulatory standards, operate safely, and deliver long-term reliability and compliance confidence.