A regenerative thermal oxidizer (RTO) is an industrial air pollution control system that destroys volatile organic compounds (VOCs) in process exhaust while recovering heat to reduce fuel consumption.
TANN Corporation designs and manufactures regenerative thermal oxidizers for demanding industrial applications. Our systems combine high destruction efficiency, regenerative heat recovery, and heavy-duty construction to deliver reliable long-term performance.
- VOC destruction efficiency up to 99%+
- Thermal efficiency up to 97%
- Heavy-duty equipment manufactured in-house
- Engineered and built in Kaukauna, Wisconsin
What Is a Regenerative Thermal Oxidizer?
A regenerative thermal oxidizer (RTO) is an industrial air pollution control system that destroys volatile organic compounds (VOCs) in process exhaust through high-temperature oxidation.
Unlike conventional thermal oxidizers, regenerative designs use ceramic heat exchange media to recover heat from treated exhaust. This stored energy preheats incoming process air, reducing fuel consumption while maintaining high VOC destruction efficiency.
How a Regenerative Thermal Oxidizer Works
Explore the regenerative heat recovery process, airflow reversal, and operating principles in TANN's technical PDF.
View Technical PDF →How a Regenerative Thermal Oxidizer Works
A regenerative thermal oxidizer uses ceramic heat exchange media to recover heat while destroying VOC emissions. The process follows three main stages:
1. Preheating the Process Exhaust
Industrial exhaust enters the first media chamber, where ceramic saddles or honeycomb blocks transfer stored heat to the incoming air. As a result, the exhaust reaches the combustion chamber at a higher temperature, reducing the need for supplemental fuel.
2. Destroying VOC Emissions
The preheated exhaust enters the combustion chamber, where high temperatures oxidize VOCs into carbon dioxide and water vapor. The burner supplies additional heat when needed to maintain the required oxidation temperature.
3. Recovering Heat and Reversing Airflow
After combustion, the cleaned exhaust passes through the second ceramic media chamber, transferring heat to the media before exiting the system. Typically, every 2–4 minutes, poppet valves reverse the airflow direction. Consequently, the heated outlet chamber becomes the inlet chamber, allowing the system to reuse stored energy.
See the Regenerative Cycle in Action
These animations show how the inlet and outlet chambers alternate during operation. This repeating cycle supports high thermal efficiency and reduces fuel consumption.
Before the switch: exhaust enters through the left media chamber and exits through the right chamber after combustion.
After the switch: the poppet valves reverse airflow, allowing the previously heated outlet chamber to preheat incoming exhaust.
Regenerative Thermal Oxidizer Performance and Design
TANN designs regenerative thermal oxidizers around each facility's airflow, emissions, and operating requirements. System performance depends on factors such as VOC concentration, inlet temperature, required destruction efficiency, and operating schedule.
Performance and Efficiency
Regenerative thermal oxidizers combine high VOC destruction efficiency with regenerative heat recovery. As a result, they can reduce fuel consumption compared to less efficient thermal oxidizer designs.
- VOC destruction efficiency up to 99% or higher, depending on system design
- Thermal efficiency up to 97%
- Reduced natural gas consumption through ceramic heat recovery
- Potential self-sustaining operation under sufficient VOC loading
Under suitable operating conditions, the heat released during VOC oxidation can maintain the required temperature without supplemental burner fuel. This self-sustaining operation can further reduce operating costs.
Regenerative Thermal Oxidizer Configurations
The appropriate configuration depends on process airflow, emissions requirements, production schedules, and the facility's long-term operating needs.
Two-Chamber RTO Systems
Two-chamber systems use alternating ceramic media beds to recover heat from treated exhaust. They provide an efficient solution for many continuous industrial applications.
Three-Chamber and Puff Capture Designs
Three-chamber systems and puff capture arrangements can help reduce untreated emissions during airflow reversal. These designs may be appropriate for applications with demanding destruction efficiency or odor control requirements.
Tandem RTO Systems
Tandem arrangements integrate multiple oxidizers to increase process capacity and improve operating flexibility. They are useful for plant expansions and applications requiring production continuity.
Custom Engineering and Design Capabilities
Custom Airflow Capacity
Each system is sized for the required process airflow. Fan capacity, ceramic media beds, and valve configurations are selected for the application.
Regenerative Heat Recovery
Ceramic heat exchange media captures energy from treated exhaust and transfers it to incoming process air, reducing supplemental fuel demand.
Integrated System Design
TANN engineers systems for new installations, plant expansions, and integration with existing pollution control equipment.
Key Components of a Regenerative Thermal Oxidizer
A regenerative thermal oxidizer relies on several components working together to control airflow, recover heat, and destroy VOC emissions. Each component plays an important role in maintaining reliable system performance.
Ceramic Media Beds
Ceramic media stores heat from treated exhaust and transfers it to incoming process air. This heat recovery reduces the amount of supplemental fuel required during operation.
Poppet Valves
Poppet valves control airflow direction through the ceramic media chambers. Reliable sealing and consistent switching help maintain destruction efficiency and long-term performance.
Burner System
The burner heats the system during startup. It also provides supplemental energy when VOC loading is insufficient to maintain oxidation temperature.
Combustion Chamber
The combustion chamber maintains the temperatures needed to oxidize VOCs into carbon dioxide and water vapor. Proper temperature control supports consistent emissions performance.
Fans and Airflow Control
Fans, dampers, and ductwork move process exhaust through the system while maintaining appropriate airflow and pressure conditions.
Controls and Instrumentation
PLC controls, HMIs, temperature sensors, pressure transmitters, and safety interlocks help operators monitor and control system operation.
TANN-Engineered Poppet Valves
TANN manufactures and tests its poppet valves in Kaukauna, Wisconsin. By controlling production in-house, we maintain oversight of valve construction and quality.
Our valves feature machined metal-to-metal sealing surfaces instead of conventional gaskets. In addition, we use finite element analysis (FEA) to evaluate blade strength and durability. These design choices support reliable switching and long service life.
TANN-manufactured poppet valve assembly used to control airflow in a regenerative thermal oxidizer.
Why Choose TANN for Your Regenerative Thermal Oxidizer?
TANN Corporation designs and manufactures regenerative thermal oxidizers in Kaukauna, Wisconsin. With in-house engineering, fabrication, and testing capabilities, we maintain direct control over critical aspects of system quality and construction.
In-House Engineering and Manufacturing
Our team designs and manufactures key RTO components in-house. This approach gives us greater control over equipment quality, fabrication, and system integration.
Heavy-Duty Construction
TANN systems are built for demanding industrial environments. Refractory-lined chambers and durable components help protect equipment during high-temperature operation.
Integrated Controls and Monitoring
Our systems incorporate controls and instrumentation for monitoring operating conditions, identifying faults, and supporting dependable operation.
Long-Term Service and Support
TANN supports customers beyond installation with maintenance, troubleshooting, and aftermarket services to help keep equipment operating reliably.
Featured Project: 50,000 SCFM Tandem Regenerative Thermal Oxidizer
TANN designed and manufactured a 50,000 SCFM regenerative thermal oxidizer to operate alongside an existing 50,000 SCFM unit. Together, the two systems provide 100,000 SCFM of combined nominal capacity.
Instead of replacing the existing oxidizer, the facility expanded its emissions control capacity while supporting continued production. The tandem arrangement also provides greater operating flexibility.
TANN worked with plant personnel to evaluate airflow requirements, system balance, and integration with the existing equipment. Our team engineered and manufactured the new RTO in-house, including its reaction chambers, ceramic media chambers, and poppet valves.
Existing RTO: 50,000 SCFM
New TANN RTO: 50,000 SCFM
Combined nominal capacity: 100,000 SCFM
Configuration: Tandem operation
Reaction chamber fabrication for the new 50,000 SCFM regenerative thermal oxidizer installed in a tandem configuration.
Regenerative Thermal Oxidizer Industries and Applications
TANN regenerative thermal oxidizers serve a wide range of industrial applications, including manufacturing processes that generate VOC emissions, solvent-laden exhaust, and odors. Each system is engineered around the facility's specific emissions and operating requirements.
- Automotive Manufacturing
- Aerospace Manufacturing
- Can Manufacturing
- Adhesive Coating
- Film Coating
- Printing & Graphic Arts
- Packaging Products
- Paint & Finishing Operations
- Paper Processing
- Petroleum & Chemical Processing
- Pharmaceutical Manufacturing
- Animal Rendering
- Wood Products & Finishing
- Filter Paper Manufacturing
- Asphalt Production
- Engine Test Stands
- Ethanol Production
- Semiconductor Manufacturing
Regenerative Thermal Oxidizer Cost and System Selection
The cost of a regenerative thermal oxidizer depends on process airflow, VOC loading, system configuration, and installation requirements. Evaluating these factors early helps establish a realistic project budget while accounting for long-term operating costs.
What Affects RTO Cost?
Airflow Requirements
Higher airflow typically requires larger fans, valves, ceramic media beds, and structural components.
VOC Loading
VOC concentration and composition affect system design, burner requirements, and supplemental fuel consumption.
System Configuration
Two-chamber, three-chamber, and specialized configurations have different equipment, performance, and cost requirements.
Thermal Efficiency
Higher heat recovery can reduce fuel consumption and lower operating costs over the system's life.
Controls and Integration
Custom controls, plant integration, monitoring, and data logging can influence project scope.
Installation Requirements
Foundations, ductwork, utilities, electrical work, and startup requirements affect total installed cost.
Choosing the Right Oxidizer Technology
Regenerative thermal oxidizers are often well suited for continuous industrial processes where high heat recovery can reduce operating costs. However, direct-fired, recuperative, and catalytic oxidizers may be better suited to certain exhaust conditions. For high-airflow, low-VOC applications, pairing a concentrator with an RTO may also be worth evaluating.
Explore our thermal oxidizer technologies to learn more about available options.
What We Need to Quote Your RTO
Providing a few process details helps TANN evaluate your application and prepare an appropriate proposal.
Information to Get Started
- Process airflow (SCFM or ACFM)
- Inlet air temperature
- VOC composition and concentration (ppm or lbs/hr)
- Operating hours per day and days per year
- Required destruction efficiency
- Project location and site conditions
Don't have every detail yet? TANN can begin with preliminary process information to develop a budgetary estimate, then refine the design as project requirements become clearer.
Frequently Asked Questions About RTO Systems
Regenerative Thermal Oxidizer Resources
Explore TANN's maintenance and upgrade services to support reliable performance throughout the life of your regenerative thermal oxidizer.
RTO Maintenance and Service
Learn about preventive maintenance, inspections, troubleshooting, and service options that help keep your equipment operating reliably.
Explore RTO Maintenance →RTO Upgrades and Retrofits
Explore equipment upgrades, controls modernization, and retrofit options to improve system performance and extend equipment service life.
Explore RTO Upgrades →Discuss Your Regenerative Thermal Oxidizer Project With TANN
Planning a new RTO installation or upgrading an existing system? TANN's engineering team can help evaluate your process requirements, discuss equipment options, and determine the right solution for your facility.