Sure your RTO saves you money, but does it MAKE you money!

Since the advent of the Clean Air Act in 1970, the EPA has mandated the abatement of
over 100 Hazardous Air Pollutants (HAPS) across the country. When energy wasn’t as precious a
resource as it is today the primary equipment used was the afterburner to break the Volatile
Organic Compounds (VOC’s) into harmless water vapor and carbon dioxide. Greenhouse gas
was not even though of yet.
As the 70’s energy crisis hit the world suppliers evolved the afterburner to make it more
energy efficient. Thus followed the development of the catalytic and recuperative thermal
oxidizers. Either using a lower operating temperature or an upstream heat exchanger or a
combination of both the systems became 70% efficient at best. In addition a number of
economically viable add-ons were used to reclaim the exhaust heat which ranged from 500-900+
ºF.
Systems were fitted with waste heat boilers, steam generators, adsorption chillers,
makeup air systems, etc. Most systems were appropriately applied and the companies benefitted
from the additional energy savings and usage.
As exhaust volumes grew and the process heat values decreased leaner there was a
demand for an even more efficient system. Based on the 1950’s technology of a rotary thermal
regenerator the Regenerative Thermal Oxidizer was born. This system used a multiple number of
chambers containing a ceramic heat sink to increase the thermal efficiency to 95%.
Although the RTO made great strides in saving fuels it left the user with little or no
usable heat on the outlet of the unit for the most efficient RTO’s. A printing application with
minimal VOC loading and an inlet temperature of less than 150 degrees has an outlet
temperature of 250 degrees at best from a 95% TER unit. The economics for additional heat
recovery was poor and in many cases unjustifiable even in the harshest economies.
In 2005, working with Calnetix group out of Cerritos, CA, Robert Miller has developed a
waste heat gas generator that fits just this market. Robert Miller has been working in the power
generation field for over 20 years. Calnetix is a leading developer in high efficiency motors and
generators, and turbo-machinery. In November of 2007 with acquisition of Elliot Energy
Systems Calnetix announces the creation of Calnetix Power Solutions in Stuart, FL.
Originally designed to boost the efficiency of the Microturbine efficiency to over 44%
Robert Miller and Calnetix PS developed the waste heat gas generator to use the thermal energy
coming off the Microturbine. It is this expertise and synergy that Bob exploited to create a turbo
expander module to power the generator in the waste heat gas generator. Seeing the potential for
the waste heat generator Bob decided to explore other industries.
Utilizing the organic rankin cycle energy model, the Waste Heat Generator (WHG-100)
utilizes an organic refrigerant to capture effluent heat from thermal oxidizers to power the turbo
expander module to spin the rare earth alternator at over 30,000 rpm creating 140kW of electrical
power.
The exhaust stack or heat source is retrofitted with an air to liquid evaporator coil that
contains the refrigerant. This heated refrigerant is pressurized and pumped to the power module

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 Sure your RTO saves you money, but does it MAKE you money!

skid through a liquid separator to the expander module that spins the alternator. The high speed
turbine with full heat load can generate 140kW of power.
The power module skid contains the piping, pumps, valving and turbo expander module
for the power generation. Power conditioning is regulated via the Power Electronics module
mounted on the packaged skid.
The refrigerant is then cooled using a condenser or cooling tower before it is pumped
back into the evaporator to complete the cycle.
Requiring only 2.3mmBtu of recovered heat at 230ºF, the WHG-100 can generate 100kW
net of free power. The electricity produced by the system is used directly by the host in lieu of
buying it from the Electric Utility or it can be sold back through the grid.
A company paying $.10/kwh running 8,760 hours per year can realize an annual savings
of $87, 600.00 employing one of our systems. Multiple systems can the paralleled for larger heat
volumes or temperatures. Typical payback period is less than three years.
The end-user could also benefit from any tax incentives or rebates available for
renewable energy applications. Waste heat is already classified as renewable in the States of
Connecticut, Florida, and Nevada in the U.S. and throughout European Union. The WHG100 can
be powered via gases, liquids, or vapors such as steam.
Major markets include customers with stationary engine or turbine exhaust such as
landfill gas plants, solid waste plants, wastewater treatment plants, gas compressors, distributed
generation prime movers, combined heat and power production units, and the food industries.
Call Calnetix Power Solutions at 772-219-9449 in Stuart, FL to find a local Sales
Representative for your area.

Paul Stefanic
Thermal Systems Services, Inc.
920 Thornewood Lane
Algonquin, IL 60102
847-854-9818
tssinc-us@comcast.net www.tssinc-us.com