---
title: RTO Savings Guide
description: "RTO Savings Guide: Cut Down on Repacks, Energy Costs, and Unplanned Shutdowns"
image: https://info.knightmaterials.com/hubfs/KMT%20Thumbnail.png
---

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RESOURCE

# RTO Savings Guide

 

## Cut Down on Repacks, Energy Costs, and Unplanned Shutdowns

Looking to reduce downtime and save on operational costs? Learn how switching to FLEXERAMIC® structured packing in your regenerative thermal oxidizer (RTOs) can help. In our detailed guide, we explore the advantages of structured vs. random ceramic media, with real-world case studies showing how this simple switch leads to: 

- **Fewer repacks** and extended media lifespan
- **Lower energy consumption** with improved thermal efficiency
- **Minimized unplanned shutdowns** for better operational uptime

Discover how these benefits lead to significant cost savings and improved productivity. 

![knt-wtpp-regenerative-thermal-oxidizer-v02](https://info.knightmaterials.com/hubfs/knt-wtpp-regenerative-thermal-oxidizer-v02.jpg "knt-wtpp-regenerative-thermal-oxidizer-v02")

### Get the Guide Now

### **Download the full guide to explore:**

- Data-backed comparisons of structured and random ceramic media

- Case studies detailing energy savings and reduced downtime

- Expert tips for maximizing RTO performance

**Unlock valuable insights for your operation. Download the PDF now!** 

### **Structured packing checklist**

   
     **✓**   Made in America   
     **✓**   Reduce bed depth    
     **✓**   Minimize plugging    
     **✓**   Maximize gas distribution in the bed    
     **✓**   Increase capacity in the unit    
     **✓**   Reduce fuel costs    
     **✓**   Lower pressure drop    
     **✓**   Utilize entire bed instead of a fraction 

### **FLEXERAMIC Competitive Advantage**

FLEXERAMIC structured packing provides 35% lower pressure drop as compared to 1” ceramic saddles at the same gas flow. 

| **FLEXERAMIC® Structured Packing** |
| --- |

| **FLEXERAMIC® Structured Packing TYPE 28** |  |  |  |  |
| --- | --- | --- | --- | --- |
| Block Dimension | % Void Space | Surface Area | Packing Density | Crush Strength |
| 12 1/8 x 12 1/8 x 12 1/8 (+/- .25 in) 308 x 308 x 308 mm (+/- 6mm) | 77% | 98 ft²/ft³ 320 m²/m³ | 35 lbs/ft³ 560 kg/m³ | 150 psi 10.5 kg/cm² |

| **TER** (Thermal Energy Recovery Efficiency) |  |  |  |  |  |
| --- | --- | --- | --- | --- | --- |
|  | 150 SCFM /FT² | 200 SCFM /FT² | 250 SCFM /FT² | 300 SCFM /FT² | 350 SCFM /FT² |
| FLEXERAMIC® 28 Structured Packing | 95.54% | 95.12% | 94.77% | 94.46% | 94.19% |
| 1" LPD® Random Packing | 93.46% | 92.86% | 92.35% | 91.91% | 91.53% |
| 1" FLEXISADDLE® Random Packing | 93.46% | 92.86% | 92.35% | 91.91% | 91.53% |

| **Pressure Drop** (inches wc through inlet and outlet beds) |  |  |  |  |  |
| --- | --- | --- | --- | --- | --- |
|  | 150 SCFM /FT² | 200 SCFM /FT² | 250 SCFM /FT² | 300 SCFM /FT² | 350 SCFM /FT² |
| FLEXERAMIC® 28 Structured Packing | 3.8" | 6.8" | 10.6" | 15.3" | 20.9" |
| 1" LPD® Random Packing | 4.7" | 8.3" | 13.0" | 18.8" | 25.7" |
| 1" FLEXISADDLE® Random Packing | 5.9" | 10.6" | 16.6" | 23.9" | 32.6" |

Conditions: Based on two 8' deep beds with 70°F inlet, 1500°F combustion, and 180 second switch time. Fuel is natural gas with 0% excess combustion air added.

 

#### About Knight Material Technologies

Founded in 1910, Knight Material Technologies (KMT) designs, installs, services and manufactures custom acid-resistant linings used in highly corrosive processes for the chemical and mining industries worldwide. Headquartered in East Canton, OH, the company sells products in more than 40 countries, with sales offices in Australia and Chile and a fabrication shop in Baytown, Texas. In addition, KMT produces industry-leading ceramic packing media for chemical processing and regenerative thermal oxidation systems with customers in a wide range of industrial applications. It markets fluoropolymer linings under the Electro Chemical Manufacturing (ECM) brand and fiberglass-reinforced plastic dual laminate equipment under its Superior Dual Laminate Products (SDL) brand. 

## Need Additional Heat Transfer and Acid-Resistant Solutions?

Learn more about products, lining and coating systems, installation services and engineering consulting at:

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