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.

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.