Regenerative Thermal Oxidizers for VOC & Emissions Control

Malco fabricates regenerative thermal oxidizers (RTOs) engineered for industrial VOC and HAP destruction. These systems offer high-efficiency emissions control through heat recovery and thermal oxidation, and we build them fast, to spec, and fully integrated.

Whether you’re operating in petrochemical, power, or renewables, Malco delivers responsive RTO fabrication across North America. From raw plate to wired, insulated, and coated assemblies, we build the system you need, on the timeline you have.

What Is a Regenerative Thermal Oxidizer?

A regenerative thermal oxidizer (RTO) destroys volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) by heating exhaust air to combustion temperatures. Its unique energy recovery process dramatically cuts fuel use, ceramic beds transfer heat from outgoing clean air to incoming process air.

Every Malco RTO is custom-fabricated to meet extreme thermal, chemical, and structural demands.

How RTO Systems Work

1. Polluted Air Intake
Contaminated process air enters one of the RTO chambers.

2. Pre-Heating via Ceramic Media
The air passes through ceramic media beds, gaining heat from previous cycles.

3. Thermal Oxidation
Air is heated to approximately 1,400°F in the combustion chamber, where VOCs and HAPs are oxidized and eliminated.

4. Heat Recovery
Exiting clean air transfers its heat to the next cycle, making the system highly fuel-efficient.

5. Clean Exhaust Output
Emission-free air is safely released into the atmosphere.

Why Industrial Teams Choose Malco for RTO Fabrication

Malco is built for critical-path fabrication projects where timing, complexity, and execution matter. Our 20-acre facility includes a 40-foot under-hook crane capacity and full in-house fabrication capabilities, from plate cutting and rolling to welding, wiring, coating, and insulation. We specialize in high-heat fabrication at the intersection of refractory and emissions control.

With fully integrated processes and rapid project coordination, Malco eliminates delays caused by multi-vendor sourcing. We build complete RTO systems under one roof and on your schedule.

Integrated Fabrication with Built-In Refractory Support

Malco is more than a fabricator. We’re a single-source partner equipped to handle every stage of your build. We manufacture our own refractory hardware, supply the ceramic fiber and refractory materials, and perform all sandblasting, painting, and assembly in-house. This end-to-end capability not only shortens lead times, it eliminates the need for multi-vendor coordination, a competitive advantage that keeps your project moving.

Key Advantages of Malco RTO Units

Malco RTOs offer destruction efficiencies greater than 99%, engineered specifically to meet your airflow, BTU, and pressure specifications. Heat recovery systems use high-performance ceramic beds to reduce fuel usage significantly. Each system is constructed from corrosion-resistant stainless or specialty alloys and includes fully integrated mechanical, structural, and electrical components, all fabricated in-house.

As a veteran-founded U.S. manufacturer, Malco has been known for speed and responsiveness since 1982.

Industries & Applications Served

Malco fabricates regenerative thermal oxidizers for emissions-heavy industries throughout North America. We support operations in petrochemical processing, power generation (including HRSG systems), battery recycling, renewables like wood pellet plants, pulp and paper, cement and aggregates, and complex fabrication work for OEMs and EPCs.

Custom Options & Features

Our RTO systems can be built as modular or skid-mounted units and configured with dual or triple combustion chambers. Custom burners, ignition systems, and refractory lining are available to match your exact performance needs. We fabricate using carbon steel, stainless steel, and specialty alloys, and offer integration of fans, dampers, controls, instrumentation, and complete wiring. Exterior coatings and industrial finishes ensure long-lasting protection in harsh environments.

Our Fabrication Advantage

Your RTO system isn’t off-the-shelf, and neither are we. Malco delivers faster turnarounds through single-source project execution. We coordinate directly with your engineers and project managers to build smarter, more efficient systems. Our in-house QA, certified welding, and fully integrated mechanical and electrical fabrication ensure top-tier quality.

We don’t just cut and weld, we deliver finished, ready-to-install RTO systems.