Blog / Hot duct with dust and fume
15 September 2025
integratedAIR, alongside our strategic partner DURR, was approached by a global leading canmaker for a site in Denmark operating an external regenerative thermal oxidiser (RTO) system. The client required a new RTO externally as the existing unit no longer satisfied the production requirements. Additionally, the existing ducting systems that fed into the old system had to be extended and modified whilst accommodating future capacity. With duct temperatures ranging from 70°C to 250°C across the system careful consideration had to be made to ensure high temperature ducting was properly insulated to avoid internal build-up of condensation within the ducting the challenge lay in designing a tailored system for the new hot ducting and a new fume extraction system with filter as well as relocating the existing filters to the new RTO area and changing all existing change over stacks on the roof during a set shut down period.
The project required rigorous planning to adhere to strict production schedules, facilitate the retrofit of complex systems with minimal downtime. All works needed to be carried out without compromising compliance with stringent safety, environmental, and regulatory standards. Despite these constraints, integratedAIR delivered each phase of the installation without disrupting ongoing operations..
The project was strategically divided into three phases, which were completed over 12 months, to address specific functional requirements while ensuring continuity of production. As part of the overall works, integratedAIR also completed a fume enhancement extraction system installation, finalised the high-temperature hot ductwork, and successfully repositioned the filtration units and. These implementations were coordinated in conjunction with our partner DURR as the Main RTO was installed.
For the highest-temperature areas of the ducting system, which operate at a maximum of 250°C, integratedAIR installed 100 mm-thick wired mattress insulation. This mineral wool-based material is designed to perform in sustained high-heat environments, maintaining thermal stability while resisting shrinkage and degradation over time. This insulation was securely fixed and further clad with plain aluminium sheeting, fastened with pop rivets to provide durability and resistance to external elements.
Crucially, integratedAIR delivered a fully integrated, multi-zone extraction system across three active production windows, all while maintaining zero production downtime during installation. The solutions meet stringent standards and comply with site-specific requirements, delivering significant improvements in air quality and maintenance access.
From design to installation, this project required a high level of planning. We faced the challenge, built beyond it, and now we stand on the other side stronger, smarter, and ready for what’s next.
The success of this Abatement project demonstrates why multiple global can makers are continuing to turn to DURR and IntegratedAIR’s partnership for the industry's best Thermal Oxidiser solutions.
At integratedAIR Systems, we deliver intelligent, tailored solutions for abatement and thermal management and ductwork insulation carefully designed to match your process needs.
Contact our expertsto discuss how we can support your next project.
