How a Catalytic Oxidizer Works
Efficiently Control Air Pollution with Catalytic Oxidizers
Our advanced catalytic oxidizers are designed to deliver exceptional efficiency, significantly reduce emissions, and ensure environmental compliance.
How does a Catalytic Oxidizer work?
Catalytic Oxidizers are air pollution control devices designed to destroy volatile organic compounds (VOCs) and other pollutants by oxidizing them into carbon dioxide and water vapor. They achieve this through a catalytic reaction that allows oxidation to occur at lower temperatures compared to thermal oxidizers, making them energy-efficient and cost-effective.
A pollutant-laden airstream is pushed through the oxidizer, usually with a system fan (1). When equipped with an air-to-air heat exchanger, the flow of air will pass through the air-to-air heat exchanger (2) to preheat the air before entering the burner/combustion chamber (3). In the combustion chamber, the air is heated to a sufficiently high (>600F) temperature and then passes through the catalyst material (bed) (4) where VOCs are destroyed. The hot, cleaned air then continues through a hot pass of the heat exchanger (if a heat exchanger is used) (5). The cooled, clean air is then exhausted to the atmosphere (6).
Advantages and disadvantages of catalytic systems over other technologies such as regenerative thermal oxidizers are discussed in this comparison of thermal oxidizers.
The Catalytic Oxidation Process
- Preheating the Polluted Air: The process begins with the polluted air being drawn into the system by a fan. This air is preheated using a heat exchanger, which transfers heat from the outgoing clean air to the incoming polluted air. This step reduces the amount of additional energy required from the burner to reach the optimal temperature for the catalytic reaction.
- Final Heating of the Polluted Air: The air exiting the heat exchanger is further heated to the set-point temperature by the burner.
- Passing Through the Catalyst Bed: The polluted air then passes through a catalyst bed. The catalyst, typically made of precious metals like platinum or palladium, facilitates the oxidation of VOCs at lower temperatures (between 500°F and 1000°F). The catalytic reaction converts VOCs into carbon dioxide and water vapor. The air exiting the catalyst bed is clean and is also hotter than when it entered the catalyst bed. The destruction of VOCs is exothermic, giving off heat as the VOCs are oxidized. This heat release raises the temperature of the air as it passes through the catalyst bed.
- Heat Recovery: The air exiting the catalyst bed is clean and hot. This hot air is used to preheat the incoming polluted air in the heat exchanger. Utilzing a heat exchanger significantly reduces the energy needed for the oxidation process. Typical thermal efficiencies (effectiveness) of a heat exchanger in a catalytic oxidizer is 70%.
- Exhausting the Clean Air: Finally, the cleaned air, now free of VOCs and other pollutants, is released into the atmosphere. The exhaust air is typically much cooler than the air entering the system, thanks to the heat recovery process.
Benefits of Catalytic Oxidizers
Catalytic oxidizers operate at lower temperatures than thermal oxidizers, reducing fuel consumption and operating costs. When configured with a heat exchanger they also can be comparable to regenerative thermal oxidizers (RTO) in fuel/electric efficiency. They can achieve destruction efficiencies of up to 99% for VOCs and other pollutants, ensuring compliance with stringent environmental regulations. The lower operating temperatures of a CATOX leads to long life of the equipment and reduces maintenance costs. They also are lightweight compared to RTO systems.
Applications of Catalytic Oxidizers
- Chemical Manufacturing: Effective in controlling emissions from chemical production processes.
- Paint and Coating: Used to treat exhaust from paint booths and coating operations.
- Pharmaceuticals: Helps in reducing emissions from pharmaceutical manufacturing processes.
- Food Processing: Controls odors and emissions from food processing plants.
Maintenance and Operation
In terms of CATOX maintenance and operation, regular inspections are necessary to ensure the catalyst is functioning properly and the heat exchangers are clean. Routine maintenance helps in identifying potential issues before they become major problems. Over time, the catalyst may need to be replaced to maintain efficiency. The lifespan of the catalyst depends on the type of pollutants being treated and the operating conditions. Continuous monitoring of system performance helps in early detection of issues and ensures optimal operation. Advanced control systems can provide real-time data on the performance of the catalytic oxidizer, allowing for proactive maintenance.
Catalytic Oxidizers offer an efficient and cost-effective solution for controlling air pollution. By using a catalytic reaction at lower temperatures and incorporating heat recovery, they provide high destruction efficiencies and energy savings. Their versatility makes them suitable for various industrial applications, helping industries reduce their environmental impact while maintaining operational efficiency.
CATOX Frequently Asked Questions
Get quick answers to common questions about Catalytic Oxidizers (CATOX)
In most cases, yes. But proper evaluation is recommended to establish that no potential catalyst poisons or masking agents are present in your airstream.
Catalyst utilized in a regenerative catalytic oxidizer (RCO) allows chemical reactions to occur at lower temperatures (700-800F) than they occur in a thermal oxidizer (typical 1400-1450F) or an RTO (typical 1600F).
Your operating permit will define a time (typically every 5 years), but a wise maintenance practice is to test annually as part of a preventive maintenance inspection.
RCOs offer greatest fuel economy by far, while recuperative units may be best for high VOC concentration airstreams (or an RTO can be considered).
It depends on numerous factors. See Selecting an Oxidizer for guidance or call us for guidance.
Extensive catalyst application experience allows our engineers to select the best catalyst type, and pair it with an optimized ceramic media mix for long life, and for low fuel and electric use.
Up to 99% VOC destruction efficiency; and up to 97+% thermal efficiency.
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