Catalytic Products International (CPI) recently completed the installation of a new VECTOR Series Catalytic Oxidizer (CatOx) at a Western USA manufacturer of pharmaceutical products for the abatement of Volatile Organic Compounds (VOCs) including isopropyl alcohol (IPA) and acetone.
This new CPI VECTOR-15,000 Catalytic Oxidizer replaces an older 14,600 scfm oxidizer from a competitor which was used to treat the exhaust from two (2) fluidized bed coating processes. The existing oxidizer suffered serious internal degradation and heat damage due to burner flame impingement, resulting in costly and recurring repairs. Repairing the stainless steel interior was not a good long-term solution due to the condition of the interior structure.
Catalytic Oxidizer treatment of VOC's and other air pollutants works by reacting the harmful air pollutants over a specially designed catalyst where VOC's are converted to CO2, water vapor (H2O), and usable heat. These harmless byproducts are passed through a heat exchanger where the gas stream energy is transferred to the incoming exhaust.
Each VECTOR Catalytic Oxidizer utilizes a high velocity mixing chamber at the burner, which forces flame impingement and turbulence to occur, providing excellent mixing of the air stream. This is perhaps the most underestimated part of any catalytic oxidizer, and the key design element that makes VECTOR systems unique. By designing for the highest mixing, VECTOR system can deliver the highest temperature uniformity before the catalyst bed. Temperature uniformity ensures that 100% of the catalyst is efficiently oxidizing the VOC’s.
When the stream enters the catalyst bed, a catalytic reaction occurs and efficiently oxidizes the VOC’s. This VECTOR system is designed to operate with a monolith catalyst product. The systems catalyst is contained in a catalyst T-bar frame and incorporates a ceramic guard bed located prior to the VOC catalyst. The guard bed will trap both inorganic and organic particulate and can be self- cleaned by simply raising the oxidizer temperature. This design will greatly increase catalyst life by prohibiting active surface area being coated with particulate. The VECTOR Catalytic Oxidizer provides a minimum +98% VOC destruction and is not hindered by any operational characteristics.
CPI worked closely with the customer to minimize the downtime associated with the removal of the old oxidizer and installation of the new catalytic oxidizer. Since this was a replacement of an existing oxidizer, CPI could utilize the existing the VOC collection system and particulate removal system. CPI provided on-site supervision to ensure coordination with the third-party sub-contractors and was able to complete a good portion of the installation activities before the new unit arrived on site. This approach guaranteed that entire system was installed correctly, and the facility was back up and producing product with minimal downtime.
Since 1969 CPI has been providing a variety of industries including the pharmaceutical manufacturing industry with solutions to their air pollution control needs.
Today, CPI partners with its customers as a trusted resource in resolving the most complex air pollution and energy conservation problems. We provide our customers with innovative and cost-conscious solutions to their most complex volatile organic compounds (VOC), NOx, hazardous air pollutants (HAPs), and Odor pollution challenges. Our equipment is also at work meeting energy conservation strategies and minimizing greenhouse gas (GHG) emissions.