A Catalytic Oxidizer is a combustion device that controls volatile organic compounds (VOCs), hazardous air pollutants (HAPs), and odorous emissions by reacting the pollutants over a specially designed catalyst and converting the pollutants into CO2, H2O, and usable heat.
A catalyst is a substance that is used to accelerate the rate of a chemical reaction, allowing the reaction to occur faster and at a lower temperature range. The catalyst may be precious metal, such as platinum or palladium, or it may be a basic metal, such as metal oxides or metal carboxylates using iron, vanadium, or molybdenum.
A catalytic oxidizer uses a heated bed of precious metal catalyst to destroy VOCs from process exhaust streams at temperatures ranging from 400 F to 750 F, much lower than temperatures utilized in a thermal oxidizer.
As a catalytic oxidizer manufacturer, CPI offers extensive knowledge - in both oxidizers and catalyst technologies - necessary to achieve the most complete and cost effective elimination of VOCs.
The CPI Recuperative Catalytic Oxidizer combines a low-temperature oxidation catalyst, primary heat exchanger, and an efficient combustion system in a convenient integrated package. These systems are easy to install, provide very high VOC removal efficiency, and offer low operating costs. With zero moving parts in the reactor, the CPI Catalytic Oxidizer provides the highest uptime reliability and long equipment life.
Catalytic treatment of VOCs and other air pollutants works by reacting the harmful air pollutants over a specially designed catalyst where VOCs are converted to CO2, water vapor (H2O), and usable heat. These harmless byproducts are passed through a heat exchanger where the gas streams energy is transferred to the incoming exhaust.
A booster fan draws VOC-laden exhaust from the process lines into the system.
The VOC laden exhaust is directed to our unique stainless steel primary air-to-air heat exchanger where energy is transferred to the process exhaust before passing through to the preheat burner. The main heat exchanger can eliminate the auxiliary fuel required for operation.
A pre-heat burner is used to maintain the desired catalyst inlet temperature precisely. The burner is designed to promote mixing of the exhaust gasses with oxygen when fired through our specialized burner plenum. This innovative design provides the highest degree of flame impingement and high-velocity mixing, leading to airflow and temperature uniformity for which CPI Catalytic Oxidizers are known.
The pre-heated exhaust stream then enters the catalyst bed and reacts with the specially selected catalysts where an exothermic reaction occurs, leading to complete combustion of the VOCs. The oxidation of hydrocarbons (VOCs) typically results in carbon dioxide, water vapor (H2O), and useable heat. The catalyst-induced oxidation level for most VOCs occurs at temperatures between 400 F and 750 F. This is sufficient to achieve a VOC destruction efficiency of 99%.
The cleaned exhaust is sent to the primary heat exchanger to give its heat up to the incoming exhaust gas for pre-heating purposes. After the primary heat exchanger, the cleaned exhaust is sent to the atmosphere or to auxiliary heating systems such as; secondary air to air recovery, air to water recovery, or directly back to the process in a closed-loop direct recirculation process.
Catalytic oxidizers are recommended for processes with low concentrations of VOCs where a TO would be impractical and an RTO would be oversized.
A Catalytic Oxidizer is applied to a broad range of industrial processes especially applications with no halogenated compounds, sulfurs, silicone, or particulates. Common processes and applications using Catalytic Oxidizers include:
CPI Catalytic Oxidizers meet today's environmental challenges by using the most cost-effective manufacturing techniques to bring to industry reliable pollution control systems that offer lower capital costs, simplified installations, and minimal maintenance.
Integrating all the major components into one unitized system saves on field installations, improves reliability, and lowers the overall costs of air compliance. The CPI Catalytic Oxidizer System utilizes only the highest quality components. From the all stainless steel mixing and combustion chamber, the heavy-duty, heat exchanger, the specialized burner system, to the catalyst system, each component is contained within a well insulated, maintenance-free exterior designed for long life and low costs.
Each CPI Catalytic Oxidizer System is custom engineered and built for maximum performance and flexibility. Therefore, the catalyst is selected based on the ability to provide the highest performance and longest life. Pressure requirements, particulate size, solvent types, concentrations, performance requirements, installation requirements all come into catalyst design consideration. The catalyst choices can include precious metal group metals on a pourable bead or a monolith support. Each group offers individual benefits for each application. For beaded catalyst products, poison-resistant catalyst provides resistance to many common contaminates while low-temperature formulations allow minimal fuel input. The most noticeable advantage about CPI Systems is found in the innovative, split-bed containment system. The catalyst is contained in a specially developed catalyst tray that offers partial catalyst replacement, faster inspections, cross-sectional analysis, and longer life. Monolith Catalyst groups are used for general industrial applications or for specialized emissions.
Learn more about how catalyst works in a Catalytic Oxidizer: Catalytic Oxidizer General Operating Conditions
CPI Catalytic Oxidizer Systems lead the industry with the lowest operating costs. The primary heat exchangers are made of all high-grade stainless steels and incorporate our unique floating plate expansion system. This unique design provides for long life, high efficiency, and the ability to accommodate the highest solvent loads. Catalytic Oxidizer heat exchangers can be designed with thermal efficiencies in excess of 80% and can be equipped with fully automatic hot gas or cold gas bypass dampers for self-sustaining operations.
The CPI Catalytic Oxidizer System is fabricated entirely of stainless steel alloys designed to prevent embrittlement and fatigue. The entire unit is continuously welded to eliminate hydrocarbon leakage and provide the highest uptime reliability. All the interior components are fully insulated with a high quality lining system designed to reduce heat losses for continued energy savings.
Every CPI Catalytic Oxidizer system is integrated to our customized PLC-control panel called TSS. TSS communicates with the CPI system and your process for optimal performance, safety, and reliability. TSS optimizes fuel efficiency by managing temperatures, controlling drives, and positioning valves. This user friendly system provides automated operations, one button start-stops, self diagnostics, and data monitoring options for simplified maintenance and compliance verification. Catalytic Products International, Inc. has vast processor experience and can integrate any industrial processor into your operations.
|Catalyst Choices Based On Your Application
Provides a method of controlling the oxidizer under high VOC conditions and ensures VOC destruction is maintained without cause for high-temperature shut-down.
Heat Exchanger Efficiency Based On The Needs Of Your Application
|PLC control and man-machine-interface options based on your needs|
|Footprint Design Flexibility To Suit Your Space Availability|
|Secondary Heat Recovery Solutions|
|Electric Catalytic Oxidizer Heating Option|