One example of technical ceramics is the monolithic catalyst supports that are the core of most catalytic converters used in automotive vehicle emission control. They are also used in stationary emission control devices, as well as other kinds of reactors in the chemical industry. During an extrusion process, raw materials such as synthetic cordierite, alumina, talc, clay (kaolinite) and silica are reduced to powder and blended into a water-based paste. Additives which may be added in the process include lubricants (e.g. ethylene glycol), bonding agents (e.g. methylcellulose), and fluxes (alkaline hydroxides). Extrusions made from the paste are dried, cut to length, and calcined at temperatures above 1400°C. Organic compounds result from the decomposition and/or incomplete combustion of the binder and other volatile organics in the green product. The flue gases from the drying and firing of the ceramics in the kiln contain Volatile Organic Compounds (VOCs).
Both Thermal Oxidizers and Catalytic Oxidizers are the most widely accepted control technologies available to control VOC emissions from the ceramics manufacturing process.
Catalytic Products has installed multiple QUADRANT Series Thermal Recuperative Oxidizers at East Coast USA locations of a global manufacturer of ceramic catalyst substrate for the abatement of Volatile Organic Compounds (VOCs).
Thermal (recuperative) Oxidation was selected in these applications based on the customer’s desire to obtain 99.5% VOC and 99% CO destruction efficiencies from their tunnel kiln exhaust while providing a system that offers the highest ability to remove oxygen from the exhaust stream and provide heat recovery back to the kiln with less than 2% O2. The only system capable of providing this high VOC removal efficiency, while meeting the oxygen removal needs necessary for the process is the QUADRANT Series Thermal (recuperative) Oxidizer. Other comparable technologies such as Regenerative Thermal Oxidation or Catalytic Oxidation simply cannot provide the high clean up rates or oxygen removal.
