Electric Catalytic Oxidizer

Electrically Heated Catalytic Oxidizer

An electric catalytic oxidizer (CatOx) utilizes an electric heating system to eliminate burner generated NOx and CO2 emissions. This flameless, electrically heated oxidizer is an ideal option for VOC control and removal that achieves the same destruction rates in a more sustainable way.

Electric Catalytic Oxidizer Process

The CPI VECTOR-e Catalytic Oxidizer substitutes the standard natural (propane) gas combustion system with an electric heating module. As a result there are no combustion products of natural gas and no formation of NOx.

The Electric Recuperative Catalytic Oxidizer (ERCO) combines a low temperature oxidation catalyst, our unique primary heat exchanger, and a long lasting heating element all in a convenient integrated package. These systems are easy to install, provide high VOC removal efficiency, and offer low operating costs. With zero moving parts in the reactor the Catalytic Oxidizer provides the highest uptime reliability and long equipment life.

Cost-Effective Air Pollution Control

Electric Recuperative Catalytic Oxidizer (ERCO) systems represent a cost-effective air pollution control alternative. When compared to thermal oxidation, their lower operating temperatures (400°F - 650°F) reduce operating costs and extend equipment life. Each is designed and fabricated for your specific application, and each system utilizes materials and metallurgy that will afford the highest performance, longest life, and economical cost of ownership.

The Catalytic Oxidation Process starts by incorporating a booster fan to draw VOC-laden exhaust from your process into the system. The VOC laden exhaust is directed to our unique stainless steel primary air-to-air heat exchanger where energy from the exhaust of the oxidizer is used to preheat the incoming process air before passing over the electrical heating element. The primary heat exchanger can actually eliminate the auxiliary heating required for operation.

The electric Catalytic Oxidizer utilizes an electric heating element to precisely maintain the desired catalyst inlet temperature. The heating element is designed to provide even heating of the exhaust gases prior to entering the catalyst bed. This innovative design provides the highest degree of high-velocity mixing, leading to airflow and temperature uniformity for which CPI's 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 VECTOR Catalytic Oxidizer can be designed for use with several different styles of catalyst; Monolith Elements and Pourable Beads are the most common types of catalyst. The oxidation of hydrocarbons (VOCs) typically results in carbon dioxide, water, and useable heat. The catalyst induced oxidation level for most VOC's occurs at temperatures between 400 F and 650 F. This is sufficient to achieve conversion of VOC/HAP pollutants in excess of 99%.

Typical applications for ELECTRIC Catalytic Oxidizers

Ethylene Oxide (EtO) Sterilization
Pharmaceuticals
Ethanol, Acetaldehyde, and Formaldehyde Removal (Bakery)
Carbon Monoxide Removal
Ammonia Removal
Oxygen Removal
Or hazardous areas that do not allow gas combustion

Electric Catalytic Oxidizer Features

VECTOR 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. Building the experience gained since its formation in 1969, CPI can replace the gas burner in a traditional Catalytic Oxidizer with an electric heating element.

VECTOR System's Features

VECTOR CATALYTIC OXIDIZER INTEGRATED DESIGN

Integrating all the major components into one unitized system saves on field installations, improves reliability, and lowers the overall costs for air compliance. The VECTOR System utilizes only the highest quality components. From the all stainless steel mixing and combustion chamber, the heavy-duty, all stainless steel heat exchanger, the specialized electric heating system, to the catalyst system, each component is contained within a well insulated, maintenance-free exterior designed for long life and low costs.

BEST CATALYST FOR HIGH PERFORMANCE AND LONG LIFE

Catalyst is selected based on the ability to provide the highest performance and longest life. The catalyst choices can include precious metal group metals on a monolith support, or a pourable bead. Each group offers individual benefits for each application. Monolith catalyst groups are used for general industrial applications or for specialized . emissions.

For beaded catalyst products, poison-resistant catalyst provides resistance to many common contaminates, while low temperature formulations allow minimal fuel input.

ELECTRICALLY HEATED OXIDIZER SYSTEMS

An integrated electrical heating element replaces the gas or oil combustion system. This flameless design is especially useful for smaller sized oxidizers and applications that require hazardous ratings or are not supported by gas fuel products. Electrically heated oxidizer systems are also available for retrofit applications to replace burners.

INTERIOR AND EXTERIOR VECTOR SYSTEM CONSTRUCTION

The VECTOR 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.

VECTOR SYSTEMS THERMAL EFFICIENCY

VECTOR 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. VECTOR 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.

OPTIONAL FEATURES

Catalyst choices based on your application
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
Prepipe and wire to reduce installations costs

TEMPERATURE SAFETY SYSTEM

Every VECTOR system is integrated to our customized PLC-control panel called TSS. TSS communicates with the VECTOR 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.