CO Catalytic Combustion Furnace

Catalytic Oxidizer (CO) | High-Efficiency VOC Abatement

Engineered for low-to-medium exhaust flows with superior energy recovery & catalyst technology.

Catalytic Oxidizer process flow diagram with heat exchangers and VOC treatment stages

Figure 1: CO system integration with dual heat exchangers, zeolite rotor concentration (optional) and catalytic combustion chamber.

Unlike traditional RTOs with ceramic media, our CO unit does not incorporate a regenerator bed but instead integrates external or internal heat exchangers to preheat the incoming VOC-laden air. The hot side of the heat exchanger receives treated high-temperature flue gas, maximizing thermal recovery. Preheated process gas enters the catalytic combustion chamber where auxiliary energy (natural gas or electric heater) raises the temperature to catalyst light-off levels (250–350°C). VOCs are oxidized over the catalyst bed into CO₂ and H₂O, releasing heat. The purified hot flue gas then passes back through the heat exchanger(s) to preheat incoming air before being discharged to the stack — a truly energy-conscious design.

💡 Lower operating costs – Because the catalytic bed operates at relatively low temperatures (250–350°C), the energy needed to sustain catalyst light-off is significantly reduced compared to thermal oxidizers. For many applications, the exothermic heat from VOC oxidation maintains the required temperature with minimal fuel input.

VOC Destruction Process & Heat Recovery

📌 VOCs Flow Path 1 – Rotor Concentration & Primary Heating

Driven by the desorption fan, low-concentration VOC gas from the cooling zone of the zeolite rotor enters the cold channel of the Stage 1 heat exchanger. The gas temperature rises from 60°C to 200°C after heat exchange, then flows back to the desorption sector of the rotor. The hot gas efficiently desorbs VOCs from the zeolite surface, creating a highly concentrated VOC stream (controlled below 10g/m³).

🔥 VOCs Flow Path 2 – Secondary Heating & Catalytic Oxidation

The high-concentration VOC gas (approx. 10g/m³) enters the Stage 2 heat exchanger cold channel, raising its temperature from 120°C to 300°C. It then flows into the catalytic combustion chamber. If the inlet temperature is below 300°C, the burner automatically ignites to ensure a range of 300–350°C before the catalyst bed. As VOCs oxidize over the catalyst (exothermic reaction), a temperature rise of ~250°C occurs (based on specific heat ~25°C per g/m³ VOC). Therefore, 300°C inlet gas reaches ~550°C after catalytic combustion. The purified hot air supplies heat to both Stage 1 & Stage 2 heat exchanger hot channels, then discharges via stack.

⚙️ Catalyst Bed Performance: Due to the presence of active catalyst, furnace chamber temperature (catalyst inlet) is maintained between 250°C and 350°C, depending on catalyst formulation. The temperature rise across the catalyst bed depends on VOC concentration & calorific value. Example: At 10g/m³ VOC concentration, ΔT ≈ 250°C, which significantly reduces auxiliary fuel demand.

💨 Final energy recovery & reuse: After catalytic combustion, the clean high-temperature gas (≈550°C) sequentially releases its heat to the cold streams of both heat exchangers, maximizing thermal efficiency. Moreover, waste heat recovery design can be optionally integrated to supply hot water or space heating for manufacturing facilities — turning pollution control into a sustainable energy source.

✔️ Suitable Applications & Process Constraints

1 Ideal for

Medium to high VOC concentration at relatively low to medium air flows
Facilities with strict energy budget (gas/electricity saving priority)
VOCs that are catalytically oxidizable (no catalyst poisons)
Streams free of particulate & sticky substances that could foul catalyst surface
Gases without dust-forming compounds after oxidation (prevents catalyst deactivation)

2 Industries & Compounds

Primary sectors: Paint & coatings, spray booths, printing, packaging, adhesives, chemical processing.

Typical VOCs handled: Ethyl acetate, propyl acetate, ethanol, aromatic hydrocarbons, ketones, and other oxidizable organics.

Painting
Printing
Coating lines
Lamination

📊 Technical Specifications

Air Flow Capacity

5,000 – 100,000 Nm³/h (customizable)

VOC Components

Ethyl acetate, Propyl acetate, Ethanol, Xylene, Toluene, etc.

Inlet Concentration

200 mg/Nm³ < Concentration < 1,200 mg/Nm³ (optimal catalytic range)

CO / RCO Inlet Temp.

≥ 300°C (ensured by preheating / burner trim)

Outlet Temperature

≤ 600°C (after catalytic oxidation & heat recovery)

Catalyst Light-off Temp.

250 – 350°C (based on catalyst type)

Destruction Efficiency

Up to 99%+ (depending on VOC & residence time)

🎛️ Customization & Diverse Options

🔥 Heating Method

Choose between fuel-fired burner (natural gas / LPG) or electric heating elements based on site utility availability and carbon reduction goals.

🧪 Catalyst Types

Multiple options available: precious metal catalysts (Pt/Pd) for high activity, or non-precious metal catalysts (transition metal oxides) for cost-effective performance.

🌿 Post-treatment Integration

Easily couple with downstream systems: wet scrubber modules for acid gas removal, DeNOx unit (SCR/SNCR) for NOx control if required.

♨️ Heat Exchanger Variants

Based on thermal recovery needs, we offer shell & tube, plate-type, or customized primary/secondary heat exchangers to maximize energy saving and meet specific ΔT requirements.

🔄 Detailed VOC Pathway & Temperature Control Logic

Inside the catalytic combustion chamber, a temperature sensor verifies the VOC gas temperature after the secondary heat exchanger. If the gas is below 300°C (setpoint), the burner automatically ignites to provide supplementary heating, ensuring stable catalytic activity across a range of 300°C–350°C. After passing through the catalyst bed, flameless oxidation occurs, raising the gas temperature by as much as 250°C (for 10g/m³ VOCs). The resulting clean exhaust is first directed to the hot side of the Stage 2 heat exchanger, then to Stage 1, releasing thermal energy to preheat incoming VOCs. Ultimately the purified air is discharged to the stack, meeting stringent environmental standards.

♻️ Future waste heat recovery: The high-temperature, clean flue gas after catalytic oxidation can be further utilized for factory heating, hot water supply, or preheating other process streams — tailored to client energy management strategies.

⚡ Why Choose Our Catalytic Oxidizer?

💰 Lower Energy Demand

Low operating temperature (250–350°C) significantly cuts fuel/electricity consumption compared to thermal oxidizers (760°C+).

📦 Compact Design

No massive ceramic beds required; footprint efficient with integrated heat exchanger configurations.

📈 Flexible Configurations

Support for zeolite rotor pre-concentration, multi-stage heat recovery, and future expansion of post-treatment.

⚠️ Important Preconditions for Optimal Performance

The waste gas stream must be free of catalyst poisons (e.g., heavy metals, halogens, phosphorus, silicon compounds).
Particulate matter, tars, or sticky aerosols should be removed upstream to prevent catalyst fouling.
Compounds that generate solid dust upon oxidation (e.g., certain siloxanes) must be pre-treated.
For chlorinated VOCs, optional post-scrubber recommended to handle acid gas byproducts.

Note: Our engineering team provides comprehensive feasibility analysis — catalyst life, poisoning risks, and heat recovery potential — for every specific application.

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