How does a Catalytic Oxidizer (Catox) work?
“Hover“ over interactive image and “click“ for more details.
Vapors enter the catalytic oxidizer through a flame arrestor where multiple layers of stainless steel screen prevent flame propagation in either direction.
The FALCO 300 stainless steel spiral plate heat exchanger provides over 132 square feet of surface area which recovers exhaust heat to preheat incoming flow.
The temperature control system cycles electric heaters. Vapors are heated to catalytic oxidation temperature. Minimum inlet temperature for VOC’s is typically 330˚C.
Hot vapors enter the catalyst inlet plenum and flow velocity is dropped. Catalyst inlet temperature (T1) is measured with a thermocouple.
Vapors enter the massive packed bed catalyst and are destroyed by flameless surface combustion. Heat is released as vapors are converted into C02 and water.
Catalyst operating temperature is between 330˚C and 600˚C. Temperature rise is measured at the catalyst midpoint (T3), and on the discharge (T2). The temperature control system receives input from all three thermocouples and regulates dilution air to control input concentrations.
Treated vapors enter the discharge portion of the heat exchanger. The heat exchanger surrounds the catalyst chamber minimizing conductive heat losses.
Heat recovery is adjustable: A portion of the treated flow can be diverted through a bypass valve directly to the discharge stack. Reduced heat recovery (bypass open) enables operation at high input loading. Conversely, maximum heat recovery (bypass closed) enables energy efficient operation at low input loading. A stack damper applies pressure to the discharge circuit when the heat exchanger bypass valve is opened to enhance bypass flow. When the bypass valve is closed, the damper is fully open. When the catox is off, the damper closes to reduce heat loss.
The long discharge passage of the heat exhanger recovers the heat of combustion. The heat exchanger outer surfaces are insulated and protected by an aluminum jacket.
The treated flow is discharged out the stack. Discharge temperature is between 125˚C and 300˚C. For more information on the catalytic oxidation process visit: HOW FALCO CATALYTIC OXIDATION WORKS
