Total cost of ownership is the overall expense of a capital purchase and its recurring operating and maintenance costs that accrue over the lifetime of the equipment (typically >20 years).
A primary ongoing operating cost of any thermal oxidizer system is utility consumption. VOC oxidation occurs at much lower temperatures for catalytic oxidizers than other technologies, so gas requirements are reduced significantly.
Fewer utilities needed to run the system = more money you save.
In addition, catalytic oxidizers only have one moving component, the system fan. Other competing technologies have various moving parts, such as valves, dampers, seals, etc., that pose greater reliability concerns and higher maintenance costs due to the constant impact of operations on these components.
Fewer moving parts = reduced unplanned downtime and maintenance costs.
Recuperative Catalytic Oxidizers (RCO) have a small design footprint, minimal impact on the manufacturing process, and generate less nitrogen oxides (NOx) and carbon monoxide (CO) due to their lower natural gas consumption. Avoiding resources and emissions is a win in our book and probably a win in yours, too.
Pollution Systems’ recuperative catalytic oxidizers also incorporate heat exchangers for heat recovery. Depending on the process, the energy evolved from the VOC destruction may be enough to heat the exhaust to the necessary catalyst activation temperature, meaning no auxiliary fuel is required, and the system can operate auto-thermally.
An Electric Catalytic Oxidizer (ERCO) uses an electric heater rather than a natural gas burner, eliminating any NOx contributions that would occur with burning gas. Further, if the electricity utilized to run the system is renewable sourced, an ERCO may be a more sustainable solution for your application.
The catalyst used for air pollution abatement is a metal foil element with Platinum or Alumina being the formulation class. Catalyst can either be structured or unstructred and consists of a catalyst carrier impregnated with the catalytic metal.
Close up of catalyst modules inside of a Electric Catalytic Oxidizer Model# ERCO-1
During the initial discussion about your project, it is critical to make us aware of the complete composition of your waste stream to ensure the pollutants present are suitable for treatment with a catalytic oxidizer. View our Catalyst Deactivation and Poisoning Agents Bulletin to see a list of poisoning agents and inhibitors that can cause significant damage to your catalyst.
It is recommended that regular annual inspections are performed with all air pollution control equipment to minimize any potential system downtime and extensive repairs. Additionally, the National Fire Protection Association (NFPA) has standard requirements for operating and maintaining industrial combustion equipment.
Generally, these are the primary maintenance considerations of a catalytic oxidizer:
PSI tailors our system designs to the unique conditions of each application, and the accompanying owner’s manual has instructions detailing the proper maintenance schedule for your particular system.
Catalytic oxidation is effective for processes that contain low concentrations of volatile organic compounds (VOCs) or hazardous air pollutants (HAPs). With few internal moving parts, catalytic oxidizers are favorable for continuous steady-state operation and, if properly designed for your process, can achieve greater than 99% destruction rate efficiency (DRE).
Suitable for a wide array of industrial applications, many of our customers who purchase catalytic technologies are industry leaders in microelectronic manufacturing, chemical processing, product safety testing, ethylene oxide sterilization, transportation electrification, pharmaceutical, and medical technologies manufacturing.
Pollution Systems is a catalytic oxidizer manufacturer that prides itself on providing comprehensive solutions that fit your business and technical needs. Catalytic oxidizers are fit for many industrial applications and can have minimal impact on your process and the environment if designed to your operating conditions. However, there are pros and cons to each type of equipment, and our priority is to help you evaluate the options available so that you feel confident you are installing the most appropriate technology for your situation.
Is a CatOx the right technology for your industrial air pollution control needs? Our engineering team will determine the suitability of the technology based on your process and the composition of your waste stream. To get the discussion started, submit an inquiry.
Explore our infographic depicting the many features of Pollution Systems’ Electric Catalytic Oxidizers (ERCO) and how to capitalize on the technology to support ESG and sustainability objectives within your industrial process.
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