Catalytic Combustion Equipment

Catalytic combustion is a purification method that uses a catalyst to oxidize and decompose combustible substances in exhaust gas at lower temperatures. Therefore, catalytic combustion is also known as catalytic chemical conversion. Since the catalyst accelerates the process of oxidation and decomposition, most hydrocarbons can be fully oxidized at temperatures of 300~450°C through the use of a catalyst. Little auxiliary fuel is needed for catalytic combustion, with low energy consumption and compact equipment size. However, issues such as catalyst poisoning, the replacement and cleaning costs of the catalyst bed, and high expenses have affected the promotion and application of this method in industrial production processes. In the chemical reaction process, a method called catalytic combustion is used to reduce the combustion temperature and accelerate the complete oxidation of toxic and harmful gases by utilizing catalysts. Due to the carrier of the catalyst being made of porous materials with a large specific surface area and appropriate pore size, when the organic gas heated to 300~450°C passes through the catalytic layer, oxygen and organic gases are adsorbed on the catalyst at the surface of the porous material, increasing the chances of contact and collision between oxygen and organic gases, enhancing their activity, and causing a vigorous chemical reaction between the organic gases and oxygen to produce CO2 and H2O. This also generates heat, transforming the organic gases into non-toxic and harmless gases. When designing the catalytic combustion device, the following aspects should be considered: 1. Uniform air flow and temperature distribution. To ensure even air flow and temperature distribution across the catalyst surface, and to prevent direct flame contact with the catalyst, the combustion chamber must have adequate length and space. The catalytic combustion unit should have good thermal insulation. The furnace shell is typically made of a steel structure lined with refractory materials, or a double-walled construction. 2. Easy to clean and replace. Catalyst reactors should generally be designed with easy-to-load/unload drawer structures for convenient cleaning and replacement of the catalyst carrier. 3. Auxiliary Fuel and Combustion Aid. Catalytic combustion typically uses natural gas as auxiliary fuel, but can also utilize fuel oil, electric heating, etc. as auxiliary fuel. Combustion aid usually employs purified gas; if the purified gas is not suitable for combustion aid, air should be introduced for combustion aid. 4. High conversion rates. As catalytic combustion is an irreversible exothermic reaction, it should be conducted at the highest possible temperature at any stage of the reaction to achieve high conversion rates. However, operating temperatures are often limited by certain conditions, such as the heat resistance of the catalyst, the availability of high-temperature materials, the supply of thermal energy, and the presence of side reactions. Therefore, in actual production, appropriate choices should be made based on the specific circumstances.