Catalytic Combustion Equipment

Catalytic combustion is a purification method that uses a catalyst to oxidize and decompose combustible substances in waste gases at lower temperatures. Therefore, catalytic combustion is also known as catalytic chemical conversion. Since the catalyst accelerates the oxidation and decomposition process, most hydrocarbons can be fully oxidized at temperatures between 300~450°C with the help of a catalyst. Little auxiliary fuel is needed for catalytic combustion, resulting in low energy consumption and compact equipment and facilities. However, issues such as catalyst poisoning, the replacement and cleaning of the catalyst bed, and high costs, have impacted the promotion and application of this method in industrial production processes. In the process of chemical reactions, the method of using a catalyst to lower the combustion temperature and accelerate the complete oxidation of toxic and harmful gases is known as catalytic combustion. Due to the carrier of the catalyst being made of porous materials with a large specific surface area and appropriate pore size, when organic gases heated to 300~450°C pass through the catalytic layer, oxygen and organic gases are adsorbed on the catalyst at the surface of the porous material, increasing the opportunities for contact and collision between oxygen and organic gases, enhancing activity, and causing a violent chemical reaction between the organic gases and oxygen to produce CO2 and H2O. Simultaneously, heat is generated, transforming the organic gases into non-toxic and harmless substances. When designing a catalytic combustion unit, the following aspects should be considered: 1. Uniform air flow and temperature distribution are required. To ensure that the air flow and temperature across the catalyst surface are even, and to prevent the flame from directly contacting the catalyst surface, the combustion chamber must be of sufficient length and space. The catalytic combustion unit should have good insulation properties. The furnace shell is typically made of a steel structure lined with refractory material, or a double-walled structure. 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 fuel oil, electric heating, and other options can also be used. Combustion aid usually involves purified gases; if the purified gases are not suitable for combustion aid, air should be introduced. 4. High conversion rate. 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 a high conversion rate. However, the operating temperature is 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.