Catalytic Combustion EquipmentIt Is An Environmentally Friendly Equipment Used To Treat Volatile Organic Compounds (VOCs) And Harmful Gases. Its Core Principle Is To Use The Action Of Catalysts To Reduce The Activation Energy Of Organic Compounds, So That Pollutants In Exhaust Gas Undergo Oxidation Reactions At Lower Temperatures (usually 200-400 ℃), Ultimately Producing Harmless Carbon Dioxide (CO ₂) And Water (H ₂ O), While Releasing Heat. The Following Is A Detailed Analysis Of Its Application Principle:
1、 The Core Principle Of Catalytic Combustion
1. The Essence Of Catalytic Reactions
The Function Of Catalysts: Catalysts (such As Precious Metals Such As Platinum And Palladium, Or Transition Metal Oxides Such As Copper And Manganese) Adsorb Organic Molecules In Exhaust Gas, Change The Reaction Pathway, Reduce The Activation Energy Of The Reaction, And Enable Oxidation Reactions To Occur At Temperatures Much Lower Than Direct Combustion.
2. Temperature Advantage
Traditional Combustion Vs. Catalytic Combustion:
Direct Combustion Requires High Temperature (600-1000 ℃) And High Energy Consumption;
Catalytic Combustion Only Requires 200-400 ℃, Significantly Reducing Energy Consumption And Minimizing The Generation Of Nitrogen Oxides (NOx).
2、 Composition And Workflow Of Catalytic Combustion Equipment
1. Main Components
Preprocessing Unit:
Filtering Devices (such As Dry Filters And Cyclone Separators): Remove Dust And Particulate Matter From Exhaust Gas To Prevent Catalyst Poisoning.
Catalytic Combustion Chamber:
Catalyst Bed: Filled With Honeycomb Or Granular Catalyst To Provide A Reaction Surface.
Heat Exchange System:
The Heat Generated By The Recycling Reaction Is Used To Preheat The Intake Or Heat Other Process Steps, Improving Energy Efficiency.
Control System:
Monitor Parameters Such As Temperature, Pressure, And Exhaust Gas Concentration, And Automatically Adjust The Combustion Process.
2. Workflow
Exhaust Gas Pretreatment:
The Exhaust Gas First Passes Through A Filtering Device To Remove Impurities And Prevent Catalyst Failure.
Preheating Stage:
The Pre Treated Exhaust Gas Is Heated To The Required Temperature For Catalytic Reaction (usually 150-300 ℃) Through A Heat Exchanger Or Electric Heating Device.
Catalytic Reaction:
High Temperature Exhaust Gas Enters The Catalytic Combustion Chamber And Undergoes Oxidation Reaction On The Catalyst Surface, Decomposing Into CO ₂ And H ₂ O, While Releasing A Large Amount Of Heat.
Heat Recovery And Emission:
The High-temperature Gas After The Reaction Is Preheated By A Heat Exchanger To Reduce The Overall Energy Consumption Of The Newly Introduced Exhaust Gas; The Purified Gas Is Tested And Meets The Standards Before Being Discharged, And The Heat Can Be Further Used For Drying, Heating, And Other Purposes.
3、 Selection And Deactivation Reasons Of Catalysts
1. Catalyst Type
Precious Metal Catalysts: Platinum (Pt), Palladium (Pd), Etc., With High Activity And Wide Applicability, Commonly Used In Low Concentration Exhaust Gases.
Non Precious Metal Catalysts: Oxides Of Copper (Cu), Manganese (Mn), And Iron (Fe), With Low Cost But Low Activity, Suitable For Specific Exhaust Gases (such As Sulfur-containing And Nitrogen-containing Compounds).
Composite Catalyst: Combining Precious And Non Precious Metals To Optimize Activity And Stability.
2. Catalyst Deactivation Factors
Poisoning: Substances Such As Sulfur, Phosphorus, And Heavy Metals (such As Lead And Zinc) In The Exhaust Gas Adsorb Onto The Surface Of The Catalyst, Hindering The Reaction.
Sintering: The Surface Structure Of The Catalyst Collapses And The Number Of Active Sites Decreases Under Long-term High Temperature.
Carbon Deposition: Carbon Deposits Generated By Incomplete Reactions Cover The Surface Of The Catalyst.
Response Measures: Regularly Clean And Replace Catalysts, Or Use Anti Poisoning Catalysts.
4、 Application Scenarios And Advantages
1. Typical Application Areas
Industrial Waste Gas Treatment: VOCs Waste Gases (such As Benzene, Toluene, Xylene, Formaldehyde, Etc.) Emitted From Industries Such As Chemical, Painting, Printing, Electronics, And Pharmaceuticals.
Odor Control: Odor Gases From Catering Fumes, Garbage Treatment Plants, And Sewage Treatment Plants.
Automobile Exhaust Purification: The Three-way Catalyst Belongs To The Application Of Catalytic Combustion Technology, Which Converts CO, HC, And NOx Into Harmless Gases.
2. Technical Advantages
Efficient Purification: The Removal Rate Of VOCs Can Reach Over 95%, Meeting Strict Emission Standards.
Low Energy Consumption: The Reaction Temperature Is Low, And The Energy Consumption Is Only 1/3-1/2 Of Direct Combustion.
High Safety: No Open Flame Combustion, Reduces Explosion Risk, Suitable For Flammable And Explosive Exhaust Gases.
Strong Adaptability: Capable Of Handling Low To Medium Concentrations (500-5000 Mg/m ³) Of Exhaust Gas, With A Wide Range Of Allowable Fluctuations.
5、 Limitations And Improvement Directions
1. Limitations
High Catalyst Cost: Precious Metal Catalysts Are Expensive And Require Regular Replacement.
Exhaust Gas Restriction: Not Applicable To Exhaust Gases With High Concentrations Of Particulate Matter And High Sulfur/phosphorus Content, Which Can Easily Cause Catalyst Poisoning.
High Pre-treatment Requirements: Strict Filtering Of Impurities In Exhaust Gas Is Required, Increasing Equipment Complexity.
2. Improvement Direction
Develop Low-cost, Highly Active Non Precious Metal Catalysts (such As Perovskite Type Catalysts).
Optimize The Pre-treatment Process And Improve The Compatibility Of Exhaust Gas.
Combining Adsorption Technology (such As Activated Carbon Adsorption Catalytic Combustion Integrated Equipment) To Treat Low Concentration High Air Volume Exhaust Gas.
