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Product Description
Efficient exhaust gas treatment method, so that combustible substances in the exhaust gas can be oxidized and decomposed at a lower temperature.
Catalytic combustion is an efficient waste gas treatment method. Its main principle is to use a catalyst to oxidize and decompose combustible substances in the waste gas at a lower temperature (usually 200-400c). This method has low energy consumption, simple operation, safety and high purification efficiency, and is very suitable for the application of chemical industry, painting, insulating materials, coating production and other industries.
The basic principle of catalytic combustion is as follows: catalytic combustion, with the help of a catalyst, organic waste gas at a low ignition temperature, flame less combustion, and oxidation decomposition into carbon dioxide and water, at the same time release a large amount of heat.
Catalytic combustion process can be divided into:
1. Preheating type.
The preheating type is the most basic process form of catalytic combustion. When the temperature of organic waste gas is below 100ºC and the concentration is low, the heat cannot be self-sufficient, so it needs to be heated in the preheating chamber before entering the reactor. Gas or electric heating is usually used to heat the exhaust gas to the ignition temperature required for the catalytic reaction. The purified combustion gas is heat exchanged with the untreated waste gas in the heat exchanger to recover part of the heat.
2. Self-thermal equilibrium.
Organic waste gas has a high temperature and a high content of organic matter, so it is usually only necessary to set an electric heater in the catalytic combustion reactor to be used when starting combustion. The heat generated by part of the purified gas can be recovered through the heat exchanger, and the thermal balance can be maintained under normal operation without adding heat.
Driven by the "dual carbon" goal, industries such as chemical and coating face severe pressure to reduce VOCs emissions. Catalytic combustion technology has become a popular choice to replace traditional RTO/RCO with its core breakthroughs of 200-400ºC low-temperature decomposition and 98% purification efficiency. This article will deeply analyze the process principles, equipment selection strategies and industry application data of catalytic combustion, and provide enterprises with a full-chain solution from exhaust gas detection, system design to carbon emission reduction accounting.
1. Technical principles and process innovation: scientific breakthroughs behind low-temperature decomposition
Catalytic combustion achieves disruptive technology upgrades through precious metal catalyst activation and thermal energy recycling system:
Low-temperature catalytic oxidation mechanism
Under the action of Pd-Pt-CeO2 composite catalyst, the adsorption activation energy of VOCs molecules is reduced by 70% (benzene series <50kJ/mol), and the ignition temperature of 200ºC is achieved (traditional combustion requires 600ºC+);
The honeycomb ceramic carrier (pore density 300cpsi) increases the exhaust gas contact area by 5 times and shortens the residence time to 0.8 seconds (traditional equipment requires 2 seconds).
Dual-mode process system
Preheating catalytic combustion:
Applicable scenarios: exhaust gas concentration <1.5g/m³ (such as printing workshop), equipped with tubular heat exchanger (heat recovery rate 65%);
Operation cost: electric heating power only needs 15kW/10000m³·h, which is 40% more energy-saving than direct combustion.
Self-heating balance system:
Applicable scenarios: exhaust gas concentration >3g/m³ (such as resin synthesis line), adopting regenerative catalytic combustion (RCO) structure;
Thermal efficiency: when the combustion chamber outlet temperature is 650ºC, the heat recovery rate reaches 92%, and the natural gas consumption is <3m³/h.
Intelligent temperature control technology:
Infrared thermal imaging monitors the catalyst bed temperature in real time (accuracy ±2ºC), and automatically adjusts the re-combustion valve;
Anti-sintering protection module: when the toluene concentration suddenly increases to 5000ppm, the system starts the emergency dilution program within 30 seconds.
Treatment of high-concentration waste gas in the chemical industry
Epoxy resin production line: To treat waste gas containing phenol and formaldehyde (concentration 8g/m³), three-stage catalytic combustion is used:
First-stage catalyst: MnO2-CuO (sulfur-resistant type);
Second-stage catalyst: Pt/Al2O3(high activity);
Purification efficiency: 99.2%, catalyst life extended by 30%.
Energy-saving transformation of painting workshop:
Water-based paint spraying line: equipped with zeolite wheel (concentration ratio 20:1) + catalytic combustion system, equipment investment recovery period <2 years;
Measured data: The energy consumption of electrophoresis drying waste gas treatment is reduced to 0.6kW·h/kgVOCs, meeting the special emission limit of GB 37822-2019.
Precision temperature control requirements in the electronics industry:
Semiconductor cleaning process: To treat isopropyl alcohol waste gas (concentration 1.2g/m³), plate heat exchanger + ceramic fiber catalyst is selected;
Temperature control: Bed temperature fluctuation <5ºC to avoid thermal stress damage to precision equipment.
Key parameters for equipment selection:
Catalyst selection: precious metal loading 0.3-0.5% (benzene series), perovskite type (chlorine-containing waste gas);
Air speed setting: 15000-25000h(adjusted according to waste gas composition);
System pressure loss: <800Pa (to ensure that fan energy consumption is controllable).
The Internet of Things platform monitors the activity of the catalyst in real time (by inferring the amount of CO generated), and the accuracy of predicting the replacement cycle is >85%;
Development of new catalysts:
Sulfur-resistant catalyst: When treating H2S-containing waste gas, the life span is extended from 6 months to 3 years;
Low-temperature ignition material: MnOx-Co3O4 composite system achieves complete decomposition of toluene at 150ºC.
Modular equipment design:
Containerized catalytic combustion system: The installation period is shortened from 45 days to 7 days, suitable for emergency renovation projects;
Mobile treatment vehicle: equipped with a micro catalytic combustion unit (processing capacity 500m³/h) to solve the pain points of sporadic emissions.
Strategic value of catalytic combustion technology
Catalytic combustion is reshaping the industrial waste gas treatment pattern with its low temperature, high efficiency, energy self-sufficiency and zero secondary pollution. When selecting a model, enterprises need to focus on the anti-poisoning performance of the catalyst, the efficiency of the heat recovery system (recommended> 80%) and the intelligent temperature control accuracy (±3ºC). For waste gas with complex components (such as halogens and sulfides), it is recommended to adopt the "adsorption concentration + catalytic oxidation" combined process, and give priority to technical service providers with hazardous waste incineration qualifications (such as Jiangsu Blue Sky Environmental Protection, which provides catalyst recovery and regeneration services).
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Factory Address
QINGDAO SANZHUJI
Specializing in the production of sand casting machinery, including green sand casting production line, furan resin sand casting production line, lost foam casting production line, coated sand steel sand buried casting production line, the company has a history of 14 years since its establishment.
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Address:North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China
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