Catalytic Recuperative Oxidizers: What they are, how they work & more

How does a Catalytic Oxidizer work?

A pollutant-laden airstream is pushed through the oxidizer, usually with a system fan (1). When equipped with an air-to-air heat exchanger, the flow of air will pass through the air-to-air heat exchanger (2) to preheat the air before entering the burner/combustion chamber (3). In the combustion chamber, the air is heated to a sufficiently high (>600F) temperature and then passes through the catalyst material (bed) (4) where VOCs are destroyed. The hot, cleaned air then continues through a hot pass of the heat exchanger (if heat exchanger is utilized) (5). The cooled, clean air is then exhausted to the atmosphere (6).

Advantages and disadvantages of catalytic systems over other technologies such as regenerative thermal oxidizers are discussed more completely here Selecting an Oxidizer.

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The Three T’s of Catalytic Oxidizers – Time, Temperature and Turbulence

Note: Gas hourly space velocity (GHSV) is sometimes substituted for “time” when describing catalytic system performance. Two T’s of turbulence and temperature are critical in a catalytic oxidizer. The third “T” of time is better defined by gas hourly space velocity (GHSV) which is a technical term that defines a ratio of catalyst volume to treated airflow volume. It is a critical value in determining the performance and life expectancy of a catalytic system. High GHSV values represent lower performance and shorter catalyst life.

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Who Uses Catalytic Oxidizers?

Catalyitc Oxidizers are used by manufacturers in a wide range of industries and applications. The Kono Kogs team has experience with practically every possible oxidizer application across many industries around the globe.

Industrial Processes using Catalytic Oxidizers

Many industries incorporate catalytic oxidizers in their pollution control systems. Some industrial processes where they're used include: 

• Fiberglass gel coating
• LCD panel production
• Semiconductor fabrication
• Steel furniture paint booths
• Wood furniture surface finishing
• Rotogravure printing
• Flexographic printing
• Heatset web offset printing
• Label printing
• Rubber production
• Automotive paint processes
• Medical products
• Material coating
• Surface coating
• Wood Products
• Chemical processing/manufacturing
• Lamination
• Spiral core winding
• Foil stamping
• Flow coating

We have an in-depth understanding of every process airstream our systems are used to treat. Explore our case studies or contact us with questions about the different technologies available for your specific application.

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How Much does a Catalytic Oxidizer Cost?

The cost of a catalytic oxidizer addition includes the initial capital investment in the equipment as well as the operating and installation costs. Buying a pre-owned, fully refurbished catalytic oxidizer from Kono Kogs can save you 40% or more in capital costs compared to the cost of new, with comparable guarantees and warranties.

Kono Kogs recommends carefully thinking through the Total Cost of Ownership (TCO) before making a purchase. A catalytic oxidizer system with a low capital cost might not represent your lowest TCO in operation over time. As a rule of thumb, consider a two-year period when calculating the total cost.

Capital Costs Include:

• Equipment
• Shipping
• Installation
• Commissioning (start-up)

Operating Costs Include:

• Fuel
• Electricity
• Compressed air
• Maintenance service

Both capital and operating costs can vary widely between different catalytic oxidizers. Some TOX technologies have fuel costs 5-10x higher than other systems. A Catalytic Oxidizer with a low initial cost could have a higher TCO over two years compared to that of a Catalytic Oxidizer or Regenerative Thermal Oxidizer.

Kono Kogs is happy to provide a cost-benefit analysis for your project. We’ll compare multiple technologies, explain the trade-offs of each option, and give you our professional recommendation on the most cost-effective system.

Questions to ask when considering a catalytic recuperative Oxidizer (CATOX)

• Is a catalytic oxidizer the most cost-effective oxidizer solution for my airstream?
• See Selecting an Oxidizer for guidance or call us for guidance
• Are catalyst poisons (halogens) in the airstream?
• If present, consider a different oxidizer technology
• Are catalyst masking agents/contaminants (silicone, phosphorus) in the airstream?
• If present, low concentrations may still be viable for catalytic technology
• If present in high concentrations, consider a different oxidizer technology
• A heat exchanger is a cost-effective option for most applications
• For catalytic systems, plate or shell & tube heat exchangers will perform well
• Is there a potential for particulates?
• Catalytic systems do not handle particulates well; consider other technologies
• VOC concentrations over 16% will require special consideration

Kono Kogs Knows Everything about Catalytic Oxidizers

Kono Kogs is the world’s leading supplier of used oxidizers. We also offer oxidizer field services including turnkey installation, repair, preventive maintenance, and upgrades. Our team has over 150 years of combined experience, and a 100% success rate in meeting performance guarantees. Whether we can help you get more years out of your existing system or find a replacement, we look forward to the challenge!

Kono Kogs is the world’s leading supplier of used catalytic recuperative oxidizers.

Reach out to us for a quote or contact Kono Kogs for more information.

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