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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.
Catalytic 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.
Many industries incorporate catalytic oxidizers in their pollution control systems. Some industrial processes where they're used include:
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.
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:
Operating Costs Include:
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.
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!
For more Low VOC Catalystinformation, please contact us. We will provide professional answers.
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.
Catalytic oxidizers, also known as catalytic incinerators, are oxidation systems (similar to thermal oxidizers) that control VOC and volatile HAP emissions. Catalytic oxidizers use a catalyst to promote the oxidation of VOCs to CO2 and water (i.e., increase the kinetic rate). The catalyst therefore allows oxidation to occur at lower temperatures than for thermal oxidation; catalytic oxidizers generally operate between 650°F and °F.
Important design factors for catalytic oxidation include temperature (an operating temperature high enough to oxidize the waste gas on the catalyst), residence time (sufficient residence time in the catalyst bed for the oxidation reaction to occur), turbulence or mixing of combustion air with the waste gas, VOC concentration and species, catalyst characteristics, and the presence of masking agents in the waste gas that can reduce the effectiveness of the catalyst bed.
To reduce fuel usage required for oxidation, catalytic oxidizers may have some form of heat recovery. The percentage of heat recovery in the design of catalytic oxidizers generally increases with decreasing inlet VOC/HAP concentration. Heat recovery may either be regenerative or recuperative. In regenerative heat recovery, hot exhaust gases and cool inlet gases are alternatively passed through a fixed bed, typically employing ceramics. In recuperative heat recovery, heat is recovered by passing the hot exhaust gases through a non-contact air-to-air heat exchanger to heat incoming air to the oxidizer.
For more information, see the box More About Catalytic Oxidizers.
The primary indicators of catalytic oxidizer performance are the outlet VOC or volatile HAP concentration, catalyst bed inlet temperature, and catalyst activity. Other indicators of catalytic oxidizer performance include temperature rise across the catalyst bed, catalyst bed outlet temperature, outlet CO concentration, exhaust gas flow rate, fan current, outlet O2 or CO2 concentration, and pressure differential across the catalyst bed.
The Compliance Assurance Monitoring (CAM) Technical Guidance Document (TGD) provides information on monitoring approaches for different types of control devices. Specific information provided in the CAM TGD related to catalytic oxidation include example CAM submittals based on case studies of actual facilities.
For more information, see the box More About Monitoring and the CAM Rule.
Industry Specific InformationTo search for additional monitoring information specific to an industry, see the monitoring information by industry type page.
Costs of catalytic oxidation are discussed in the EPA Air Pollution Control Cost Manual*, Section 3.2, Chapter 2 - Incinerators (pdf) (64 pp, 182 KB). Costs of monitoring systems, both Continuous Emission Monitors and parametric monitoring systems, are addressed in the EPA Air Pollution Control Cost Manual*, Section 2, Chapter 4 - Monitors (pdf) (42 pp, 542 KB).
Costs for catalytic oxidation of styrene emitted from fiber-reinforced plastics facilities is discussed in a report titled, Assessment of Styrene Emission Controls for FRP/C and Boat Building Industries (EPA-600/R-96-109). The report includes spreadsheets designed to quickly analyze the control cost for a catalytic oxidizer (and other VOC/HAP control technologies) based on control device input flow rate and pollutant loading (in tons per year or ppm). An introductory text file lists the controls that are analyzed and gives basic instructions for using the spreadsheets. The spreadsheets were developed for styrene (C8H8, 4.326 mg/m3 per ppm, 0. Btu/ppm) and would need to be altered to address other pollutants.
For more information, see the box Costs for Catalytic Oxidizers.
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