Thermal and Catalytic Reators

ComEnCo has developed an efficient alternative to high temperature thermal oxidation. Since oxidation is purely a chemical process, it can be enhanced by the presence of a suitable catalyst. Properly designed and installed, the ComEnCo reactor can dramatically lower the temperature and energy required to oxidize contaminants.

ComEnCo catalytic reactors are presently working successfully in numerous installations for a variety of industries including:

• Chemical Processes, such as Phthalic Anhydride Plants, Formaldehyde Plants, Other Air Oxidation Processes, Organic Chemical Production, and Pharmaceuticals
• Automotive Paint Systems
• Can Manufacturing
• Wire Enameling
• Metal Sheet and Strip Coating
• Soil Remediation
• Groundwater Treatment
• Food Processing, such as Coffee Roasting, and Bakeries
• Asphalt Processes
• Tire Cord Treating
• Fabric Coating
• Printing Processes, such as Flexographic, Web-Offset, and Lithographic
• Converting Processes
• Magnetic Film Coating
• Foundry Core Molding
• Plastic and Resin Processing
• Electronics

Actual operating temperatures are typically 600 to 900 degrees Fahrenheit for catalytic incineration and 1350 to 2000 degrees Fahrenheit for thermal incineration depending upon the specific design features of the system, the pollutants involved and the percentage conversion required. A correctly selected catalyst can help you conserve energy in more ways than simply reducing the operating temperatures of your equipment. Often, the heat resulting from the catalytic oxidation of offending pollutants can be recovered or recycled to provide additional savings. In some cases, the heat may be utilized to sustain the oxidation reaction after initial start-up. The processed air stream is passed through a ComEnCo recuperative heat exchanger before venting to the atmosphere. Incoming pollutant-laden vapor is then preheated to either totally sustain the oxidation or, at the least, reduce the amount of fuel required to keep the reaction at the operating temperature. The heat in the cleaned air stream may be suitable for direct use as a recirculated, controlled atmosphere for the process itself. It may also be recovered in a secondary heat exchanger or waste heat boiler. Heat recovery offers large fuel saving potential.

Mineral wool SS Inner and aluminized outer skins Structural steel support
	Nema 4 or 12 construction Prewired and tested Colour coded wires with numbered terminal strips Dust or oil tight push to test lights Optional computer controls Continuous temperature monitoring and recording Annunciation systems
Wide turndown ratio Raw gas or premix Line or nozzle mix Controlled by modulating discharge temperature controls
	Prewired and tested Built to FM, IRI, CIRA, and local standards
Built to suit customers Access availability Pre-assembled prior to shipment
	All welded 304, 316 or 347 stainless steel Custom designed efficiencies, pressure drop, cell spacing and physical size Laminar flows No effluent leakage or cross contamination

Features

• High percent VOC destruction
• Expertly designed catalytic reactors
• Easily handles mixtures of VOCs
• Easily handles wide variations in gas flow
• Easily handles wide variation in VOC concentration
• Field proven catalyst in over 1,000 installations worldwide
• Utilizes catalysts and heat recovery equipment
• Catalyst formulations matched to customer application requirements
• Automatic system controls
• Prevents nitrogen and oxygen fixation
• Precious metal catalyst
• Converts VOCs to harmless water and carbon dioxide
• Smaller size and weight than thermal systems
• Catalyst impregnated on honeycomb monolith
• Ceramic or metal substrate honeycomb
• Peletized catalyst systems

Benefits

• Meet regulatory requirements
• Allows flexibility in solvent formulations
• Allows multiple source flexibility
• Allows production rate flexibility
• Dependable operating performance
• Lower operating costs and higher energy efficiency
• Long catalyst life (typically 5-8 years)
• Simple and reliable operation
• No nitrogen oxides formed from atmospheric nitrogen
• No solid or liquid waste disposal
• Flexible, easy and low cost installation
• Low pressure drop
• Very good shock and vibration resistance
• Catalyst washable for long life
• Suitable for use with chlorinated hydrocarbons

Unit Sizing

The actual unit sizing and selection of the volume of catalytic modules must be done by ComEnCo to ensure that space velocities, pressure drops, heat exchanger efficiencies, burner sizing and turn-down ratios correspond to the destruction efficiencies required for the application. Standard or high activity catalytic cells may be selected dependent upon the VOC type, volume and concentration of the exhaust. It is therefore important that the Survey Form be filled out as completely as possible to ensure the most economical selection of the equipment.

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