Equipment Description:
I. Process Flow
1. Combined Adsorption-Catalytic Combustion (RCO)
Activated Carbon Adsorption Concentration: Honeycomb activated carbon adsorbs low-concentration VOCs. After saturation, it is desorbed by hot air (80-120°C), concentrating the exhaust gas to 20-50 times its original concentration.
Catalytic Oxidation: The concentrated exhaust gas enters the catalytic combustion chamber, where it undergoes oxidation and decomposition at 200-350°C. The heat energy is recycled to the desorption stage through a heat exchanger, achieving self-sustaining operation.
2. Independent Catalytic Oxidation (CO)
After being preheated to the catalyst's ignition temperature in a heat exchanger, the exhaust gas directly enters the catalytic bed for oxidation. This process is suitable for medium- and high-concentration exhaust gases (>1000 ppm).
II. Key Equipment Technical Parameters
| Parameters | Value Range |
| Applicable exhaust gas concentration | ≥3g/Nm³ (self-sustaining combustion) |
| Reaction temperature | Catalyst inlet 250-350°C |
| Emission concentration | NMHC ≤20mg/Nm³, NOx ≤50mg/Nm³ |
| Thermal efficiency | 70-90% (metal heat exchanger) |
III. Equipment Features and Advantages
Low Energy Consumption: Reaction waste heat is recovered through a heat exchanger, reducing gas or electricity consumption by over 30%;
High Safety: Equipped with a flame arrester, explosion relief valve, and temperature interlock control system to prevent the risk of catalyst sintering or explosion at high temperatures;
Modular Design: The activated carbon adsorption tank and catalytic combustion chamber can be independently replaced, supporting continuous operation with multiple gas paths and reducing downtime for maintenance by 50%.
IV. Application Scenarios
Spray Coating Industry: Treats high-concentration organic waste gases such as benzene and esters, with a purification efficiency of ≥98%;
Petrochemical/Chemical Industry: Suitable for waste gases with stable composition (free of catalyst poisons such as sulfur and phosphorus);
Packaging and Printing Industry: Combined with activated carbon adsorption and concentration technology, it can treat high-volume, low-concentration VOCs. V. Operation and Maintenance Key Points
Catalyst Maintenance: Test activity every 1-2 years, regularly remove surface carbon, or replace expired catalysts.
Heat Exchanger Cleaning: Check heat exchange channels for blockage every quarter to prevent a decrease in thermal efficiency.
Activated Carbon Replacement: Test adsorption saturation every 3-6 months based on exhaust gas concentration to ensure concentration efficiency.
Main structures and components:
I. Pretreatment Unit
1. Filtration Device
Dry Filter/G4-F9 Grade Filter: Used to intercept dust, particulate matter (particle size ≥ 1μm), and droplets in the exhaust gas, with a filtration efficiency of ≥ 98%, preventing impurities from clogging the catalyst layer.
Spray Tower (Optional): Removes acidic gases (such as HCl, SO₂) and some VOCs through water or chemical spraying, reducing the load on subsequent treatment.
2. Heat Exchanger
Plate/Tube Heat Exchanger: Utilizes high-temperature exhaust gas (250-400°C) after catalytic combustion to preheat the intake air, increasing thermal efficiency to 70-90% and reducing heating energy consumption.
Double-layer Insulated Shell: Made of carbon steel or stainless steel, with an aluminum silicate fiber insulation layer between the shells. The shell temperature is maintained at ≤ 60°C, ensuring safe operation.
II. Catalytic Reaction Unit
1. Catalytic Combustion Chamber
Electric Heating Chamber: Equipped with stainless steel electric heating tubes (24kW power), it heats the exhaust gas to the catalyst ignition temperature (200-350°C). The temperature is automatically controlled by a PLC within ±5°C.
Catalytic Bed: Filled with a honeycomb precious metal catalyst (platinum/palladium coating), the exhaust gas residence time is ≥1 second, oxidizing and decomposing VOCs into CO₂ and H₂O, with a purification efficiency of ≥95%.
2. Catalyst Assembly
Honeycomb Ceramic Substrate: Specific surface area ≥500 m²/g, loaded with precious metal active components (Pt-Pd), temperature resistance ≥600°C, and resistant to sulfur and phosphorus poisoning.
Modular Design: Supports staged replacement of expired catalysts, with a maintenance cycle of 1-2 years.
III. Heat Recovery and Discharge System
1. Waste Heat Recovery Device
Shell-and-Tube Heat Exchanger: Recovers heat from high-temperature flue gas to preheat fresh air or desorb activated carbon, reducing overall energy consumption by over 30%;
Waste Heat Boiler (Optional): Converts heat into steam for production, achieving cascaded energy utilization.
2. Discharge Piping
Carbon Steel/316L Stainless Steel Piping: Air velocity 10-15 m/s, equipped with pneumatic valves to control gas flow and reduce pressure loss;
Chimney Monitoring System: Built-in VOC, temperature, and humidity sensors provide real-time emission data feedback to the control center.
IV. Control System
1. PLC Automatic Control
Temperature Interlock: Monitors combustion chamber temperature, automatically shuts off power and issues an alarm if overtemperature occurs, preventing catalyst sintering;
Differential Pressure Monitoring: A differential pressure gauge determines filter/activated carbon clogging status and indicates replacement intervals. 2. Safety Protection
Flame Arrester: Multi-layer metal mesh/ceramic fiber structure intercepts sparks and high-temperature particles to prevent backfire and explosion.
Explosion Relief Valve: Automatically opens when pressure ≥ 0.3 MPa, releasing internal pressure.
V. Auxiliary Devices
1. Activated Carbon Adsorption Device (Optional)
Honeycomb Activated Carbon Layer: Adsorbs low-concentration VOCs (<500 ppm). After desorption, the exhaust gas concentration increases by 20-50 times, reducing the catalytic combustion load.
Circulating Desorption System: Hot air (80-120°C) desorbs the activated carbon, and the desorbed exhaust gas is returned to the catalytic combustion unit for treatment.
2. Fan System
High-temperature-resistant centrifugal fan: Air volume 2000-50,000 m³/h, air pressure 1200-2500 Pa, variable frequency control to meet operating conditions.
Features:
1.High cost performance: Based on the customer's product positioning and development strategy, and with economic affordability as the foundation, we achieve the best cost performance.
2.The advanced and meticulous design concept of the equipment, along with the highly automated industrial equipment, showcases the image of a modern and advanced enterprise.
3. It has high adaptability, meeting the current production requirements and reserving room for development, taking into account the needs of increased production and improved quality in the future.
4.Quality compliance strictly adheres to the ISO900 quality management system, with every minute detail of the entire equipment installation being strictly controlled.
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Energy-Saving and Safe Environmental Protection Equipment for High-Concentration VOCs Treatment Images
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