Precious Monolith-to-Base metal oxide Bead Catalyst
Catalytic Oxidizer Retrofit
The Problem
The printing company wanted to upgrade their catalytic oxidizers to improve destruction
efficiency and reduce operating and maintenance costs.
The basic design of the oxidizers was good; the units were well maintained, structurally
sound, and operationally reliable. However, the precious metal monolith catalyst used in
these oxidizers deactivated quickly due to trace amounts of silicone, sulfur and
phosphates in the process exhaust airstream. These contaminants routinely masked the
active metal sites on the monolith catalyst, which required frequent cleaning and/or
replacement in order to maintain destruction efficiency.
While cleaning monolith catalyst is somewhat less costly than replacement, it is a
time-consuming procedure that typically requires 8 to 10 days of down time. Even if a
thorough job is done, the cleaning procedure is not able to remove all of the masking
agents. And because each cleaning cycle removes some of the active metal sites,
catalyst performance decreases with each cycle. While in theory the catalyst can be
washed repeatedly, in reality, after the second washing, catalyst performance can become
unacceptable very quickly.
The Solution
We proposed to upgrade this equipment by replacing the metal monolith with 1/8” base
metal oxide bead-type catalyst (other bead sizes are also available). The bead catalyst
has shown superior poison resistance in numerous flexographic facilities with similar
applications, maintaining good catalyst activity for 15 years and counting. In this particular
situation, the cost of the upgrade, including unit modification, matched a one-time
replacement cost of the monolith catalyst.
The units were fit with catalyst beds of proven design, the same beds that are currently
supplied in the catalytic oxidizers. The 5-day installation of the upgrade began at 7:00 am
on a Monday and was completed by the end of the day Friday.
We used thermal imaging to ensure integrity of the retrofit, which involved removal of the
entire end wall of the oxidizer. After completion of the upgrade and thermal imaging review,
a stack test was performed as part of the project to confirm the oxidizers’ improved
destruction efficiency levels. A portable Flame Ionization Detector (FID) was used to
determine that the new destruction efficiency was 99.6%.
The Result
Since completion of the upgrade, the oxidizers have been operating flawlessly.
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