Catalytic Oxidizer Services

From routine inspections to catalyst upgrades, our catalytic oxidizer services help improve system reliability, efficiency, safety, and environmental compliance.

Don’t Let a Repair Become a Replacement

Catalytic oxidizers are typically low-maintenance systems with few moving parts, designed for long-term, steady operation. However, regular inspections and upkeep are essential to ensure optimal performance and cost-efficiency. Pay special attention to the catalyst, as fouling from masking agents like dust, dirt, and debris can reduce pollutant destruction. Additionally, stainless steel components should be inspected regularly to avoid expensive future replacements.

Catalytic Oxidizer On Site

 

Services include:

  • Catalyst cleaning, repair, and replacement
  • Cleaning and/or repairing heat exchanger tubes
  • Control upgrades for better performance and faster troubleshooting
  • Burner tuning
  • Gas train leak testing (mandatory, annual NFPA safety testing)
  • Process fan balancing and repairs
  • Ductwork repairs and replacement
  • Replacement parts
  • Servicing wet scrubbers (e.g., acid gas scrubbers) and/or dust
    collectors/baghouses if used upstream of a catalytic oxidizer

We’ve helped a variety of facilities solve compliance and/or safety challenges in the following ways:

  • Exchanging a lower-performing catalyst with a higher-performing catalyst
  • Recalibrating instruments to avoid outages or deviations
  • Inspecting equipment specifically for leaky bypasses or components
  • Installing specialized equipment to prevent chamber emissions “spikes” that can cause
    an upset condition
  • Substituting forced draft fan configuration to induced draft (a negative pressure on the
    system lowers the potential for fugitive emissions through leakage

CATALYST CAUSING COMPLIANCE ISSUES?

Regular catalyst testing is key to environmental compliance. Often, a drop in temperature rise across the catalyst means a proportional drop in destruction of pollutants. We’re experienced with types of catalysts, including Precious Metals (e.g., platinum, palladium), Metal Oxides (e.g., cobalt oxide, chrome oxide, copper oxide), and Metal Carboxylates (e.g., iron carboxylate), and we can resolve your issues quickly and cost-effectively.

Round catalyst with anti-telescoping bars

DOES YOUR CATOX NEED A CONTROLS UPGRADE?

Catalytic Oxidizer on-site
Our controls engineers can upgrade your catalytic oxidizer’s control system to enhance system efficiency, reliability, and ease of use. Upgrades improve temperature regulation to protect the catalyst and can include robust options like remote monitoring, data logging, and hazardous area classification. Keep in mind: older control systems may contain obsolete parts, increasing the risk of extended downtime.

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What Can Poison Catalyst?

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Table showing types of catalyst poisons, their examples, and effects.
AGENT EXAMPLES EFFECT
Coating Agents Rust, Dirt, Inorganic Oxide Covers catalyst active site. Catalyst replacement may be required.
“Glass” Forming Coating Agents Silicones, Organic Silicates, Phosphorous-containing materials Washing may remedy the situation; Factory reactivation or replacement often necessary
Halogens Chlorine, Fluorine, Iodine, Bromine Prolonged exposure and/or higher concentrations result in temporary or permanent deactivation of catalyst
Sulfides Permanent deactivation of catalyst
Organic Droplets / Aerosols May carburize the catalyst or cause substrate deterioration

NEED TO RENT A CATALYTIC OXIDIZER?

Our RCO-8.5 recuperative catalytic oxidizer is designed to provide destruction of Volatile Organic Compounds (VOCs) from an air stream at >95%. This rental unit’s flexible design can adapt to multiple conditions while operating independent of your process.

PolSys rental Catalytic Oxidizer

If Your Facility is Involved in Ethylene Oxide (EtO) Sterilization…

We can help you keep up with ever-changing industry changes in emissions standards with services like upgrading your control system and inspecting safety interlocks to allow for the safest treatment of EtO. Upgrading and/or altering existing oxidizer systems to achieve higher destruction efficiencies requires an understanding of a complex array of factors, such as your operational goals, DRE requirements, waste stream, and existing system limitations. Let us help you determine whether your system needs relatively minor adjustments or a retrofit.

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