Catalytic Filtration
Catalytic Hot Gas Filtration
Envanio’s catalytic hot gas filtration is based on an integrated 3-in-1 process for industrial hot gas and exhaust air purification. Rigid, high-temperature ceramic filter elements enable the simultaneous removal of particulate dust, heavy metals, sulfur oxides (SOx), and nitrogen oxides (NOx) from process exhaust in a single compact system. Because the catalytically active filter elements operate across a wide thermal window, the system delivers high destruction and removal efficiencies with exceptional energy efficiency.
High Removal Efficiency
Thanks to a high pollutant removal efficiency up to 95%, the Envanio system ensures dependable compliance with stringent environmental regulations and emission limits.
Energy Recovery from Waste Heat
Because clean gas exits the filter at elevated temperatures, valuable waste heat can be recovered downstream of the air pollution control system for steam generation or plant heating.
Compact & Rugged Design
Envanio’s compact, heavy-duty design provides a space-saving lightweight footprint built for a long operational service life.
Energy-Efficient Purification of Medium to Large Air Flow Rates with Constant Pollutant Concentration
| Process | Catalytic Filtration |
|---|---|
| Air Flow Rate | 1,000 Nm³/h to 100,000 Nm³/h |
| NOx Concentration | up to 3 g/Nm³ |
| Exhaust Air Temperature | up to 450 °C |
| Removal Efficiency | up to 95% |
| Typical Target Pollutants | Particulate matter, dust, nitrogen oxides (NOx), sulfur dioxide (SO2) and sulfur trioxide (SO3), hydrogen chloride (HCl) |
Each system is custom-designed based on your requirements and processes.
The Design of Our Catalytic Filter Element System
Depending on the exhaust air volume, our catalytic filter element system consists of one or more modular filter chambers that can be flexibly operated in series or in parallel. Each module is equipped with catalytically active ceramic filter elements. Modules can also be isolated individually to accommodate fluctuating air volumes or for maintenance, allowing filter cleaning in offline mode without disrupting ongoing production operations.
Typical Applications for Catalytic Hot Gas Filtration
Envanio designs and manufactures systems for the purification of exhaust gases and exhaust air tailored to your facility’s production processes. Thanks to its robust construction and high cleaning performance, our catalytic filter element system is well suitable for the following applications.
- Glass Industry View Industry Catalytic hot gas filtration removes fine particulate matter, nitrogen oxides (NOx), and acidic gases such as sulfur oxides (SOx) or HCl from the complex exhaust gas emitted by glass melting furnaces in a single, compact footprint. This combined 3-in-1 process enables the glass industry to comply with strict environmental regulations while operating a cost-effective exhaust gas treatment system.
- Cement Industry View Industry Catalytic hot gas filtration removes fine particulate matter, nitrogen oxides (NOx), and acidic gases such as sulfur oxides (SOx) or HCl from the complex exhaust gas emitted by rotary kilns and clinker coolers in a single, compact footprint. This combined 3-in-1 process enables the cement industry to comply with strict environmental regulations while operating a cost-effective exhaust gas treatment system.
- Woodworking Industry View Industry Catalytic hot gas filtration removes fine particulate matter, nitrogen oxides (NOx), and acidic gases such as sulfur oxides (SOx) or HCl from the complex exhaust gas emitted by wood chip and waste wood combustion systems, wood gasification plants, and particleboard/MDF production in a single, compact footprint. This combined 3-in-1 process enables wood product manufacturers to comply with strict environmental regulations while operating a cost-effective exhaust gas treatment system.
360° Service for Your Air Pollution Control System
Take advantage of our 360° support for air pollution control systems from Envanio or third-party manufacturers. Our service teams support your plant throughout the entire equipment lifecycle, providing routine inspections, preventative maintenance, system audits, efficiency retrofits, repairs, and genuine replacement parts.
FAQ
The use of recuperative thermal oxidation systems is recommended when destruction efficiency, dependable process reliability, and flexibility in handling diverse pollutants are required. The system is particularly effective when high VOC loads must be treated safely and reliably. When VOC concentrations, exhaust air flow rates, or pollutant compositions vary widely, a TNV system often performs far more robustly than biological or adsorptive processes.
More Ways to Treat Exhaust Air
To deliver solutions tailored to your specific requirements and varying operating conditions, Envanio offers a wide range of standard and custom-engineered air pollution control systems based on thermal oxidation.
Regenerative Thermal Oxidation
Regenerative thermal oxidation (RTO) is a highly efficient process that cleans industrial exhaust by destroying hazardous air pollutants (VOCs and HAPs) and eliminating unpleasant odors. By using internal ceramic heat exchange media, the system traps and recycles its own heat, making the entire purification process incredibly energy efficient.
Electric Regenerative Thermal Oxidation
Envanio's electrically heated regenerative thermal oxidizer (eRTO) combines high VOC destruction efficiency, operational reliability, and exceptional energy performance. By using electric heating elements instead of gas-fired burners, the system avoids combustion-related byproducts and significantly reduces NOₓ emissions. The result is a cleaner, more sustainable solution for industrial air pollution control.
Recuperative Thermal Oxidation
Recuperative thermal oxidation is a highly efficient process that cleans industrial exhaust air by destroying hazardous air pollutants (VOCs and HAPs) and eliminating unpleasant odors. The system is also well suited for processes where particulate matter and aerosols are generated. An integrated metallic shell-and-tube heat exchanger enables efficient primary heat recovery.
Direct Fired Thermal Oxidation
Direct fired thermal oxidation is a highly efficient process that cleans industrial exhaust by destroying hazardous air pollutants (VOCs and HAPs) and eliminating unpleasant odors. The system is particularly well-suited when heavily contaminated exhaust streams must be treated reliably with high removal efficiencies, and when complex heat recovery systems are not economically feasible.
VOC Concentration
Envanio’s VOC concentration process uses adsorption to concentrate dilute solvent emissions. For cost-effective air pollution control, adsorption is recommended first to concentrate large exhaust airflows with low pollutant loads. The concentrated exhaust air is then routed to downstream recuperative or regenerative thermal oxidation for highly energy-efficient destruction.
Activated Carbon Adsorption
Envanio’s activated carbon adsorption is based on the physical adsorption process to purify industrial process air of volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) from industrial exhaust air, with the option for solvent recovery. In our regenerative systems, both the adsorbent and solvents are recovered for reuse, while in non-regenerative systems, the spent activated carbon is safely disposed of or replaced along with the captured pollutants.
Wet Scrubbing
Envanio’s wet scrubbers rely on absorption for the wet separation of inorganic compounds, particulates, mist, and acidic gases. During the regenerative or direct-fired thermal oxidation of halogenated hydrocarbons or sulfur compounds, substances such as hydrogen halides or SOx are generated, which must be scrubbed from the exhaust air in a downstream wet scrubber.
Liquid Distillation
Envanio’s distillation systems efficiently separate solvents from water and split complex solvent mixtures into reusable components. Integrated recovery processes reduce raw material consumption and operating costs, with flexible designs for batch or continuous operation.
