Catalytic Oxidizer (CO)

Ever-power Catalytic Oxidizer (CO) destroys VOCs at low temperatures with up to 98% efficiency—cutting energy use, eliminating NOx, and saving space. Custom catalysts, smart controls, and global compliance built in. Perfect for pharma, electronics, and printing. High performance. Lower cost. Trusted worldwide.

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Aromatics

Oxygenated Hydrocarbons

Alkanes & Alkenes

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Contains catalyst poisons

High-efficiency Catalytic Oxidizer – Ever-power CO

Catalytic oxidizers (CO) utilize highly efficient catalysts to completely oxidize volatile organic compounds (VOCs) into harmless CO₂ and H₂O at low temperatures of 250–400°C, avoiding the high energy consumption and NOₓ generation problems of traditional high-temperature incineration. As a key technology for industrial waste gas treatment, CO is particularly suitable for scenarios involving low to medium concentrations of organic waste gas with clearly defined components and high cleanliness.

The Ever-power CO system employs customized anti-poisoning catalysts, intelligent temperature control logic, and a compact design, ensuring a removal efficiency of ≥98% while significantly reducing fuel consumption and operation and maintenance costs. It requires no heat storage structure, resulting in lower investment and faster deployment—providing a cost-effective and highly reliable green solution for industries such as pharmaceuticals, electronics, and printing.

What is Catalytic Oxidizer (CO)

A Catalytic Oxidizer (CO) is an air pollution control device that uses a catalyst to oxidize volatile organic compounds (VOCs) and hazardous air pollutants (HAPs) into carbon dioxide (CO₂) and water (H₂O) at lower temperatures. Compared to traditional thermal combustion, CO achieves high purification efficiency without the need for high temperatures, making it an ideal solution for medium-to-low concentration, clean organic emissions.

Key Mechanism: The catalyst lowers the activation energy required for VOC oxidation, allowing the reaction to proceed rapidly at temperatures far below the auto-ignition point (typically 600–800°C).

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Preheating Exhaust Gas

VOC-containing exhaust gas first enters a heat exchanger, where the residual heat of the purified high-temperature gas preheats it to the catalyst ignition temperature (typically 250–400°C).

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Catalytic Oxidation Reaction

The preheated exhaust gas enters the catalytic bed, where a low-temperature oxidation reaction occurs on the catalyst surface (e.g., Pt/Pd), efficiently decomposing VOCs into CO₂ and H₂O.

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Release of Reaction Heat

The oxidation reaction is exothermic, releasing a large amount of heat, significantly increasing the outlet gas temperature (typically higher than the inlet temperature).

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Energy Recovery

The high-temperature purified gas passes through the heat exchanger again, transferring heat to the incoming cold exhaust gas, achieving thermal energy recycling and significantly reducing external fuel consumption.

For a typical VOC like acetone (C₃H₆O):

C₃H₆O + 4O₂ → 3CO₂ + 3H₂O + Heat

General reaction equation:

VOC + O₂ → CO₂ + H₂O + Thermal Energy

Technical Features (CO vs. RTO/RCO)

Feature	CO (Catalytic Oxidizer)	RTO (Regenerative Thermal Oxidizer)	RCO (Regenerative Catalytic Oxidizer)
Operating Temperature	250–400°C	760–850°C	250–400°C
Energy Consumption	Low (no regenerators, but continuous heating needed)	High (can be self-sustaining at high concentrations)	Very low (regeneration + catalysis, often self-sustaining)
NOₓ Generation	Nearly zero	Possible (due to high temperatures)	Nearly zero
Footprint	Small (simple structure)	Large (multi-chamber/rotary design)	Moderate
Capital Cost	Lower	Higher	Moderate to higher
Applicable Emissions	Clean, non-toxic, medium-to-low concentration VOCs	Various VOCs (tolerant to dirt)	Clean, non-toxic, medium-to-low concentration VOCs
Catalyst/Materials	Requires catalyst (may deactivate)	No catalyst	Requires catalyst + regenerators
Startup Speed	Fast (low thermal inertia)	Slow (requires preheating regenerators)	Moderate

⚠️ Note: CO requires high intake air cleanliness and is not suitable for exhaust gases containing halogens, sulfur, silicon, dust, or oil mist. For complex exhaust gases, it is recommended to use a pretreatment system or select RTO/RCO.

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Low-temperature operation

Significant energy savings, avoiding high-temperature safety hazards

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High removal efficiency

Up to 95–99% for applicable VOCs

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Compact structure

Flexible installation, suitable for space-constrained scenarios

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Zero NOₓ emissions

Strong environmental compliance

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Quick start-stop

Suitable for intermittent production conditions

Which Gases are Suitable for CO Treatment?

Gas Category	Typical Representative Substances	Suitable for CO	Common Application Industries	Typical Processes/Scenarios
Alcohols	Methanol, Ethanol, Isopropyl Alcohol (IPA)	✅ Yes	Pharmaceuticals, Electronics, Cosmetics, Food	Reaction solvents, Cleaning, Extraction, Drying
Ketones	Acetone, Methyl Ethyl Ketone (MEK), Cyclohexanone	✅ Yes	Electronics Manufacturing, Pharmaceuticals, Coatings	Photoresist cleaning, Synthesis reactions, Degreasing
Esters	Ethyl Acetate, Butyl Acetate, Isopropyl Acetate	✅ Yes	Printing, Packaging, Furniture Coating, Adhesives	Flexographic/Gravure printing, Laminating, Varnishing
Aromatic Hydrocarbons	Toluene, Xylene, Ethylbenzene	✅ Yes (Concentration assessment needed)	Paints, Inks, Chemicals, Automotive Parts	Spraying, Drying, Resin synthesis
Alkanes/Olefins	n-Hexane, Cyclohexane, Heptane	✅ Yes	Electronics, Pharmaceuticals, Precision Cleaning	Cleaning agents, Extraction solvents
Ethers	Tetrahydrofuran (THF), Ethylene Glycol Monomethyl Ether	✅ Yes (Polymerization prevention needed)	Pharmaceuticals, Lithium Batteries, Fine Chemicals	Polymerization reactions, NMP alternative solvents
Aldehydes	Formaldehyde, Acetaldehyde	⚠️ Conditionally suitable	Resin manufacturing, Textiles, Food processing	Concentration control required to avoid catalyst fouling
Organic Acids	Acetic Acid, Propionic Acid	⚠️ Conditionally suitable	Food flavors, Pharmaceuticals	Feasible at low concentrations; high concentrations may corrode or affect catalyst performance
Some Amines	Triethylamine, Dimethylamine	⚠️ Evaluate with caution	Pharmaceuticals, Pesticides	Prone to generating ammonia or nitrogen oxides; custom catalysts required

❌ Not Suitable or High-Risk Gases (Generally not suitable for direct use in CO; pre-treatment or RTO is recommended):
Halogenated Compounds: Chlorobenzene, Dichloromethane, Freon (Generate corrosive acids, poison catalyst)
Sulfur Compounds: H₂S, Mercaptans, SO₂ (Cause permanent deactivation of catalyst)
Siloxanes/Silicones: From defoamers, sealants (Generate silica at high temperatures, clog catalyst beds)
Phosphorus Compounds, Heavy Metal Vapors: Catalyst poisons
High Concentrations of Particulates, Oil Mist, Tar: Physical blockage of catalyst bed

✅ Prerequisites: The exhaust gas must be clean, dry, free from catalyst poisons, with VOC concentrations typically within the range of 200–3,000 mg/m³.

CO2 Customized Design
Tailor-made Solutions for Your Exhaust Gases

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Gas Composition Analysis

Identify VOC species, concentration ranges, fluctuation patterns, and potential catalyst poisons (e.g., Cl, S, Si) via GC-MS, FTIR, or on-site sampling.
Determine suitability for catalytic oxidation and assess catalyst poisoning risks.

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Operating Condition Review

Capture dynamic parameters: airflow (Nm³/h), temperature, humidity, pressure, LEL (Lower Explosive Limit).
Understand production mode (continuous vs. batch), startup/shutdown frequency, and peak emission periods.

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Site & Interface Assessment

Evaluate available space, lifting constraints, and foundation load capacity.
Confirm integration requirements with existing infrastructure: ducting, fans, stack, electrical systems (flange standards, control signals, etc.).

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Catalyst Compatibility Evaluation

Select optimal catalyst formulation: precious metal (Pt/Pd) or non-precious alternatives, based on gas composition.
Customize anti-poisoning or anti-coking formulations for challenging components (e.g., amines, aldehydes).

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System Configuration Customization

Choose heat exchanger type (plate or shell-and-tube), heating method (electric or natural gas), and safety interlocks (LEL monitoring, dilution system).
Integrate optional features: CEMS, remote diagnostics, explosion-proof design (ATEX/SIL2).

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Performance Simulation & Validation

Use thermodynamic modeling to simulate light-off temperature, fuel consumption, and destruction efficiency.
Deliver third-party verifiable performance guarantees (e.g., ≥98% DRE, emissions ≤XX mg/m³).

Case Study: Ever-power CO2 helps a South Korean semiconductor packaging plant achieve green compliance by efficiently treating electronic cleaning exhaust gases.

SemiCore Co., Ltd. (pseudonym, to protect customer privacy)
Location: Gyeonggi Province

Background

SemiCore is a mid-sized manufacturer specializing in advanced chip packaging (such as Fan-Out WLP and SiP). Its cleaning processes heavily utilize isopropanol (IPA) and acetone as photoresist removers. With the implementation of the 2023 amendment to South Korea’s Atmospheric Environment Protection Act, VOC emission limits have been tightened to ≤50 mg/m³. Existing activated carbon adsorption systems are no longer sufficient to meet these standards and suffer from high hazardous waste disposal costs and frequent replacements.

Key Challenges

The exhaust gas composition is complex but clean: mainly IPA (~800 mg/m³) and acetone (~400 mg/m³), halogen-free/sulfur-free, but with large humidity fluctuations (30–70% RH).
Space is extremely limited: the plant is a converted workshop, with only a 3m × 4m installation area reserved.
High production continuity requirements: the equipment needs to support 24/7 operation, with a downtime window of <8 hours.
Budget sensitive: the customer wants to keep CAPEX within 60% of the RTO (Recovery To Take) plan while complying with regulations.

How to find Ever-power

The client learned about Ever-power’s numerous successful VOC treatment cases in the electronics industry through LinkedIn technical articles and proactively contacted our Korean distributor. After initial technical discussions, it was confirmed that their exhaust gas was fully compatible with CO technology, and the client subsequently invited the Ever-power engineering team to conduct an on-site survey.

Our Solution

Equipment Model: EP-CO-5000 (Airflow Capacity: 5,000 Nm³/h)
Core Technology Configuration:
Dual-channel plate heat exchanger (heat recovery efficiency ≥92%)
Moisture-resistant Pt/Pd catalyst (optimized for high humidity IPA/acetone)
Electric heating assistance + LEL safety interlock (explosion-proof rating ATEX Zone 2)
Skirt-mounted design (overall dimensions 2.8m × 3.5m × 2.6m, meeting site limitations)
PLC automatic control + remote monitoring platform (supports Korean interface)
Delivery Time: 10 weeks (including sea freight and customs clearance)

Results After Implementation

Metric	Before Retrofit (Activated Carbon)	After Retrofit (Ever-power CO)
VOC Destruction Efficiency	~85% (highly variable)	≥98.5% (verified by third-party testing)
Emission Concentration	120–200 mg/m³	<30 mg/m³ (consistently compliant)
Energy Consumption	No direct energy use, but high hazardous waste disposal costs	55% lower fuel consumption vs. RTO
Operating & Maintenance Cost	Activated carbon replacement monthly (~$8,000/month)	Annual catalyst maintenance < $3,000
Footprint	Occupied space for two adsorption towers	40% less space required

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Client Testimonial

“
Ever-power’s CO system not only helped us pass Korea’s Ministry of Environment compliance inspection on the first attempt, but also significantly reduced our operational burden. The remote diagnostics feature allows us to monitor equipment status even outside working hours—truly ‘install and forget.’
— Kim Min-jae
EHS Manager, SemiCore Co., Ltd.