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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
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Oxygenated Hydrocarbons
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Alkanes & Alkenes
Contains catalyst poisons
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Standard Catalytic Combustion CO System
Standard Series

Catalytic Combustion (CO) Furnace

Engineered for high-efficiency VOC destruction and optimal thermal recovery. Ensure strict environmental compliance while drastically driving down operational costs across diverse industries.

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CO Device for Oil Tank Area Waste Gas
Specialized Solution

CO Device for Oil Tank Area Waste Gas

A specialized catalytic combustion device strictly engineered for the unique safety and volatility requirements of treating high-concentration waste gas specifically in oil tank areas.

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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).

Catalytic Combustion Process
Catalytic Combustion Process
Process Introduction

Catalytic Combustion Process

Our BL-CO series furnace integrates design, manufacturing, installation, and commissioning. It represents internationally leading advanced equipment in the fields of environmental protection and energy recovery.

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    High Stability & Efficiency: Continuous optimization in industrial projects ensures a highly rational structure, stable operation, and exceptional processing efficiency.
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    Strict Compliance: Fully capable of meeting various rigorous environmental protection and energy efficiency standards.
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    Wide Application: Extensively utilized across industries such as chemicals, coking, pharmaceuticals, spraying, and printing.
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    Dual Benefits: Achieves highly efficient and safe treatment of VOCs and carbon monoxide alongside valuable energy recovery and utilization.

 

For a typical VOC like acetone (C₃H₆O):

C₃H₆O + 4O₂ → 3CO₂ + 3H₂O + Heat

General reaction equation:

VOC + O₂ → CO₂ + H₂O + Thermal Energy

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Working Mechanism of Catalytic Oxidation

Catalytic Oxidation Process Diagram

The key to the catalytic oxidation process is that the catalyst lowers the energy barrier of the reaction. Its working mechanism can be summarized in the following five key steps.

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1

Adsorption of Reactants

VOCs molecules and oxygen (O₂) enter the reaction zone. They are physically or chemically adsorbed by the unique pore structure and active sites, enriching on the catalyst surface.

2

Activation & Bond Weakening

The catalyst interacts with adsorbed molecules through active components, weakening and breaking their original chemical bonds, putting them in a highly reactive "activated" state.

3

Surface Oxidation Reaction

Activated oxygen fully contacts and reorganizes with activated VOCs on the surface. A thorough redox reaction occurs: Hydrocarbons (CxHy) are cleaved, and C and H combine with O.

4

Product Desorption

The new substances generated—carbon dioxide (CO₂) and water vapor (H₂O)—desorb from the catalyst surface and re-enter the gas flow. The catalyst itself remains unchanged.

5

Heat Release

This is a strongly exothermic reaction. Part of the released heat maintains the catalyst bed's temperature, while another part preheats incoming waste gas, saving fuel consumption.

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.

Low-temperature operation

Significant energy savings, avoiding high-temperature safety hazards

High removal efficiency

Up to 95–99% for applicable VOCs

Compact structure

Flexible installation, suitable for space-constrained scenarios

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

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.

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.

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.).

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).

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).

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).
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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.

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