A catalyst is the heart of an effective emission control system. Catalytic Combustion Corporation in Bloomer, Wisconsin, is an inventor, developer, and manufacturer of precious metal-based catalysts on a variety of substrates.
Manufacturing catalyst substrates at our Bloomer, Wisconsin facilities provides a higher level of quality control meaning a more durable and long-lasting asset for your business.
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Substrates | Catalyst Elements | Precious Metals | VOC Oxidation Catalyst | Oxidation Catalyst for Coffee Roasting | Formaldehyde Oxidation Catalyst | Hydrogen Mitigation Catalyst | 3-Way Catalyst | CO Oxidation Catalyst | Diesel Oxidation Catalyst | Diesel Oxidation Trap Catalyst | Catalyst for Gas Turbine | Ventless Technology
Substrates
A strong foundation is vital to a successful outcome in anything you do: a catalyst’s substrate is no different. CCC only offers our larger round elements in a brazed foil format to ensure that they stay together in the demanding service of an industrial engine. Our smaller round elements can be either brazed construction or produced using our proprietary metal foil folding technology. For rectangular elements, our folded catalysts have provided trouble-free service for over a decade. To improve performance we use a herringbone foil pattern and have cell density choices from 75 CPSI to 600 CPSI.
Singular Catalyst Substrates
Catalysts made out of our unique substrates offer many performance advantages. The size and number of openings can be tailored to meet your needs, and our metal mesh catalyst substrates can be produced in an almost endless number of shapes and sizes. Furthermore, the fact that both of these substrates are metallic means they have low thermal mass, and are able to heat up quickly, and provide accelerated performance.
Wire Mesh Substrate
Catalysts made with a wire mesh substrate offer many performance advantages. The size and number of openings can be tailored to meet the appliance’s airflow conditions. Wire mesh catalysts can be produced in almost an endless number of shapes and sizes, again specifically tailored to meet your needs. In addition, the fact that the substrate is metallic means it has low thermal mass so it heats up quickly providing accelerated performance.
Honeycomb Substrate
Ceramic honeycomb catalyst substrates have been widely used since the 1980s. They can be extruded in a variety of shapes and cell densities. Ceramics are often used where the required catalyst volume is more than is practical for wire mesh catalysts. Ceramics make for very dimensionally stable catalyst support over the range of operating temperatures. Ceramic substrates can carry a heavier amount of coating than metallic supports, which gives ceramics the advantage in applications where catalyst deactivators are present or where high levels of precious metals are needed to reach the desired performance.
Metal Foil Substrate
Metal foil as a catalyst substrate has some of the properties of both wire and ceramic materials. It can be formed into an endless variety of shapes, sizes, and cell densities, enabling it to make larger volume pieces. Metal foil has low thermal mass relative to a comparable ceramic so it heats up quickly. Metal foil can also be expanded to form a wire mesh-like material where the openings can be specifically tailored to meet your needs.
Replacement and Custom Catalyst Elements
Through our various proprietary catalyst coating techniques, we can offer toll coating as an option for you. We provide various wash coat and precious metal catalyst formulations and will consider other types of coatings including base metal catalysts. We will assist you in recommending a coating formulation or you may specify your own proprietary formulation.
Replacement Catalyst Elements
CCC manufactures replacement catalyst elements for all OEM sizes and shapes including round, rectangular, octagonal, and custom.
Custom Shapes
CCC customizes elements for a brand new catalyst and existing or aging catalysts. We can make a replacement element for any converter or combo housing. We have made elements as small as 4” in diameter and as large as 48”.
Non-Round and Rectangular Elements
Non-rounded elements pose special challenges to manufacture. Using a brazed round element as a staring point, we can cut away the sections not needed to create a monolithic form that is one solid brick. These are then coated to provide you a catalyst that achieves the best performance possible in legacy housing designs. We manufacture rectangular elements using our folded foil technology yielding an element which is structurally solid and won’t telescope or open bypass channels. This technique of manufacturing elements is very flexible so any square or rectangular element can be produced on short notice.
Precious Metals
Platinum, Palladium, and Rhodium outperform other catalytically active elements in conversion efficiency and durability and offer a wide range of versatility for controlling engine exhaust pollutants.
- Platinum
- Palladium
- Rhodium
- Custom formulations available to meet application-specific exhaust gas profiles
Catalyst Products
VOC and Process Emissions Control
VOC Oxidation Catalyst
To control VOCs in industrial settings, a Catalytic Oxidizer is a common solution. Adding catalyst technology to an oxidizer offers high destruction efficiencies, low operating cost, and low capital costs. Each catalyst used for this type of application is custom designed for the for the specific process.
Oxidation Catalyst for Coffee Roasting
Catalyst for Ventless Ovens and Commercial Appliances
The trend today is to bring commercial kitchens into the dining area. This new trend has commercial oven, charbroiler, pizza oven, fryers, and other cooking equipment manufacturers looking for new technologies to make this equipment operate in an environment without the typical vent hood and appear ventless to patrons while still protecting the air from harmful emissions, grease, smoke, and odors. Catalytic Combustion Corporation is at the forefront of this industry in developing new products for ventless commercial cooking technologies. See more below.
Formaldehyde Oxidation Catalyst
Emission reduction
- Formaldehyde (HCHO) up to 99%
- Hazardous Air Pollutants (HAPs) up to 95%
- Carbon Monoxide (CO) up to 99%
- Volatile Organic Compounds (VOCs) up to 95%
Used for lean burn natural gas engines, gas turbines, and in regenerative catalytic oxidizers
Industries: Wastewater treatment plants, Gas Compression, Power Generation, Combined Heat and Power, Greenhouses
Hydrogen Mitigation Catalyst
With the growing realization that hydrogen will play a larger role as a non-greenhouse gas contributing fuel, the question of how to control both excess and fugitive hydrogen emissions is asked. Catalytic Combustion, drawing on our decades of experience in controlling hydrogen in the nuclear power industry, has the answer readily at hand.
At our disposal is a family of catalyst formulations that utilize the hydrogen in a reaction with oxygen to form harmless water vapor. The catalysts have been developed to have high levels of reactivity at the lowest temperatures possible. To permit us to tailor the format of the catalyst to the requirements of your equipment these formulations can be coated on a variety of substrate supports such as:
- Metal Foil
- Woven Wire Cloth
- Knitted Wire Forms
- Micro-Expanded Metal
- Ceramic Monoliths
- Ceramic Pellets
Catalytic Combustion’s technology can be utilized to mitigate the hydrogen emissions from many sources including:
- Exhaust flow from an engine or turbine operating on blended natural gas & hydrogen fuel
- Residual hydrogen emissions from a fuel cell
- Electrolytic hydrogen generation process
- Gas reforming process
- Fugitive emissions from the charging of lead-acid batteries
The advancement of the hydrogen economy will inevitably lead to other processes that will require control of excess hydrogen. So whether your source of hydrogen is from a well-known process or a cutting edge development, Catalytic Combustion has the technology and products to help you eliminate those emissions.