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.

Emission Control Products

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.

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 Recombination Catalyst

The advent of nuclear power plants necessitated a way to recombine the hydrogen, which was released from both the disassociation of water and the interaction of high-energy particles on the fuel cladding, with oxygen to form water. If left unchecked, the hydrogen would accumulate in the containment vessel and eventually build up to an explosive level. This is why all commercial nuclear power generating units have employed a catalyst to facilitate the recombination reaction.

Catalytic Combustion Corporation supplied its first catalyst for this service in 1956 and, since then, has supplied catalysts for over half of the nuclear power plants in the world. Catalytic Combustion technology has also been employed in the boron-stripping loop for pressurized water reactors (PWR) and in water-cooled linear accelerators.

Catalytic Combustion Corporation provides design assistance for both process and passive autocatalytic recombiners. The catalysts used for the recombination of hydrogen require a very high activity level so that they function at low temperatures and low hydrogen concentrations. They also need to have a low thermal mass and not be affected by the presence of water.

To meet these requirements, Catalytic Combustion has developed a metal-based catalyst plug that combines these desirable attributes with a conveniently usable bulk substrate. The substrate is a knitted wire form that maximizes the available surface area without restricting the flow of gases through the plug.

The plug’s loose bulk form allows it to be easily poured and drained from the process vessel, either by gravity or with a vacuum conveyor. And unlike ceramic pellets, Catalytic Combustion´s plugs do not adsorb water and are self-drying.

Reciprocating Engine Emissions Control

Three Way Catalyst

Three Way Catalyst is a non-selective catalytic reduction product for rich burn natural gas engines, propane and gasoline industrial engines, and chemical processes providing very high reduction rates of NOx, CO, HC, VOCs, and HAPs over a broad temperature operating range. Platinum/Rhodium and Palladium/Rhodium versions for NOx, CO, and VOCs, and dithering and non-dithering control schemes compatible.

CO Oxidation Catalyst

Oxidation Catalyst (CO Catalyst) is designed for use in combined cycle gas turbine power plants, simple cycle gas turbine power plants, and for new installations for replacement/retrofit. Formaldehyde (HCHO) reduction technology available.

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

Diesel Oxidation Catalyst

Diesel Oxidation Catalyst is used on diesel engines primarily for carbon monoxide (CO) reduction as well as to reduce the total hydrocarbon emission and particulate matter.

Diesel Oxidation Trap Catalyst

Diesel Oxidation Trapping Catalyst is designed for use in applications requiring a more significant particulate matter reduction than a Diesel Oxidation Catalyst alone, but less than what a Diesel Particulate Filter would provide.

Gas Turbine Emissions Control

Sulfur-Resistant CO Oxidation Catalyst

Sulfur-Resistant Catalyst is designed for use in combined and simple cycle gas turbine power plants where inlet temperatures may dip below 700° F or where variable composition natural gas or dual-fuel may be present. Formaldehyde reduction technology available.

CO Oxidation Catalyst

Oxidation Catalyst (CO Catalyst) is designed for use in combined cycle gas turbine power plants, simple cycle gas turbine power plants, and for new installations for replacement/retrofit. Formaldehyde (HCHO) reduction technology available.

Formaldehyde Control 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

How can we help you today?

Contact Catalytic Combustion