FLAMELESS CATALYTIC HEATERS
Industrial Gas Infrared Heating
Vulcan Catalytic Heater Systems manufactures industrial infrared catalytic heaters for the OEM market for industrial oven applications.
Infrared Catalytic Heaters (5:34)
An overview of their construction
and how they operate.
Vulcan manufactures natural gas or propane fired industrial catalytic heaters that emits infrared heat through a safe, flameless heater technology which produces a uniform low intensity heat. This heat is in the form of medium to long wavelength energy which is readily and evenly absorbed by a wide range of organic materials. Industrial Catalytic heaters have been around for many years. Since the 1990s Vulcan Catalytic Heater Systems has become the leading innovator and builder of catalytic ovens using Catalytic Heater Panels for the industrial paint finishing and drying industry. The reduced operating costs offered by Catalytic heaters, has become the preferred system for retrofits of large electrical Infrared application, offering substantial energy cost reduction with rapid payback.
Using a propriety platinum based catalyst, the products of combustion are extremely environmentally friendly, emitting only water vapor and carbon dioxide and none of the regulated gases such as Nox and Carbon Monoxide. The absence of a flame, while maintaining a heater surface temperature of 400 - 900 degrees Farenheight, generates a totally diverse and evenly distributed, long to medium wave IR across the surface of the heater. It is this particular of low intensity IR that matches the absorption characteristics of organic coatings such as powder and liquid as well as that of water, as a result these coatings quickly increase in temperature when exposed to catalytic heaters.
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Catalytic Heater Operation
When the catalytic heater is turned on the catalyst is preheated with a tubular electric heating element for approximately 15 minutes. Once the catalyst has reached 300F, safety devices are activated allowing gas to enter the back of the heater. The gas intermingles with the hot platinum catalyst and oxygen present in the surrounding air, starting an oxidation reduction reaction. This raises the catalyst temperature to between 350F and 900F, at the same time releasing water vapor and carbon dioxide. Efficiency tests have established that up to 80% of the gas is converted into infrared heat. Since the reaction temperature is well below the auto-ignition temperature for natural gas (1300 F), the reaction is flameless. The catalytic reaction is fully established five minutes after the gas enters the heater, and the pre heater is turned off.
Long to medium wave Infrared energy
The long - medium wave infrared energy emitted by the catalytic heaters is optimally absorbed by materials such as polyester, epoxy, ABS, styrene and HDPE. The infrared energy has wavelengths that are in the 3.5 to 10 microns in length, this coincides with the ideal range of 3 to 4 microns for absorption by organic materials. Matching what is emitted with what is absorbed is the key to rapid temperature increase of the object to be heated.
This energy in the form of infrared, is completely diffused and is able to be reflected. Using hotter emitting surfaces produces shorter wavelengths that miss this ideal absorption range. The lower temperature of the catalytic heaters produces a more uniform heating of substrates, with less temperature difference between the top and bottom surface of the plastic or coating. This improves product quality for molded plastic parts and product consistency for curing of paint finishes.
Gas Pulse Control
A Vulcan Catalytic heating system is controlled with state-of-the-art UL approved controls, which incorporate our unique gas pulse technology (GPS). Proved and tested for many years GPS is the most economical method of providing multi zone capability for catalytic ovens via PLC based controls. GPS carefully meters precise volume pulses of gas, ensuring ideal temperature settings while allowing for multi zoned heating arrays. The Vulcan Gas Pulse System incorporates a recipe-based menu which interfaces with digital output cards. Operators call up the recipe on the touch-sensitive PLC screen and the system automatically sets the control using the Gas Pulse System.
Vulcan offers a rebuild / refurbishment program for all industrial catalytic Heaters and your existing IR Oven(s)
Older generation catalytic heaters degrade and lose uniformity and heat output. While the catalyst (catalytic pads) may not have been consumed over time, its ability to oxidize gas may be diminished through over-spray contamination and by inert materials that will not burn off. As a result heaters that achieved surface temperatures of 800°F can lose 100-200°F after a few years of use, if operating in a dusty environment.
This service includes:
- Testing to determine defective components
- Replacement of catalyst (catalytic pads), heating elements or face screen
- Rebuilding at customers facility or at Vulcan in Portsmouth, RI
- Overnight service available
If you’re experiencing poor performance from your heaters or their catalytic pads and are interested in a quotation, fax or email your heater sizes and quantities and we will respond with a quote promptly.
Platinum Catalyst
The platinum impregnation process in Vulcan's catalyst is highly automated ensuring the very best distribution of materials within the catalyst composite. The basis for this structure is Saffil, a highly refined alpha alumina ceramic fiber. One gram of Saffil would represent a 2 inch cube of material. The surface area within this cube measures 100 sq. ft., providing maximum exposed surface area to react the gas. By definition, a catalyst allows a chemical reaction to take place but the catalyst is not consumed within the reaction - life expectancy is unlimited.
In case of process damage or catalyst poisoning, see our Refurbishing page.
Catalytic Oven Applications
Vulcan engineers design catalytic heating systems for heating processes that require a part temperature of up to 650 degrees Farenheight. Whether it is for plastics, powder or liquid coating, web drying, or preheating, the systems are carefully tested in our state of the art facility, ensuring complete satisfaction before shipping the system. Vulcan supply OEM oven producers with a number of options; heaters only or a full package of heaters, controls and gas management assemblies. A design facility is available for customers, where the oven is designed and part files (dxf) are sent for customer fabrication, Vulcan sends the hearers and control equipment for on site assembly.
Vulcan supplies industrial catalytic heaters for thermoforming, paint finishing, powder coating ovens and drying ovens. READ MORE >>
