Catalytic Oxidation

We have already proven our worth in the following industries, sectors, and applications:
Chemical and pharmaceutical industries, semiconductor and automotive industries, solar and recycling industries, printing and coating industries, surface finishing, painting, paint and varnish manufacturing, plastics processing, contaminated site remediation, odor control, biogas, landfill and low-temperature gas purification, and much more.


Prantner exhaust air purification systems are used in all these areas. With minimal energy consumption, they ensure reliable compliance with regulatory requirements. Ask about our systems for autothermal operation—you too can rely on energy savings! With the appropriate concentrations of your pollutants, our systems can even generate valuable energy.

Procedural Principle

The process exhaust air is drawn in by a fan and first preheated in a heat exchanger using the purified exhaust air. An electric heater or gas burner brings the exhaust gas stream up to the required reaction temperature, after which it is oxidized into carbon dioxide and water in the catalytic reactor. The oxidation takes place in a specially designed reactor. At higher pollutant concentrations (from approx. 3 g C-equiv/Nm³), autothermal plant operation is possible. This means that no additional energy is required for the conversion of the pollutants. The plant is controlled and monitored via an instrumentation and control system with a programmable logic controller (PLC), optionally also with remote monitoring or integration into a process control system. The systems can be equipped with explosion protection devices, such as concentration monitoring systems (FID, FTA, IR, WT), detonation arresters, and pressure relief devices.

We specialize in the installation of catalytic exhaust air purification systems in containers - up to 20.000 m³/h!

Basic Equipment

Valve system • Process air blower • Electric or gas heating • Heat recovery • Reactor • Catalyst mass • Base frame/container insulation • Safety equipment • Instrumentation and control system • Data logging

Optional Equipment

Container installation (including shipping containers) • Exhaust stack • System bypass • Dust separator • Smoothing filter • Explosion protection equipment • Special catalyst fillings

Standard Sizes
Typ Durchsatz [m³/h] min. Durchsatz [m³/h] max. Durchsatz [m³/h] Länge [m] Breite [m] Höhe [m] Gewicht [t]
Kat 100100501502,21,62,21,0
Kat 500-250015060042,52,64,0
Kat 1.000-21.0004001.1007,52,52,76,0
Kat 1.500-21.5006001.6507,52,52,76,5
Kat 2.000-22.0008002.20082,52,77,0
Kat 2.500-22.5001.0002.70082,52,77,5
Kat 3.000-23.0001.0003.300102,52,79,0
Kat 4.000-24.0001.3004.400102,52,79,5
Kat 5.000-25.0001.8005.500122,52,713
Kat 7.500-27.5002.5008.250123316
Kat 10.000-210.0004.00011.000123318,0

“Type Kat 500” catalytic exhaust air purification system in a containerized design with auxiliary equipment

Modular concentrator system being installed on a building roof

Catalytic exhaust gas purification system with a downstream gas scrubber

AEK 50.000 exhaust air purification system, fully pre-installed in an oversized steel container, being positioned using a heavy-duty crane

Catalytic exhaust air purification system in a containerized design for 1.000 Nm³/h.

Gas scrubber installed in a steel container, including safety devices in accordance with Section 19 of the Water Resources Act (WHG)

Concentrator unit, including dust filter modules

Roof-mounted standard container unit “Type Kat 500” including auxiliary container

Kat 4000 catalytic exhaust gas purification system, fully pre-installed on a steel platform

FAQ's

What is the difference between catalytical and purely thermal afterburning?

Unlike thermal afterburning, catalytic afterburning operates at significantly lower temperatures. Advantages: lower energy consumption, including autothermal operation; reduced operating costs; and a more compact system design.

Is catalytic afterburning suitable for varying production processes?

Yes, but fluctuations in composition, concentration, and temperature must be taken into account during the design phase. Prantner develops process-specific solutions with appropriate control technology for this purpose.

Can a heat recovery system be integrated?

Prantner's catalytic afterburners are equipped with heat recovery systems to efficiently recover process heat and minimize energy costs.

Are there any restrictions on certain pollutants?

Certain substances (known as catalyst poisons) can damage the catalytic converter. Therefore, a precise analysis of the exhaust gas is essential. Prantner provides professional support for measurements and analyses.

Our thermal exhaust air purification system is getting old. What sustainable, energy-efficient technology can you offer?

As a rule, it is possible to switch to a catalytic process, which also has significantly lower operating costs due to its lower operating temperatures. 

We need an exhaust air purification process that can be flexibly expanded to accommodate future production growth. Do you offer modular systems and equipment?

Our systems are flexible and can be used for a wide range of throughput rates. Thanks to the container-based design favored by Prantner, this range can also be expanded in a modular fashion. 

A batch process in a production line regularly produces high concentration peaks. Which exhaust air purification method can be used for this?

Emissions from production processes, which typically exhibit highly fluctuating concentrations, are treated in an “auxiliary unit” through several process steps. They are then fed into the exhaust air treatment system and cleaned to levels below the required limits.

We want to switch our RTO to a sustainable process. Can you offer an energy-efficient process that uses electric heating?

Catalytic processes are ideally suited for electric operation. This electric mode of operation can also be perfectly combined with regenerative energy recovery or concentration.

Can a catalytic afterburner system be equipped with remote access?

Yes. Secure remote connections allow you to monitor operational data in real time, adjust settings, and perform maintenance and diagnostics efficiently. This increases system availability, operational reliability, and efficiency. 

Kann die Abluftreinigungsanlage mit variablen Konzentrationen der Prozessluft-Inhaltsstoffe umgehen?

Yes, the system can be designed to handle fluctuating concentrations of process air. Various technical solutions, such as smoothing filters, allow for flexible adaptation. This ensures that the system continues to operate efficiently and safely even under changing operating conditions.