The catalytic combustion device mainly consists of a heat exchanger, a combustion chamber, a catalytic reactor, a heat recovery system, and a chimney for purifying the exhaust gas. Its purification principle is that before entering the combustion chamber, the unpurified gas is preheated by the heat exchanger and sent to the combustion chamber, where it reaches the required reaction temperature. The oxidation reaction takes place in the catalytic reactor, and the purified exhaust gas releases some heat through the heat exchanger before being discharged into the atmosphere through the chimney.

When designing catalytic combustion devices, the following aspects should be considered:

1. The airflow and temperature are evenly distributed. To achieve uniform airflow and temperature distribution across the catalyst surface, and to prevent direct flame contact with the catalyst surface, the combustion chamber should have sufficient length and space. The catalytic combustion device should have good insulation effect. The furnace body is generally lined with refractory materials on the outer shell of the steel structure, or with a double-layer sandwich wall structure.

2. Easy to clean and replace. Catalyst reactors should generally be designed with a modular drawer structure for easy loading and unloading, facilitating cleaning and replacement of catalyst carriers.

3. Auxiliary fuel and combustion assistance. Catalytic combustion generally uses gas as an auxiliary fuel, and can also use fuel oil, electric heating, and other auxiliary fuels. Generally, purified gas is used for combustion assistance. If the purified gas cannot be used for combustion assistance, air should be introduced for combustion assistance.

4. Higher conversion speed. Due to catalytic combustion being an irreversible exothermic reaction, regardless of the stage of the reaction, it should be carried out at the highest possible temperature to achieve a higher conversion rate. However, the operating temperature is often limited by certain conditions, such as the heat-resistant temperature of the catalyst, the availability of high-temperature materials, the supply of thermal energy, and the presence of side reactions. Therefore, in actual production, appropriate choices should be made based on the actual situation.

In exhaust gas treatment engineering, different forms of catalytic combustion processes can be used for different situations of exhaust gas emissions. However, regardless of the process method used, its process components have common characteristics, such as: the gas entering the catalytic combustion device must undergo pre-treatment to remove dust, droplets, and components, avoiding blockage of the catalytic bed and poisoning of the catalyst.

The temperature of the gas in the catalytic bed must reach the ignition temperature of the catalyst used before the catalytic reaction can proceed. Therefore, for intake air below the ignition temperature, preheat it to reach the ignition temperature. Especially when driving, the catalytic combustion method is suitable for continuous exhaust purification by preheating the cold air. After preheating the intake during driving, the heat from the combustion exhaust can be used to preheat the gas. If the exhaust gas is discharged intermittently, preheating of the air conditioner is required every time the vehicle is driven, and frequent starting of the preheater increases energy consumption. The preheating method of gas can use electric heating wire or flue gas heating, and currently the most commonly used is electric heating.

Thirdly, catalytic combustion reactions release a large amount of reaction heat, resulting in high exhaust gas temperatures, which require the recovery of this heat. Generally, high-temperature exhaust gas and low-temperature gas are first heat exchanged through a heat exchanger to reduce preheating energy consumption. The remaining heat can be recovered through other methods. In situations where the exhaust gas discharged from the production equipment has a high temperature, such as for enameled wire, insulation materials, etc., the drying temperature can reach over 300 degrees Celsius, so it is not necessary to place a high preheater and heat exchanger. But the heat from burning exhaust gas should still be recovered.