Services

Matros Technologies provides clients worldwide a comprehensive set of services on VOC control including:

    • Evaluating air emission data, and selecting optimal air pollution control technology
    • Selecting catalysts for all types of catalytic oxidizers and afterburners, determining catalyst quantity and operating parameters via mathematical modeling
    • Design of regenerative catalytic oxidizers and RTOs converted to RCOs. Since the beginning of 90s MT has designed over a hundred of regenerative catalytic oxidizers (RCOs) operated worldwide
    • Process energy consumption and operating costs
    • Catalyst lifetime, effect of catalyst contaminants, and catalyst regeneration
    • Catalyst loading and operating instructions
    • Onsite assistance during catalyst start-up and maintenance shutdowns, immediate offsite consultations
    • Catalyst testing for designing new oxidizers and monitoring existing oxidizer performance. The customers use the test data for reporting to EPA
    • Recommending oxidizer operating parameters for continuous meeting of air pollution control requirements.

We also provide a wide range of consultations in general area of heterogeneous catalytic reactors involving mathematical modeling, developing of kinetic models and process simulation software, adiabatic and wall-cool reactors, reactor feasibility and optimization studies.

The company achievements include licensing of formaldehyde reactor simulation software and development of unique automotive reversed-flow converter. In 2007-2008 we were the technical lead in international adaptation of synthesis gas catalysts produced by a Russian company that propelled the company merger with a global catalyst manufacturer.

We guarantee undivided attention to our clients’ projects and problems, efficient and cost-effective services, timeliness and integrity.

Catalyst testing

Our catalyst testing lab serves dozens of US customers operating regenerative and recuperative catalytic oxidizers.

Our core test program includes:

    • Activity testing: The tests are performed in well-determined isothermal operations in continuous stirred tank reactor. This insures high data consistency and simple and direct calculations for the reaction rate. The rate is defined as quantity of VOC reacted per one gram of catalyst per second. A set of tests determines the reaction kinetics i.e. the dependence in the rate of oxidation on temperature and concentration of VOC. This kinetics is applicable for using in mathematical model, which is able to accurately predict the oxidizer performance within the area of inlet parameters overlapping the experimental. Activity tests can be done with certified gas cylinders containing air-diluted model VOCs. Transfer to the compounds of interest such as for example, methanol or toluene is provided using early found kinetics for oxidation of those compounds.
    • Contamination testing: The selected method, Scanning Electron Microscopy / Energy Dispersive X-Ray Spectrometry (SEM-EDXS) analysis uses a bombardment of catalyst surface with high energy electron beams. The analysis identifies chemical elements over the surface layer, 1-2 microns deep, and provides for semi-quantitative composition data including catalyst contaminants such as silicon. The analyses are performed over the outer surfaces of catalyst tablet and for over a surface of a pellet made from mixed finally crushed catalyst. The result of the latter test represents catalyst composition and contamination in average over the catalyst volume.
    • Catalyst regeneration: The regeneration via washing or heat treatment restores the activity of used catalyst to the level of fresh catalyst, which effectively increases the catalyst service time. We check the regeneration for samples collected from the oxidizer via heating in a laboratory oven and washing in water as well as weak citric acid and other acidic and basic aqueous solutions. After the laboratory regeneration, the samples are retested for activity.
    • Oxidizer performance evaluation: The oxidizer performance is found indirectly via mathematical model that incorporates ratios between aged and fresh catalyst activities determined in sample testing. It also accounts for earlier found rates for oxidation of actual compounds of interest (methanol, formaldehyde, etc.), and essential mass transfer processes in the oxidizer catalyst beds. For performance evaluation, Matros Technologies requests customers to furnish basic information about the oxidizer including catalyst quantity, emission air flow rate, operating temperature, etc.
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