How can a stwing furnace waste gas treatment furnace prevent pipe blockage, heat exchanger coking, and catalyst poisoning under high humidity and high oil conditions?
Publish Time: 2026-02-17
In food processing, biopharmaceutical, or chemical production, the waste gas generated by a stwing furnace waste gas treatment furnace typically has three high characteristics: high humidity, high oil content, and high concentration of odorous substances. If this complex waste gas directly enters the subsequent treatment system, it can easily lead to serious problems such as oil accumulation and blockage in pipes, coking and carbonization on the surface of heat exchangers, and deactivation of catalyst materials, significantly reducing equipment efficiency and even causing shutdowns.1. Multi-stage pre-purification: Source interception of oil mist and particulate matterThe key to preventing blockage and coking lies in "front-end interception." The waste gas first enters a cyclone oil separator or a high-voltage electrostatic oil separator, using centrifugal force or an electric field to separate more than 90% of liquid oil droplets and large particles. Then, a labyrinthine baffle + fiber filter layer combination further captures micron-sized oil mist. Some high-end systems also add automatic oil scraping and drainage mechanisms to prevent the accumulation of intercepted materials inside the equipment. After this multi-stage pretreatment, the oil content in the exhaust gas can be reduced to below 10 mg/m³, fundamentally reducing the load on subsequent heat exchangers and catalysts.2. Anti-coking design of heat exchangers: Synergistic combination of materials, structure, and temperature controlIn the waste heat recovery stage, heat exchangers in prolonged contact with high-temperature oil fumes are prone to forming a coking layer, reducing heat transfer efficiency. Therefore, the equipment uses 316L stainless steel or titanium alloy finned tubes, whose smooth surface is corrosion-resistant and does not easily attract oil stains. Structurally, a wide-spacing, wide-channel design is adopted to reduce dead corners; some models introduce online steam or hot water cleaning interfaces to periodically flush the tube walls. More importantly, an intelligent temperature control system maintains the exhaust gas temperature above the dew point after heat exchange, preventing water vapor condensation and mixing with grease to form viscous deposits, thus inhibiting coking from a thermodynamic perspective.3. Catalyst anti-poisoning protection: Filtration barrier and material upgradesThe catalytic oxidation unit is the core of deodorization, but oil decomposition products and halogens and sulfides can easily poison and deactivate precious metal catalysts. To address this, the system employs a two-stage protection system before the catalytic bed: a high-efficiency demister to remove residual oil mist, and a dedicated protective catalyst layer to preferentially adsorb poisonous substances and extend the lifespan of the main catalyst. Simultaneously, the main catalyst carrier utilizes high-specific-surface-area honeycomb ceramic, loaded with Pt-Pd bimetallic or Mn-Ce composite oxides to enhance resistance to toxicity and low-temperature activity, ensuring stable operation for over 5000 hours in complex waste gas environments.4. Intelligent Operation and Self-Cleaning Mechanism: Dynamically Adapting to Fluctuating Operating ConditionsThe stewing process is mostly intermittent, resulting in highly fluctuating waste gas emissions. The equipment is equipped with a variable frequency fan and a PLC control system, automatically adjusting the airflow based on furnace start/stop signals to prevent moisture condensation under low load. Simultaneously, integrated differential pressure sensors and temperature monitoring points assess the risk of blockage in real time, triggering backflushing or heating self-cleaning procedures. For example, when an abnormal increase in heat exchanger pressure drop is detected, the system automatically initiates steam purging; when the catalyst bed temperature is too low, auxiliary electric heating intervenes to maintain the optimal reaction window.5. Modular Maintenance Design: Reduced Downtime CostsAll components prone to oil accumulation utilize a quick-release snap-fit structure, allowing for tool-free disassembly, cleaning, or replacement. The waste oil collection tank is equipped with a level alarm to remind timely cleaning and prevent secondary pollution.Faced with the stringent challenges of high-humidity, high-oil exhaust gases, the stwing furnace waste gas treatment furnace has shifted from a "passive response" to an "active defense." Through multi-dimensional collaboration of deep front-end purification, enhanced anti-fouling properties of core components, and intelligent operation and maintenance management, it not only effectively prevents pipe blockage, heat exchanger coking, and catalyst poisoning but also ensures long-term stable and compliant emissions. This reliability-centric engineering approach is key to the high-efficiency, intelligent, and long-life operation of industrial environmental protection equipment.
