Catalytic Converters Archives - Flowtech Advantage Australia https://flowtechadvantage.com.au/category/emission-control/catalytic-converters/ Exhaust & Emission Control Specialists Thu, 21 Sep 2023 00:03:11 +0000 en hourly 1 https://flowtechadvantage.com.au/wp-content/uploads/2023/02/cropped-Flowtech-Advantage-favicon-32x32.png Catalytic Converters Archives - Flowtech Advantage Australia https://flowtechadvantage.com.au/category/emission-control/catalytic-converters/ 32 32 Fire Pump Exhaust Pipe System https://flowtechadvantage.com.au/emission-control/fire-pump-exhaust-pipe-system/ Wed, 23 Aug 2023 04:29:34 +0000 https://flowtechadvantage.com.au/?p=10145 Our client, a Victoria-based company in Australia specializing in diesel generator and engine solutions faces a similar issue and now requires a customised muffler for their 110kVA Cummins Diesel Generator. The objective was to meet certain noise level reduction (35-40 dBA) requirements while enhancing safety by reducing the emission of hot particulates from engine and exhaust systems.

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Fire Pump Exhaust Pipe System

Firepump exhaust system

What is a fire pump system?

A fire pump is specifically designed to supply large volumes of water and plays a vital role in safeguarding property and saving lives during a fire. It typically consists of an engine-driven centrifugal pump, In addition, the fire pump also functions as a backup power source, utilizing either a diesel or gas engine.

Commonly found in commercial buildings with sprinkler systems, as they are essential for delivering adequate water supply under fire conditions. It’s usually placed in an underground room separate from all other rooms.

  • 2.1 metres head clearance.
  • 1 metre wide, clear path of travel to the fire pump controller
  • 1 metre wide, clear path of travel to the manual shut-down for diesel drivers
  • 1 metre wide, clear path of travel to all other required control valves

Fire Pump Diesel Exhaust Complete Design, Supply & Insulation

Fire pumps can be dangerous and hazardous to personnel due to the fumes and heat it generates.

A compliant exhaust system design should be a top priority for a company that utilizes it. Using top-quality materials is crucial for preventing accidents and fire hazards.

Investing in such materials not only ensures safety but also leads to long-term cost savings.

Fire Pump Exhaust Package

Flowtech has a proven track record in installing fire pump exhausts system, using the following materials.

A good example of fire pump diagram for exhaust pipe installation

Fire pump Exhaust Pipes

Fire pump stainless pipes
Aluminised pipes for any custom exhaust requirements

Some of our clients expressed dissatisfaction with their previous exhaust pipes due to their use of Galvanised material, which is susceptible to corrosion, lead release, chipping, cracking, and long-term rusting. To ensure quality, we recommend aluminised or stainless steel pipes for your fire pump system.

Aluminised pipes are affordable and ideal for moderate corrosive environments. They have a durable coating that can withstand high temperatures and while stainless steel pipes are slightly dearer but offer superior corrosion resistance for harsher environments.

Advantage of using Flowtech Pipes

  • Top-quality pipe materials
  • Corrosion resistant
  • Customisable to fit preferred size for easy transport
  • Flaring the pipe for easy installation (Male & Female)

Engineering Bends

Mandrel bends

Fire Pump Catalyst Filter

Custom Muffler Silencer

Catalysts or Diesel Particulate Filters (DPF) help reduce particulates coming from the fire pump engine that is hazardous to personnel.
They trap and burn combustible particles in the exhaust gases, thereby improving air quality.

A Catalyst filter should be installed in a fire pump engine to improve air quality in confined spaces and avoid the need for additional pipes to release fumes in multi-story buildings. Saving costs and minimising installation time.

Fire Pump Thermal Insulation

High temperature insulation for Fire Pump using Thermal Tape & Blanket

Custom Spark Arrestor

The primary use of thermal insulation is to act as a heat shield to the custom-fitted pipes, bends and catalyst filter is essential to containing the heat within the system.

Any exposed pipes that are not insulated can cause discomfort for personnel and could be a potential fire hazard.

Flowtech provides Thermal tape and blanket insulation services which add an extra layer of protection, offering peace of mind as well as improved air quality in confined spaces.

Flowtech thermal tapes also provide long-term cost savings as they prevent the need for frequent replacement of pipes and bends due to corrosion.

Fire-pump-exhaust-system-with-no-thermal-insulation-2
Fire-pump-exhaust-system-with-no-thermal-insulation-2
Fire-pump-exhaust-system-with-no-thermal-insulation-2

Thermally insulated fire pumps exhaust

Flowtech Advantage provided a  solution to meet the customer’s specific needs. We design and supply high-grade thermal insulation to reduce heat transmission from the pump engine to the exhaust pipes.

Summary

  • Fire pump diesel exhaust systems are an essential part of ensuring safety in commercial buildings thru sprinkler systems.
  • Use top-quality materials and experienced manufacturers to install exhaust systems correctly.
  • Investing in quality materials helps ensure that the system is safe and reliable, and also leads to long-term cost savings.
  • Flowtech offers complete design, supply and insulation services for fire pump systems
  • Choose aluminised or stainless steel pipes and void using galvanised pipes
  • Install Catalyst Filter (to reduce particulates coming from the fire pump engine)
  • Use Heat tape and a Thermal blanket to act as a heat shield.
  • Flowtech team ensure that your fire pump exhaust system will meet all safety requirements.

Related Products for Exhaust Pipe Solution

Flowtech Advantage Alternative to Cowl muffler

Looking for a similar solution?

We have a wide range of muffler solutions for every industry.

Explore our Spark Arrestors, Exhaust Silencers, Emission Control, Aftemarket Exhaust Parts and Performance Muffler

This project is related to Generator Muffler Silencer

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The post Fire Pump Exhaust Pipe System appeared first on Flowtech Advantage Australia.

]]> Catalytic Converters for a mobile unit https://flowtechadvantage.com.au/emission-control/catalytic-converters-mobile-unit/ Tue, 09 May 2023 06:53:11 +0000 https://flowtechadvantage.com.au/?p=7737 Our client operates a Mobile Oil Polishing Plant (MOPP). The MOPP operates as a mobile unit on the Cleanaway site in Rutherford. The system cleans the oil by absorbing oil impurities into a Bauxite media by filtration and then regenerates the media by burning it clean.

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Catalytic Converters for a mobile unit

Catalytic Converter

Troubleshooting the Catalytic Converter

Our client operates a Mobile Oil Polishing Plant (MOPP). The MOPP operates as a mobile unit onsite in one of the suburbs located in NewCastle. The system cleans the oil by absorbing oil impurities into a Bauxite media by filtration and then regenerates the media by burning it clean.

The gas emission released during the burn step passes through an activated carbon bed followed by a catalytic converter manifold.
The client observed a rise in CO emissions and suspected that the manifold may be fouled.

They have tried different ways to solve the issue 

  • Using a solvent/degreaser wash
  • (20) Twenty minutes in a hot bath parts washer
  •  Purchased a new Catalytic Converter from another supplier and created a new manifold only to find out that the CO is higher than the desired level.
Catalytic Converter

The specification of the Catalytic Converter that failed to meet the
desired CO level.

2.25″ (57.15mm) Inlet/Outlet
6″ X 4″ Oval
11″ Body Length – 15″ Overall Length
Metallic Substrate
Euroii Spec
300 Cpsi

Diesel Oxidation Catalyst (DOC)

Our client came across our Flowtech website during their search for a solution. They were interested in the Diesel Oxidation Catalyst and contacted us to find out if our own version of the custom catalytic converter could address their ongoing issue.

The measured flow velocity as per the diagram above for the stack @40m/s which is split between two sets of parallel-connected CATs thus at 20m/s. The flow of primary and secondary air circuits.

The Flowtech team start to assess all information starting with the client’s initial drawing so we can propose suitable replacement DOCs.

Our client shared another photo that displays the roof arrangement of a Skid along with an air heater that supplies hot air to the Catalytic Converters (CAT Converters).

Defective Catalytic Converter

The Catalytic Converters that were fouled were opened to provide a more detailed report and shared with the Flowtech team for a thorough inspection.

Analysis showed that the original catalytic converters were built with an outdated filter material which was not able to deliver the desired CO results. The Flowtech team came up with a solution that included upgrading and using different filter materials. This had a stainless steel honeycomb filter with a combination of Platinum and other precious metals., to increase airflow rates while maintaining the desired CO emission level.

Specifications1st stage element ONE1st stage element TWO 2nd stage element ONE
Cells per square inch200cpi200cpi350cpi
Height mm (front face)150150150
Width mm (front face)707070
Thickness mm (flow-path)7575120

Solving the Problem of Excess CO Emissions with Flowtech's DOC's Solution

After a few email exchanges and phone conversations with both parties. The GA ( General Arrangement) Drawing was sent to the client for review. The drawing now includes the new style Catalyst in Stainless Steel 304 Grade.

The inlet and outlet are designed with quick-release clamps in 127mm so it is easier to clean. Custom mounts were made to suit the requirements. The final product proposed to the client was Flowtech’s Diesel Oxidation Catalysts (DOC) with a Thermal Armour blanket included. This helps contain the heat for the regeneration process.


A support leg was provided to support the stack considering wind pressure and guy wire loading on it. The client accepted the solution proposed and is currently in the process of installation as of this writing.

Catalytic Converters

A few Questions raised by the client

The elements are Diesel Oxidation Catalysts. They are designed to convert Hydrocarbons and Carbon monoxide into Carbon Dioxide and water.

Each unit is 197mm OD (including the 1.5mm stainless tube casing) x 90mm long(Casing is 100mm long)

197mm OD +/-1mm

Typically 26cm2/cm3 Geometric Surface Area is normal for 300CPSI (approx. 6.91m2 per Catalyst.). cells are not really round by design, but approx. 0.669mm across.

Considered 283m/h @ 390ᵒCelcius would likely give a 70 – 80% conversion. 

Very little happens at or below 200ᵒC. Conversion % increases sharply with temperature rise until 400ᵒC. After this, the rate of conversion slows considerably to 500ᵒ/550ᵒC. avoid operating above 620ᵒC for prolonged periods.


With over 38 years of experience, our team has a proven record of providing clients with custom solutions that meet all their needs.

If you’re facing similar issues and need help finding an efficient solution, contact us today!
Our experts are always available to provide you with the best advice and services.

Creating a Safe & Healthy Workspace

We are delighted to provide you with the perfect exhaust solution to ensure a safe and healthy working environment, free from hazardous fumes and unwanted noise. Explore our Spark Arrestors, Exhaust Silencers, Emission Control, Aftemarket Exhaust Parts and Performance Muffler

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Our client operates within the sand mining sector, heavily relying on CAT generators for their daily functions. The objective was to replace deteriorating mufflers with Flowtech Silencers to curb emissions and reduce noise pollution. This improvement was crucial for adhering to updated environmental standards and enhancing the workplace atmosphere.

Read More »
August 6, 2024 No Comments
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July 8, 2024 No Comments
Customised Silencers for Sand Mining CAT Generators
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Read More »
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Our client in Sydney needed a new muffler for their 2250KVA Cummins Diesel Generator. The old muffler had rusted and lost its effectiveness, so they approached the Flowtech team for help.

Our task was to design a modern silencer that would not only reduce noise but also resist corrosion and last longer.

Read More »
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Read More »
November 7, 2023 No Comments

The post Catalytic Converters for a mobile unit appeared first on Flowtech Advantage Australia.

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