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
2.25″ (57.15mm) Inlet/Outlet
6″ X 4″ Oval
11″ Body Length – 15″ Overall Length
Metallic Substrate
Euroii Spec
300 Cpsi
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).
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Analysis showed that the original catalytic converters were built with an outdated filter material which was not able to deliver the desired CO results.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.
| Specifications | 1st stage element ONE | 1st stage element TWO | 2nd stage element ONE |
| Cells per square inch | 200cpi | 200cpi | 350cpi |
| Height mm (front face) | 150 | 150 | 150 |
| Width mm (front face) | 70 | 70 | 70 |
| Thickness mm (flow-path) | 75 | 75 | 120 |
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.
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!
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When it comes to heavy machinery, the performance of components like DPF filters can significantly impact overall efficiency and longevity. This case study will delve into how the Flowtech Diesel High-Flow Combination Filter, specifically designed for the CAT 120M Motor Grader, has shown to be a game-changer in terms of improving emission output from harmless pollutants to cleaner releases.
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.
Once again, our loyal client in Western Sydney has entrusted the Flowtech team. The team designed a unique muffler that serves as a filter and a silencer effectively minimizes the emission of harmful fumes and reduces noise levels.
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.
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.
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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Since 1984, Flowtech Advantage has been a key manufacturing division of CSC Group Australia. With its main headquarters in Western Sydney, the company designs and produces exhaust solution components for most industries in Australia and New Zealand.
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