Regenerative catalytic oxidation (RCO, RKNV)
Regenerative catalytic oxidation combines the advantages of catalytic combustion and a regenerative (accumulation) heat exchanger. It is the most energy-efficient system for the disposal of VOCs in low and medium concentrations – thanks to the catalyst, oxidation occurs at a lower temperature and thanks to ceramic fillings, most of the heat is returned to the process. RCO achieves extremely high efficiency and at the same time very low operating costs.
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HOW DOES IT WORK?
The device usually consists of two interconnected reactors. Each reactor contains a regeneration chamber with a ceramic filling in the lower part and a catalytic chamber with a catalyst layer above it. In the upper part of the reactors there are heating chambers (electric heating element or gas burner) and a pipe connection. Operation takes place in a cyclically reversed mode: polluted air is blown into the first reactor, where it passes through a heated ceramic filling (heat accumulator) and is heated to the required catalytic combustion temperature. It then flows through the catalyst in the first reactor, where VOCs are oxidized to CO₂ and H₂O, releasing heat. The gas heated by oxidation then continues into the second reactor, which in this phase serves as a heat accumulator – the ceramic filling of the second reactor absorbs the released heat (and at the same time the remaining VOCs on the catalyst also burn out in it). After a certain time, the flow directions are reversed: the second reactor starts to heat the incoming air and the first one regenerates. The cycle also includes a short phase of purging the chamber with clean air to prevent VOC leaks during switching. Thanks to this configuration, a heat recovery efficiency of around 95–96% is achieved – only a minimal fraction of the heat escapes. Therefore, the need for additional heating with fuel is very small. Typically, RCO removes over 99% of VOCs in the air and can run completely autothermally without additional heat at concentrations of ~0.5 g/m³, which is an excellent parameter.
Key benefits:
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Maximum energy saving: Regenerative heat exchange in combination with a catalytic converter results in extremely low fuel consumption. The system recycles ~96% of the heat, making operation economical even at low VOC concentrations. Compared to other technologies, RCO has the lowest operating costs in the given application area.
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High cleaning efficiency: It achieves >99% VOC removal, significantly reducing emissions and helping to meet strict emission limits. The exhaust gases are almost completely free of organic substances.
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No NOx emissions: Thanks to the catalyst, oxidation takes place at ~300–400 °C, a temperature at which nitrogen oxides are not formed. The technology is therefore also gentle in terms of secondary pollution.
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Quick start/stop: The design allows for quick commissioning even after a short shutdown. The device can be shut down without lengthy cooling and restarted after a break (e.g. overnight) without the need for prolonged reheating – the accumulated heat in the ceramic is sufficient to immediately start the catalytic reaction. This minimizes downtime and losses during intermittent operation.
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Flexibility and reliability: The RCO can handle a wide range of concentrations (~0.3–3 g/m³) and air volumes (thousands to tens of thousands of m³/h). It is robust and stable even under variable loads. The design is robust and highly reliable even during long-term operation in high oxidation efficiency mode.
Typical use:
Regenerative catalytic units are ideal for low and medium VOC concentrations in both low and large air volumes. They are typically used where VOC concentrations do not exceed units of g/m³ and air flows range from several thousand to tens of thousands of m³/h – for example in large paint shops, lamination lines, surface treatment plants, and in the chemical and pharmaceutical industries. RCO is ideal for paint shops and equipment that run in autothermal mode most of the time at very low loads (~0.5 g/m³ VOC). Thanks to its low operating costs and high efficiency, this technology is popular as a replacement for outdated or inefficient systems and where energy savings are a priority.
