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Industrial Gas Catalytic Infrared Systems

Gas Catalytic IR Heater Refurbishment

By their inherent design and technology, Gas Catalytic IR heaters are very reliable and will operate for over 40,000 hours before they will need any maintenance. There are no moving parts to fail. However, if Gas Catalytic ovens are used in the powder coating industry, there is a chance of powder migrating from the powder booth, into the oven. This can cause two issues:

  • Powder landing on the surface of heater will oxidize and form a white ash. Over time this ash builds up and reduces the amount of Oxygen reaching the catalyst, thus reducing the heat output.
  • Airborne powder particles land on the reflective surfaces of the lower sections of the oven, reducing the reflectivity and thus the efficiency of the cure process.

The effect can clearly be seen in the images below.

ir catalytic heater

A new Gas Catalytic Heater installed in a new oven. Note the clean heater surface and fully reflective internal surfaces of the oven. Designed and manufactured to give many thousands of hours of efficinet operation.

gas catalytic ir heater

After 40,000 plus hours, white ash builds up on the surface of the heater. Powder has also built up on the reflective surfaces thus reducing efficiency of the oven. This can cause cure times to increase.

gas catalytic ir heater

A new or refurbished Gas Catalytic IR heater photographed with an IR camera should look like this.

The reduced heat output can clearly be seen in this IR photo image. However, Heraeus can refurbish heaters from any manufacturer.

Is There a Solution?

Fortunately, yes. Vulcan Catalytic® Systems offer a full heater refurbishment program and a service to bring the reflective surfaces of the oven back to full efficiency. We can carry out refurbishment of Gas Catalytic Heaters manufactured by other companies and our superior catalyst impregnation process will make them more efficient than when they were new. The refurbishment process involves rebuilding the heater with a new catalytic pad and screen, new pre heat element and thermo switch, followed by testing. 

powder coating oven

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