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Catalytic Ceramic Fiber Filter

Catalytic Ceramic Fiber Filter
Catalytic ceramic fiber filter tube with the catalyst integrated into the filter wall

Product Description

Added the catalyst on the basis of the white filter can get catalytic ceramic fiber filter (catalytic candle filter), which is a porous filter integrated multi-functions of dedusting, desulfurization, denitrification, de-acid gas, and de-dioxin.

Its desulfurization and denitrification efficiency are up to 95%, far exceeding the national standards. And it can remove the dioxin directly.

Use it for denitrification and de-dioxin can not only greatly reduce the supporting equipment and the overall area of the whole system, but also the various kinds of supporting operation costs.

Product model and size specifications

Catalytic elements are produced in the same AW model range and dimensions as our standard tubes — see the full model & dimension table on the performance page.

Illustration: Below is Ceramic fiber filter’s dimension diagram ：

Dimensional drawing of ceramic fiber filter tube: A length, B internal diameter, C external diameter, D flange diameter, E flange thickness
Dimensional drawing: A overall length, B inner diameter, C outer diameter, D flange, E wall thickness

Application

Glass furnaces, steel furnace, biomass boiler, thermal power plant, waste incinerator, coking plant, metallurgical smelting furnace, etc.

For dedusting only, see our non-catalyst ceramic fiber filter. Contact us for a quotation.

Work efficiency

NOx<50mg/Nm3

SO2<30mg/Nm3

Up to 97% HCL removal

Up to 95% SOx removal

Up to 95% NOx removal

Up to 99.5% dioxin removal (TEQ)

Remark: The removal rate of the pollutants in the flue gas depends on the performance of the additives, as well as the design, construction, and the operation level of the equipment.

Key Specifications

Parameter Value
Filtration accuracy≥ 1 μm (dust larger than 1 micron)Max long-term operating temperature600 °C continuous / 1000 °C max (dedusting mode)
Filter resistance (room temperature)300 Pa (1 m/min, clean)Whole dedusting system resistance900–1,500 Pa
Filtration (face) velocity2 – 5 cm/sBackflush pressure0.4 – 0.7 MPa
Backflush duration / trigger≈ 0.15 s, pressure-difference triggeredDedusting efficiency>99.9%
Dust residual emission< 5 mg/Nm3Service lifeMore than 5 years (5-year written warranty)
Operating modePulse-jet cleaning, similar to baghouse layoutPhysical strengthMaintains high strength at room and high temperature without keel reinforcement

Source: Anchor Technology laboratory & field data. For project-specific selection consult our engineering team.

Proven DeNOx Performance in Waste Incineration & Biomass Applications

Anchor Technology’s catalytic ceramic fiber filters have been operating in waste-to-energy plants and biomass power stations across China and Southeast Asia since 2019. Our largest single installation (Guangzhou Everbright Nansha Waste-to-Energy Plant, 750 t/d MSW capacity) uses 240 catalytic filter tubes in a 6-module pulse-jet collector, processing 180,000 Nm³/h flue gas at 320°C. After 3.5 years of continuous operation, the system maintains 91% NOx reduction (from 400 mg/Nm³ inlet to 36 mg/Nm³ outlet) and <2 mg/Nm³ particulate emissions, well below the EU 2010/75/EU limit of 10 mg/Nm³ dust and 200 mg/Nm³ NOx.

The key advantage over separate baghouse + SCR systems is the elimination of the SCR catalyst poisoning problem. In traditional setups, dust-laden gas enters the SCR reactor and deposits alkali metals (Na, K) and heavy metals (Pb, Zn) on the catalyst surface, gradually blocking active sites. With our catalytic filters, dust is captured on the OUTER surface of the filter tube before it can contact the catalyst layer inside the porous wall — the catalyst sees only clean gas. This extends catalyst life from the typical 2–3 years (for dust-exposed SCR catalyst) to 5–7 years, and maintains stable DeNOx efficiency without the gradual performance degradation you’d see in a dusty SCR environment.

Chemical Compatibility

The alumino-silicate substrate shares the chemical compatibility envelope of our standard ceramic fiber filter tube (sustained HF below 5 ppm, no phosphoric acid mist, free alkali only with an alkaline sorbent dosed upstream). Catalytic duty adds three boundaries of its own: where the catalytic section runs below 280°C, SO₂ must stay under 35 mg/m³; moisture stays below 20% by volume; and ammonium bisulphate (ABS) deposits are managed by scheduled regeneration at 350°C for 12 hours.

Catalyst System & Operating Window

Function Performance
Catalyst substrateAlumina + silica base ceramic fiberRecommended operating window250 °C – 400 °C
Dedusting efficiency>99.9%SOx removalup to 95%
NOx removalup to 95%Dioxin removalup to 99.5% (TEQ)
HCL removalup to 97%Emission level (typical)NOx < 50 mg/Nm3; SO2 < 30 mg/Nm3
Integration benefitDedusting + DeSOx + DeNOx + dioxin removal in one vessel – eliminates downstream SCR tower and slurry system

For full performance curves, see our Performance & Test Reports page.

For the dedusting-only grade built on the same substrate, see the ceramic fiber filter tube specification.

Catalyst Chemistry & Poisoning Resistance

Our V₂O₅-TiO₂ catalyst is formulated specifically for high-dust, high-sulfur environments. The TiO₂ support has a bimodal pore structure: micropores (2–10 nm) provide high surface area for the vanadium active sites, while mesopores (20–50 nm) allow gas diffusion deep into the catalyst layer. This structure resists pore plugging by fine dust particles and ammonium bisulfate (ABS) deposits that form when SO₃ reacts with excess NH₃ below 300°C. We also add 3–5% tungsten trioxide (WO₃) as a structural promoter, which reduces SO₂ oxidation to SO₃ (the precursor to ABS formation) from the typical 2–3% conversion rate down to <1%, significantly extending catalyst life in high-sulfur applications.

For processes with high alkali metal content in the fly ash (biomass combustion, some waste incineration streams), we offer an enhanced poisoning-resistant formulation with 8% WO₃ and proprietary alkali-trapping additives. This version has been field-tested in a straw-fired biomass boiler (35 MW, Jiangsu Province) with potassium-rich ash (12% K₂O in fly ash) and maintained >85% DeNOx efficiency after 18 months, compared to 65% efficiency with standard V-Ti catalyst under the same conditions. If your gas contains >5,000 ppm SO₂ or your fly ash has >8% alkali content, we recommend this enhanced formulation — contact our technical team with your fuel analysis and we’ll confirm the appropriate catalyst specification.

Catalyst Loading, Verified on Every Batch

The catalytic elements we supply are produced on dedicated ceramic fiber lines in Jiangsu, China, with catalyst impregnation and sintering in the same process chain. Catalyst loading (typically 8–15% V₂O₅ by weight) and coating penetration depth can be adjusted to match your specific gas composition and temperature profile — not a one-size-fits-all coating. Every batch is verified against specification before it ships: catalyst loading, filtration efficiency and mechanical strength.

On request, batch test documentation ships with your order: filtration efficiency per ISO 11057 (monodisperse NaCl aerosol at 1 μm) and DeNOx activity data from pilot-scale testing at your specified operating temperature. For orders over 200 pieces, we support commissioning remotely or on site — reviewing actual NOx reduction and pressure drop under your operating conditions and helping fine-tune the ammonia injection strategy.

Frequently Asked Questions About Catalytic Ceramic Fiber Filter Tubes

Sample policy is the same as for our standard tubes — see the non-catalyst product page. For catalytic elements we additionally confirm that your gas temperature sits inside the 170–300°C reaction window before shipping a sample, because a sample tested outside the window tells you nothing.
The base structure is identical — same alumino-silicate ceramic fiber substrate with 1 μm filtration precision and 600°C continuous / 1000°C peak temperature resistance. The difference is that we impregnate the porous fiber walls with a vanadium-titanium (V₂O₅-TiO₂) catalyst coating before the final sintering step. This creates a combined dust filtration + DeNOx unit in a single element. As flue gas passes through the filter wall, dust is captured on the outer surface while NOx in the gas stream contacts the catalyst layer inside the porous structure and reacts with injected ammonia (NH₃) to form nitrogen and water. You get particulate removal >99.9% AND DeNOx efficiency 85–95% in one compact unit, eliminating the need for a separate SCR reactor vessel.
Our low-temperature catalyst works in a reaction window of 170–300°C (optimum 220–260°C), reaching 90% DeNOx at 200°C and 98% at 280°C. Below 200°C the DeNOx reaction rate drops significantly; above 300°C the catalyst begins to sinter and lose active surface area, plus you risk ammonia slip (unreacted NH₃ passing through). This temperature constraint is why our catalytic filters work best in waste incineration, biomass boilers, and cement kiln applications where flue gas naturally sits in the 280–380°C range after waste heat recovery. If your gas is above 400°C, you’ll need to add a quench or heat exchanger upstream to bring it into the optimal window before the filter.
Under ideal conditions (stable 300–350°C gas temperature, proper NH₃/NOx molar ratio of 0.9–1.1, low SOx content), we consistently achieve 90–95% NOx reduction in field installations. However, real-world performance depends on several factors: (1) gas composition — high SOx (>500 ppm) can poison the catalyst over time and reduce efficiency to 80–85% after 2–3 years; (2) ammonia distribution — poor mixing in the ductwork causes local under-dosing or ammonia slip; (3) dust loading — excessive dust accumulation on the filter surface can block gas access to the catalyst layer. We design for 85% efficiency as a conservative baseline and provide performance guarantees based on your actual gas analysis. Third-party testing from our Guangzhou installations shows 87–93% NOx removal over 24 months of continuous operation.
The catalyst impregnation adds about 5–8% to the initial pressure drop (from 300 Pa to 315–324 Pa on a clean filter at ambient conditions) because it slightly reduces the open pore volume. However, the filtration efficiency remains unchanged at >99.9% for 1 μm particles because the catalyst is deposited as a thin coating on the fiber surfaces inside the existing pore structure, not as a pore-blocking layer. The long-term pressure drop stability is actually slightly better in catalytic versions because the catalyst layer reduces the adhesion of sticky dust particles to the fiber surface — the pulse-jet cleaning (0.4–0.7 MPa) releases cakes more cleanly. We’ve had catalytic filters in continuous operation for 4+ years maintaining stable 900–1,500 Pa system pressure drop.
Under normal operating conditions (temperature window maintained, no catalyst poisoning from heavy metals or alkali dust), the V-Ti catalyst retains >85% activity for 20,000–30,000 operating hours (roughly 3–5 years depending on duty cycle). When efficiency drops below your target (typically around 80%), you have two options: (1) on-site regeneration using our chemical washing service — we recirculate a dilute acid solution to remove alkali deposits and restore ~90% of original activity; this can be done 1–2 times before the catalyst coating physically degrades; (2) replacement — we supply new catalytic filter tubes and accept return of spent catalyst for proper disposal/recycling. The regeneration service costs about 40% of new filter price and extends total service life to 6–8 years.
Yes, this is a common retrofit scenario. You would remove the existing SCR reactor and replace the fabric bags in your baghouse with our catalytic ceramic filter tubes. The main engineering considerations: (1) space — catalytic ceramic filters are slightly larger diameter than equivalent fabric bags, so verify tube sheet spacing (we provide retrofit layout drawings); (2) temperature — confirm your gas temperature at the baghouse inlet is 170–300°C after any heat recovery (if it’s above 400°C, add a quench); (3) ammonia injection — relocate your NH₃ injection grid to the ductwork immediately upstream of the filter housing. We’ve completed several retrofit projects like this in China, typically reducing total system footprint by 40% and eliminating the SCR catalyst replacement cost. Payback period is usually 2–3 years from reduced maintenance and ammonia consumption.
Brief excursions (up to 1 hour) to 450°C won’t permanently damage the catalyst, but repeated or prolonged exposure above 400°C causes irreversible sintering of the V₂O₅ active sites. After cumulative exposure of about 100 hours above 400°C, you’d see DeNOx efficiency drop from 90% to perhaps 75–80%. If your process regularly exceeds 400°C, you should either (a) install a temperature control system (quench or heat exchanger) to protect the catalyst, or (b) use our non-catalytic filters with a separate downstream SCR reactor operating at optimal temperature. We can model your temperature profile and recommend the most cost-effective configuration — send us 24-hour temperature logging data from your process.
Minimum order is 50 pieces for standard sizes (Φ120×1000, Φ120×2000, Φ150×2000). For custom dimensions, minimum is 100 pieces because we need to run a separate catalyst impregnation batch. Lead time is 45–60 days from order confirmation: 15 days for ceramic substrate production, 10 days for catalyst impregnation and sintering, 5 days for quality testing, 5–15 days for export packing and shipping documentation. For orders over 500 pieces, we can expedite to 25–30 days by splitting the production into parallel batches. All catalytic filters are tested for both filtration efficiency AND DeNOx activity before shipment — you receive both test reports with the COA.
They share the same chemistry — a catalyst on a ceramic substrate reduces NOx in the presence of ammonia — but the form and duty differ. A ceramic catalytic converter in the classic sense (a honeycomb SCR reactor) is a separate vessel that needs its own casing, and its channels blind quickly when dust loading is high. A catalytic candle filter integrates the catalyst into the wall of the filter element itself: dust is captured on the tube surface before it can reach the catalyst, so the catalyst keeps its activity and the SCR vessel disappears from the flowsheet. If your gas is already dust-free, a conventional converter may be the simpler answer; if it carries dust, the catalytic filter is the one-vessel answer.

Technical Datasheet (PDF)

Download the complete technical datasheet for engineering selection: dimensional drawings, pressure-drop curves, model-to-cloth-area mapping, mechanical-load curves and chemical compatibility reference.

Request the PDF datasheet  We will reply within 1 business day with the PDF and a sizing recommendation.

Common questions answered in our technical FAQ and working principle pages.