NEWS RELEASE                                                                                                    JANUARY 2013                                                      

$26 Billion Market for Mobile and Stationary Catalytic and Thermal Treatment 

In 2013 just under $26 billion dollars will be spent to remove carbon monoxide, volatile organic compounds and particulate carbon from stationary and mobile sources. Ninety-two percent of the market purchases will be for mobile sources. This is the conclusion reached in Thermal/Catalytic World Air Pollution Markets published by the McIlvaine Company.

Mobile Catalyst Sales ($ Millions) 

Diesel Catalyst            12,420

Diesel Particulate        6,782

Gasoline Catalyst        4,727

Total                            23,929 

Gasoline fueled vehicles typically use a 3-way catalyst (TWC) to convert three pollutants: carbon monoxide (CO), hydrocarbons (HC) and oxides of nitrogen (NO_x) to carbon dioxide (CO₂), water (H₂O) and nitrogen (N₂).

Diesel-fueled vehicles use a diesel oxidation catalyst (DOC), which uses oxygen (O₂) in the exhaust gas stream to convert carbon monoxide to CO₂ and hydrocarbons to H₂O and CO₂. These converters often operate at 90 percent efficiency, virtually eliminating diesel odor and helping to reduce visible particulates (soot). A DOC can reduce particulate matter (PM) by up to 50 percent, but more effective PM removal may be required and is achieved with diesel particulate filters (DPF). NO_x emissions are more challenging, with selective catalytic reduction (SCR) and NO_x traps (or NO_x Absorbers) as the two main removal techniques used. NO_x removal treatment is analyzed in a separate report.

Diesel particulate filters remove particulate matter found in diesel exhaust by filtering exhaust from the engine. The filters are commonly made from ceramic materials such as cordierite, aluminum titanate, mullite or silicon carbide. To ensure that particulates are oxidized at a sufficient rate, the filter must operate at a sufficient temperature and with oxidizing gases, which can be supplied by the exhaust gas stream in some systems. This filter is referred to as the ‘passive’ filter, and regenerates continuously during the regular operation of the engine. Passive filters usually incorporate some form of a catalyst.

Sales of emission control systems are being driven by increased regulations. European standards are setting the pace for the world, and many countries have adopted these or similar standards. Low Emissions Zones are progressively implemented in many urban areas in Europe and these request diesel vehicles to meet a satisfactory level of exhaust emissions before they are allowed to drive inside the zone. In the state of California, the California Air Resources Board has mandated that all Class 7 and Class 8 heavy diesel trucks meet certain emission targets by 2016, with interim targets established for 2011, 2012 and 2013 such that 90 percent of current operating diesel trucks will be required to meet these targets by 2014.

The industrial market for thermal treatment not including flares will be just under $1.9 billion in 2013.

Stationary Thermal Treatment (S Millions) 

Subject                                2013

Catalytic Oxidizer                   432

RCO                                        75

RTO                                        906

Thermal                                   484

Total                                     1,897 

The biggest investment will be for regenerative thermal oxidizers (RTO). Regenerative catalytic oxidizers were once thought to be an important development, but have never met expectations. Direct thermal is used where there is ample fuel value in the gas being treated. Catalytic oxidation is used where there is enough fuel value that combustion will take place in the presence of a catalyst. The regenerative thermal approach is used where there is a low fuel value and it is important to recapture the heat of combustion in order minimize fuel consumption.

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