MULCERAFIL All-in-One Ceramic Fiber Filter Tube for Ultra-High Temp

Ceramic Fiber Filter Tubes
Filtration efficiency > 99.9% (typical conditions)
Max. temperature 900 °C (continuous & peak)
Dust emission < 2 mg/m³ (typical conditions)
NOx removal > 95% (NH₃/NOx ≈ 1.0, 240 °C, NHSV 5,000)
Dioxin removal 95%–99% (200–300 °C)
AIFILTECH（MULCERAFIL）多合一陶瓷纤维滤管超高温气体滤管 | MULCERAFIL all-in-one ceramic fiber filter tube ultra-high temperature 实拍图 1 aifiltech ceramic fiber filter tubes warehouse 01.jpg aifiltech ceramic filter tubes array.jpg aifiltech ceramic fiber filter tube production line.jpg aifiltech high temp filter housing p.jpg

Product Introduction

The MULCERAFIL all-in-one catalytic filter element blends a nano-catalyst into the inorganic fibre granules so that the catalyst is distributed evenly through the filter wall. While filtering dust at high efficiency, it simultaneously removes dioxins, NOx, VOC and acid gases, handling gaseous pollutants and dust in one step inside a single element.

MULCERAFIL All-in-One Catalytic Filter Element — Dedusting, DeNOx and Dioxin Removal in One Step

The MULCERAFIL all-in-one catalytic filter element, made by AIFILTECH (Guangzhou Tuokai Environmental Technology Co., Ltd.), is formed from inorganic fibre granules blended with a nano-catalyst, the catalyst being distributed evenly through the filter wall. It keeps the high-temperature dedusting performance of a ceramic fibre element and at the same time removes NOx, VOC, dioxins and acid gases. Dedusting, desulphurisation, DeNOx, deacidification, dioxin and VOC removal are combined into a single step inside one element. Typical duties include waste incineration, secondary aluminium, electric furnaces and glass furnaces where several pollutants have to be handled together.

<2 mg/m³Dust
>95%HCl removal
>80%SO₂ removal
>95%NOx removal
>99%VOC removal
>99%Dioxin removal

Figures are measured results for the one-step process under typical conditions. Actual performance varies with gas composition, temperature, NH₃/NOx ratio and NHSV.

How the catalytic element differs from the standard ceramic fibre element

Table 1 — MULCERAFIL all-in-one catalytic element versus ceramic fibre element
Item Ceramic fibre element All-in-one catalytic element
Main function High-temperature dedusting High-temperature dedusting plus catalytic removal of gaseous pollutants
Pollutants handled Dust (particulate) Dust, NOx, VOC, dioxins, SO₂, HCl and other acid gases
Media composition Bonded inorganic fibre granules Inorganic fibre granules plus nano-catalyst
Temperature rating 900 °C 900 °C
Dimensions Identical — interchangeable on the same tubesheet

Structure and catalytic mechanism

The nano-catalyst is distributed evenly through the whole filter wall. With a wall thickness of 10–20 mm, the gas stays in contact with the catalyst long enough to give a high utilisation rate. As the gas passes through the wall, NOx, VOC and dioxins are broken down into harmless components over the catalyst.

SEM image of the MULCERAFIL catalytic filter element showing the porous wall structure
SEM image of the catalytic filter element
Filter wall diagram — catalyst distributed through a 10 to 20 mm thick wall
Wall thickness 10–20 mm; catalyst distributed across the full section

What the structure means in practice

  • Catalyst throughout the wall; the 10–20 mm thickness provides long gas–catalyst contact time
  • On comparable duties, catalytic efficiency is 5–15% higher than with a conventional SCR process
  • Avoids the efficiency losses caused by gas turbulence in SCR reactors
  • Catalyst is distributed through the wall, so catalytic performance stays stable in service
  • No separate SCR reactor is needed, which shortens the gas-cleaning process
  • Smaller footprint and correspondingly lower overall investment

The one-step process

Dust, HCl, SOx, NOx, VOC, dioxins
Raw mixed pollutant gas
→
MULCERAFIL catalytic element
NaHCO₃ (or Ca(OH)₂) + NH₃ (ammonia or urea) injected
→
Clean discharge
Multiple pollutants removed inside a single element

Measured removal performance in a single step
<2 mg/m³Dust
>95%HCl
>80%SO₂
>95%NOx
>99%VOC
>99%Dioxins

Typical applications

1. High-temperature desulphurisation, DeNOx and dedusting in one step

For boilers, kilns, sintering machines, power plants and cement plants. At an NH₃/NOx ratio near 1.0, 240 °C and NHSV 5,000, NOx removal reaches more than 95% while ammonia slip stays low.

Chart of NH3/NOx ratio versus NOx removal efficiency and ammonia slip (NHSV 5,000, 240 °C)
NH₃/NOx ratio versus removal efficiency and NH₃ slip (NHSV 5,000; 240 °C)
Process comparison between the MULCERAFIL one-step DeNOx and dedusting approach and a conventional SCR route
One-step DeNOx and dedusting: the catalyst is integrated into the element, so no separate SCR reactor is required

2. Dioxins, VOC, deacidification and dedusting combined

For waste incineration, secondary aluminium, electric furnaces, and sulphuric and nitric acid plants. Conventional dioxin control usually captures dioxins and VOC from the gas phase and holds them on a solid sorbent; the pollutants themselves are not destroyed. The nano-catalyst in the MULCERAFIL element breaks dioxins and VOC down into harmless components, without a separate unit for the purpose.

Across the 200–300 °C range, both new elements and elements that have been in service for a long time hold dioxin removal (measured as MEK removal) at 95–99% and above.

Dioxin removal efficiency chart for new and aged elements across 200 to 300 degrees C, plotted as MEK removal
Dioxin removal efficiency — plotted against MEK removal

Applications

Table 2 — Industries and typical duties for the all-in-one catalytic element
Industry Notes
Waste incineration Flue gas from industrial, chemical, municipal, hazardous and medical waste incinerators, with emphasis on dioxins, VOC and acid gases
Metallurgy Calcium carbide, ferroalloy, primary and secondary aluminium, alumina calcining, sintering machines, copper smelting, blast furnace, converter
Glass Combined dedusting and DeNOx for glass furnace flue gas
Power generation One-step desulphurisation, DeNOx and dedusting of boiler flue gas
Cement High-temperature gas cleaning for cement kilns and sintering machines
Ceramics Flue gas treatment for ceramic kilns
Chemical processing Coal gasification and precision filtration of process gas
Precious metal recovery High-temperature gas cleaning in precious metal smelting and recovery

Operating data from installations

Case 1 — Glass furnace flue gas

Table 3 — Operating data, glass furnace project
Gas volume (Am³/h) Filter area (m²) Filtration velocity (m/h) Temperature (°C) Element size (mm) Qty (pcs) Inlet dust (mg/Nm³) Inlet NOx (mg/Nm³) Outlet dust (mg/Nm³) Outlet NOx (mg/Nm³)
183,456 2,548 72 350 150 × 3000 1,820 15,500 1,500 1.8 40

Filtered directly at 350 °C with no cooling stage. Outlet dust 1.8 mg/m³ and outlet NOx 40 mg/Nm³, a DeNOx rate of about 97%.

Case 2 — Waste incineration flue gas

Table 4 — Operating data, waste incineration project
Gas volume (Am³/h) Filter area (m²) Filtration velocity (m/h) Temperature (°C) Element size (mm) Qty (pcs) Dioxins (ng-TEQ/Nm³) Furans PCB Dust (mg/Nm³) HCl (mg/Nm³)
63,504 756 84 270 150 × 3000 540 0.00032 0.02230 0.0000325 0.3 2

Dioxin emission of 0.00032 ng-TEQ/Nm³, below the EU limit of 0.1 ng-TEQ/Nm³.

Standard specifications

Table 5 — Standard sizes for MULCERAFIL all-in-one catalytic filter elements
Overall length (mm) Outside diameter (mm) Flange height (mm) Flange diameter (mm) Filter area (m²)
1000 60 20 80 0.19
1250 60 20 80 0.23
1500 60 20 80 0.28
1800 150 30 195 0.83
2000 123 15 159 0.77
2045 130 30 160 0.82
2250 150 30 195 1.05
3000 125 30 160 1.17
3000 150 30 195 1.40

Sizes above are standard. Flange type and dimensions can be made to suit an existing tubesheet. Catalytic and ceramic fibre elements share the same dimensions and are directly interchangeable.

Frequently asked questions

How does the all-in-one catalytic element differ from a standard ceramic fibre element?
A standard ceramic fibre element handles high-temperature dedusting. The catalytic element blends a nano-catalyst into the inorganic fibre granules, distributed evenly through the wall, so it removes NOx, VOC, dioxins and acid gases at the same time as it filters dust.
What temperature can the catalytic element handle?
The MULCERAFIL all-in-one catalytic element is rated to 900 °C continuous and peak, the same as the ceramic fibre element. Dioxin and VOC removal is normally carried out in the 200–300 °C range.
Does catalytic efficiency fall over time?
The catalyst is distributed through the full 10–20 mm wall thickness, and performance stays stable in service. Because the gas flows through the wall in a stable pattern, the efficiency losses associated with turbulence in conventional SCR reactors are avoided.
How does this compare with a separate SCR reactor?
The catalyst is integrated into the element, so dedusting and DeNOx happen in the same vessel. No separate SCR reactor or associated ductwork is needed, the process is shorter and the footprint is smaller. On comparable duties, catalytic efficiency is 5–15% higher than with a conventional SCR process.
Are dioxins adsorbed or destroyed?
They are destroyed. Conventional routes typically capture dioxins and VOC from the gas phase and hold them on a solid sorbent, leaving the pollutants intact. The nano-catalyst in the MULCERAFIL element breaks dioxins and VOC down into harmless components.
Which industries can use it?
Waste incineration including hazardous and medical waste, metallurgy (calcium carbide, ferroalloy, primary and secondary aluminium, sintering machines, blast furnace and converter), glass, ceramics, cement, power generation, coal gasification and precious metal recovery.
Related product: For high-temperature dedusting without catalytic removal of gaseous pollutants, see the
MULCERAFIL ceramic fibre filter element.

Applications

Waste incineration Metallurgy Glass Cement Chemical plants Hazardous waste treatment Biomass boilers Steel sintering
Need the full technical data? Download the PDF datasheet for complete technical data, key figures and selection guidance.
Download Datasheet

All data above are obtained under specific test conditions; the actual solution must be engineered to site conditions. AIFILTECH provides custom design and sizing based on actual gas volume, temperature, dust characteristics and emission limits.

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