Gas Catalytic Infrared drying technology is a flameless infrared medium that we use to dry and cure wet product or dry powder coating on a variety of substrates, in many different industries. It is an exothermic chemical process in which gas (natural gas, propane or butane) is converted into energy and long wave IR through precious metals, such as platinum and palladium.
The process starts by heating a platinum plate to an activation temperature of approximately 150 degrees Celsius using an electric current. This ensures that the catalyst surface reaches the temperature needed for the fuel to begin reacting with oxygen. Once at temperature, the catalytic reaction can sustain itself through the heat it generates, without the need for electricity.
Fuels such as propane (C₃H₈), butane (C₄H₁₀), or methane (CH₄) are then passed over the plate, which causes the fuels to react with the heated platinum in an exothermic oxidation reaction. This process breaks down the fuel molecules and forms water (H₂O), carbon dioxide (CO₂) and infrared heat. Unlike traditional combustion, this reaction doesn’t produce an open flame, but instead generates heat through a process known as catalytic combustion.
The heat produced by the catalytic combustion heats up the surface of the catalyst to a high temperature. This heated surface then emits infrared radiation, which in our case falls in the medium to long-wave IR spectrum, which is particularly effective for drying processes.
This infrared heat accelerates the evaporation of the carrier (such as solvents or water) from paint or coatings by directly heating them as it penetrates the paint layer. This targeted heating makes the drying process faster and more energy-efficient than traditional methods, such as heating the surrounding air.
Additionally, any of these carriers, such as Volatile Organic Compounds (VOCs), that are carbon and hydrogen compounds, can also be oxidised on the platinum catalyst. This oxidation process breaks them down into carbon dioxide (CO₂) and water vapour (H₂O), reducing harmful emissions.
Our gas catalytic emitters are safer than many types of electric infrared that utilise elements susceptible to failure. Gas catalytic IR is more effective than electric infrared as the emission spectrum ideally matches the absorption spectrum of organic coatings.
When working with temperature sensitive substrate (resinous woods and plastics for example) the temperature should remain as low as possible.
We are only able to achieve this with our catalytic infrared technology, relying on the long wave infrared to cure the product and not direct heat, as with other drying media.
Changing the pressure of the gas in a catalytic infrared drying system influences the wavelength of the IR radiation produced – medium wave or long wave. Higher pressure increases the rate of catalytic combustion, leading to higher temperatures on the catalyst surface and therefore the production of medium wave IR radiation (approximately 3 to 5 micrometres).
Medium wave IR radiation has higher energy compared to long wave IR. It heats surfaces more rapidly and evenly and is typically more intense, making it an efficient method for curing powder coating.
Powder coatings are typically made from thermosetting polymers. As these absorb the infrared, they gain energy, start reacting with one another, and essentially ‘melt’. As these particles cross-link, they chemically bond together. The coating then simply cools and hardens, which is what gives the cured coating its final solid structure.
Another advantage of using infrared radiation is that it penetrates the coating evenly, ensuring that even complex shapes and thicker sections of the coating cure uniformly.
This technology can also be retrofitted inside some existing powder coating tunnels.
Having used catalytic infrared technology for more than 30 years, Schuberts has vast knowledge and experience in this field.
Our catalytic system speeds up the drying and curing process drastically. This means less work in progress, shorter drying tunnels, smaller footprint plant, little or no maintenance, full UKCA and ATEX certification on emitters, total flameless heat and, of course, full cure!
Catalytic IR is entirely flameless, meaning it’s perfect for use in environments with flammable solvents. It is also incredibly energy efficient because it targets the paint directly rather than heating the surrounding air. The process allows for precise control over drying rates, reducing the risk of defects like blistering or improper curing.
The catalytic process is totally flameless. It is an intrinsically safe process as there is no live flame involved, the face temperature is below that of solvent or gas combustion, and all oxygen at the face of the catalyst is consumed by the process.
We have the following certifications:
Our gas catalytic heaters emit medium to long wavelength infrared energy in a range from 2 to 10 µm, continuously adjustable by simply changing the gas pressures. Different materials work with different wavelengths.
Catalytic heater panels without additional ventilation range between 200°C and 450°C (392-842°F). Models with built-in additional ventilation range between 150°C and 600°C (302-1112°F).
With catalytic infrared, the cooler the process the better, especially when dealing with temperature sensitive substrates, such as solid wood or plastics. We aim for no more than 50°C on the surface of the product. With custom installations, such as powder coating for example, we can go as high as 220°C+.
Catalytic heater panels without additional ventilation emit 20 kW/m2. Models with built-in additional ventilation emit 30 kW/m2.
A Schubox unit equipped with a gas catalytic panel has a combustion efficiency of 98 percent. In other words, 98 percent of the gas fuel (natural gas or LPG) feeding the emitter is transformed into heat.
The distance depends on the material. For instance, with a sheet of glass 4mm thick, an appropriate distance would be 300-350mm.
High solid AC lacquer used on solid or veneered wood should be no closer than 500mm from the catalytic emitter.
Our innovative catalytic IR technology is at the core of our drying and curing products,
delivering exceptional performance and efficiency.
