Heating by Catalytic Gas Infrared Rays

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Heating by Catalytic Gas Infrared Rays
Article in Energy Engineering · October 2011

DOI: 10.1080/01998595.2011.10412166
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Heating by Catalytic Gas

Infrared Rays
a
Mohammed Awwad Al-Dabbas
a
Mutah University , Karak, Jordan
Published online: 22 Sep 2011.
To cite this article: Mohammed Awwad Al-Dabbas (2011) Heating by Catalytic Gas
Infrared Rays, Energy Engineering, 108:6, 26-45
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26 Energy Engineering Vol. 108, No. 6 2011
Heating by Catalytic Gas Infrared Rays

Dr. Mohammed Awwad Al-Dabbas
Mutah University, Karak, Jordan
ABSTRACT
Infrared (IR) is a form of electromagnetic radiation that has a wave-

length slightly longer than the color red in the visible light spectrum. In-
frared radiation is created when objects are heated at temperatures not

quite high enough to make them glow. You can detect infrared radiation
by the heating effect it has on your skin.
Infrared heating systems rely upon the transfer of radiant energy
from hot heat exchanger surfaces (up to 1000°F for low intensity heat-
ers) through the air to cooler surfaces without the use of an air mover.
Infrared heaters cut down fuel costs by lower temperature settings since
the building heat loss is in direct proportion to the difference between
the inside and outside temperatures. With infrared heaters, the heat is
directed to the floor and not trapped at the ceiling. As a result, you can
lower thermostat settings 5-10 degrees and still maintain desired com-
fort levels at the floor.
Consequently, in this work, infrared heating systems were evaluated
by measuring the infrared temperature, gaseous emissions, and fuel flow
rate. Several instruments were used:
• Gas flow meter

• Laser meter (pyrometer)
• Gaseous analytical
• Thermometer (dry & wet bulb temperature)
The infrared heater was operated for several hours without any
problem, the relative humidity was 50%, and the ambient temperature
was 18°C. The environmental impact that resulted from the infrared heat-
er was almost zero emissions, which was better than other heating sys-
tems with an efficiency of 96-98%.
Keywords: Infrared heating, catalytic, relative humidity, radiation, py-

rometer.
27
INTRODUCTION
Heat supply problems are caused by the growth of fuel prices on a

world level with tariffs lagging behind, a decrease in payment collection,
and a worsening of the financial situation of district heating companies [1].
Infrared heaters emulate the true efficiency of the sun [2]. They gen-
erate energy that is converted into heat when absorbed by floors, animals,
people, and other objects. The energy is then “re-radiated” to warm the
surrounding area by convection, as shown in Figure 1. This is the most ef-
ficient and effective method of heating under the diverse and challenging
conditions presented in most commercial and industrial applications [2].

When one thinks about building heat, the first consideration may be
of the forced air variety. You know—the big unit suspended from the ceil-
ing, blowing hot air with the force of a jet engine. While that might work
for some, independent reports suggest that gas-fired infrared heating can
save 20-50% in fuel consumption over forced air heating [3].
IR can be used in several applications, such as in industry, paint
shops, offshore platforms, freeze protection (valves, chokes, regulators,
etc.), pipeline coating, repairs, industrial ovens, agriculture best manage-
ment tools, drying rice, Red Flour Beetle, household equipment (indoor
and outdoor heaters, cooking ovens, geysers), and civil engineering (as-
phalt repairs, building/site heating) [3].
Infrared heating systems can serve three basic functions [4]:

A. Total building heating: Infrared heaters are used to heat the entire
building. The system is designed to heat the floor, which, in turn,
Figure 1. Heating
by radiant systems
creates convection currents that heat the air above it.

B. Partial building heating: Infrared heaters are used to heat sections of
a building such as an assembly line or an office section located in an
open area of a warehouse.
C. Spot heating: Infrared heaters are used for heating only small areas.
HOUSEHOLD ELECTRIC HEATERS
Various electric heaters are manufactured and sold in the home ap-
pliance field. The main purpose of all these heaters is to convert electrical
energy and transfer this energy in the form of heat to occupied areas or
to maintain an above-freezing temperature in non-inhabited parts of the
building [5], as shown in Figure 2. The conversion efficiency of electrical
energy to heat for all electric heaters is 100%. However, the performance
of electrical heaters differs greatly, and for that reason a heater must be se-
lected based on the application and other criteria [5].
Infrared Catalyst Heater

Figures (3-7) show the infrared catalyst heater. In the upper part, the
air is aspired from the environment by a ventilator before being pushed
equally to the inner borders of the apparatus. The air is consequently
blown equally on the surface of the panel towards the center. Electrically
heated spirals, which are incorporated in the catalyst, are heated up to cre-
ate a certain temperature [6].
Once the required temperature is reached, the gas is flowing through
one or two valves (security, regulation) and conducted to the catalyst. The
gas flows equally through the fibers (covered with Platen), which are the
Figure 2. Comparison between heaters and room temperature [5]

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31
Figure 3a. Real image of Figure 3b. Drawing of

catalyst heater catalyst heater [6]
Figure 4a. Real image of Figure 4b. Construction

catalyst heater. components [6]
support (catalyst) for the catalytical combustion. The temperature gives

the ignition for the combustion. The electricity for the electrically heated
spirals is turned off, and the apparatus is on (i.e. a flameless combustion).
The air support gives the necessary combustion quality [6].
Through the combustion process, the combustion is relatively slow
compared to traditional combustion. Therefore, a complete combustion is
obtained, with indefinite quantities of CO (carbon monoxide) at tempera-
tures around 300-700°C. The surface temperature is less than 400°C. The
low temperature level permits working NOx-free (no nitrogen oxides).
There is very little impact on the environment [6].
The apparatus is
based on modular con-
struction. The upper part
is a support for the parts
related to the control of
the functions, electrical/
electronic parts, and the
guidance of the gas. The
lower part is the panel,
i.e. catalyst. The parts can
be separated by opening
the clips on the side of Figure 5. Components of heater [6]
the panel. This permits
the fast change of the panel on site. The duration of the panel is 8,000-14,000
hours, depending on the air hygiene of the working environment [6].
Gas Catalytic Infrared Heating

Catalytic heating is the product of intensive research efforts to quan-
tity the effectiveness of catalysts in promoting the reaction of combustive
Figure 6. Top view of catalyst heater [6]

Figure 7. Internal parts of catalyst heater [6]

33
gases with oxygen or air to produce heat. There is no flame to create a

hazard, and catalytic heat can operate efficiently on low-cost natural gas,
butane, or propane [7]. The use of catalytic heaters has been approved and
accepted for dozens of industrial and petrochemical applications.
A catalyst favors a chemical process without being used or con-
sumed, and its construction is of a porous support material, a ceramic fi-
ber mat washcoat with a huge specific surface of 10-1000 m2/g with:
– Very small, open pores

– Active center: special coated catalyst
– Precious metals like: Plating Pt, Pd, Rh, etc.
– Metalloxydes
Gas catalytic infrared heaters, producing maximum wavelengths in

the 3.6-6.3 micron range, are very efficient infrared emitters for the trans-
fer of thermal energy to materials in the long-band absorption spectrum.
Most organic materials, including waterborne solvent and power coat-
ings, easily absorb infrared radiation. The larger surface area of the gas
catalytic heaters relative to other infrared emitters makes them ideally
suited for curing large part [7].
How?
This is done by breaking the CH4 molecular bond. Once the bond is
broken, the CH3 & H becomes very radical, looking to bond or react with
something; in this case its oxygen (O2). The catalyst then acts to prevent
the amount of IR energy to exceed temperatures of 425°C (being a stabi-
lizer) [7], as shown in Figure 8.
Figure 8. The fundamental of catalystic

35
How the Catalytic Principle Works

The normal ignition temperature of natural gas (80%) in air (20%) at
atmosphere pressure is given as 683°C. In the presence of a catalyst, the re-
action occurs with sufficient velocity to begin a chain reaction at 107°C in
the presence of oxygen; it is oxidized to carbon dioxide and water vapor.
Sufficient heat is, therefore, evolved to raise the temperature of the bed of
the heater, and oxidation will continue as long as gas and oxygen are sup-
plied [10].
No flame is produced under these conditions, since the gases are
well below ignition temperature of 683°C. However, approximately the
same amount of heat is produced as if the gas had been burned in the nor-
mal manner.
The thermal efficiency of a catalytic heater is substantially higher
than that of a conventional heater. A considerably larger proportion of the
heat produced is radiant heat of wavelengths 2-16 microns, and much less
heat is required to heat the evolved gases.
Practically no heat is utilized to heat the large volume of nitrogen as-
sociated with the oxygen, as in a conventional heater, because most of the
heat content of the carbon-dioxide and water is recovered as radiant heat
in a catalytic heater. The temperature attained in the catalyst bed is deter-
mined by two factors: the flow of the gas to the catalyst bed and the rate at
which oxygen diffuses through the bed to replace what was consumed in
the reaction [8].
If the rate of gas flow is too high, not enough oxygen can enter to
completely burn the gas. If the rate is too low, the gas is burned deeper in
the bed and the surface cools. Therefore, the temperature of the catalytic
heater is self-limiting, and the system will operate stably for long periods
of time without intervention as long as gas and air are supplied.
The Catalytic Principle

Catalytic heat is radiant heat. Radiant heat, like light, is electromag-
netic wave energy that travels in straight line at 186,000 miles per second;
casts a shadow; may be transmitted, absorbed, or reflected by matter; and
may be focused or dispersed by lenses or prisms of the proper material.
A source of radiant energy, such as a catalytic heater, floods the area
around it with heat energy in the same way that light floods the area
around it. The intensity of the heat energy varies with the square of the
distance (as with light), and the energy travels any distance without loss
as long as it does not contact matter which absorbs it [11].
The absorption of radiant energy by various materials is a property

specific to each material. A certain wavelength will be absorbed to a con-
siderable extent, others less, and some very little or not at all. Thus, each
molecular substance can be found in an atlas of infrared observation spec-
tra. Since the absorption of radiant heat is highly selective, there are many
excellent application opportunities by selecting the proper substance to
act as a filter between the sources and the object to be heated, but the de-
sired wavelength can be filtered out, as shown in Figure 9.
Figure 9. Simplified catalystic heater diagram
Figure 10 shows the reactant of combustion by using a catalyst and

non-catalyst reaction as following curve.
Observations of the energy balance of the catalytic combustion:
1. Very low activation energy

2. Combustion at very low temperatures within a porous material/me-
dium
3. Temperature of material/medium and exhaust gases at same tem-
perature (on the surface)
RESULT & DISCUSSION
Infrared radiation is the same kind of radiation as radiation from

the sun. A heat source at high temperature emits infrared waves that are
37
CH4; C3H8
O2
CO2
H2O
Figure 10. The reactant of combustion
subsequently absorbed by a colder object. Thus, the heat is transferred in

essence by electromagnetic radiation, without the aid of an intermediary.
In high temperature resistance ovens, heat is also transferred to a large
extent by radiation [9]. However, for infrared heating, it is typical that the
heat source irradiates the object to be heated directly. Sometimes reflective
surfaces (mirrors) are used to focus or direct the rays [11]. Infrared heating
is a typical surface treatment technique and preferentially lends itself to
heating products with a simple shape [9].
Two important laws describe the radiating [9]:
The Stefan-Boltzmann law [9]: The total power density of a radiat-
ing surface (i.e. the total emissivity) is proportional to the fourth power of
the surface temperature.
q = ασ Ts4 – Tsur
4
Where:
M = total power density of radiating surface (total emissivity)
σ = experimental Stefan-Boltzmann constant 5.7 x W/(m²K4)
T = absolute surface temperature [K]
ε = emissivity coefficient.
Wien’s law [9]

It gives an expression for the wavelength at which the monochro-
matic emissivity is a maximum.
q” ≈ εσTs4
Where:
Tmax = wavelength [μm]
T = absolute surface temperature [K]
The Stefan-Boltzmann law is used to find the total power density of

a radiating surface (emissivity):
q= 0.8 × (5.7 x 10-8 W/(m2K4)) × (418+273.15 k) = 10.46 (kW/m2)
This result shows that the wavelength at which the monochromatic

emissive is a maximum.
Long-wavelength infrared is obtained with temperatures of 400-
800°C as seen in Figure 11.
According to this result, the maximum spectral radiant emittance is
displaced to shorter wavelengths with increasing temperature.
Transfer of Energy by
Radiation
The transfer of energy is completely determined by the temperature
of the two bodies, their geometry, and their position with respect to one
another. The formula for the incident power is the following (radiating
surface A1 and irradiated surface A2):
Figure 11.
39
P = σ •e’ • A1 • F12 • (T14 −T4) [W]

s = experimental Stefan- Boltzmann constant 5.73 x 10–8 W/(m²K4)
e‘ = generalized emission coefficient
A1 = radiating surface [m²]
F12 = view factor (A2, seen from A1)
T1 = temperature of the radiating surface [K]
T2 = temperature of the irradiated surface [K]
By taking dimensions of cat-ray as height = 28 inches (71.1 cm),

width = 60 inches (152 cm), and thickness = 12 inches (30.48 cm), the trans-
ferred energy between two bodies can be calculated as follows:
P = (5.73 x 10–8W/(m²K4) • (0.8)•

(0,711m x 1,52m) • (1) • ((691)4 – (303)4) = 10.3 kW
Heating Power to Install

The heating power to be installed in a building is determined on
the basis of its heat losses (i.e., heat loss by conduction through the outer
walls and by convection through air exchange). An account is to be taken
of the maximum difference between the desired indoor temperature and
the outdoor temperature [6].
Figure 12 shows the total energy released by gas combustion (natu-
Figure 12. A radiant heating systems using energy three times

ral gas or propane) that is used to heat the building, either in the form of
radiative or convective heat, for the uniform heating of the air within[6].
The building and the absence of any stratification of air makes addition-
al loss due to local overheating virtually negligible. Convective heat effi-
ciently equalizes the temperature within the building, such that the exact
distribution of radiative heat over the floor becomes of secondary impor-
tance [6].
Requirements of a Building
Layout of an exhibition hall heating system:
Size of hall: 30 m x 33 m = 990 m2
Volume to be heated: 990m2 x 4 m = 3960 m3
External walls: Perimeter = 126 m

Total surface = 630 m2
of which
Doors (6 x 3m x 4m) = 72 m2
Windows = 252 m2
Façades = 566 m2
Heat loss by conduction:

Surface (m2) k (W/m2°C) (W/°C)
Doors 72 5.0 360

Windows 252 2.5 630
Façades 566 0.4 226
Roof 990 0.6 1187
Floor 990 0.35 692
——————————————————————————————
2870 m2 3095 W/°C
Loss by heat conduction:

• For T = 25°C Qcond = 45. kW
Loss by air renewal:

• Air renewal = 0.3 vol per hour V = 2967 m3 per hour
• For T = 25°C Qcond = 24.7 kW
41
Nominal heating power requirements:

• Qtot = 70.5 kW
• Qinstall = 114 kW for heating the exhibition hall
Fuel Consumption of Exhibition Hall

The calculations of fuel consumption for a heating system for either
short-term or long-term operation are difficult to perform. Records of fuel
consumption of past operating experience can provide a reliable and ac-
curate estimate [15]. However, a simple procedure that uses the annual
degree-day method can be applied to estimate the fuel consumption for
heating systems under typical winter conditions. The mass of fuel, mf,
consumed in a given period of time (one month or heating season period)
during winter operation can be estimated, using the degree-day method,
from the following relation:
24 * Q * DD * CD
mf = ————————
(Ti – To) * Cv * η
Where:
Q = the calculated heating load in units of KJ/h, based on inside
and outside design temperatures for the application
DD = the number of the degree-days for the required time period
(one month or heating season period)
Cv = the calorific value of the fuel used
η = an average efficiency factor that includes the effect of full
load efficiency and part load performance
Cd = an empirical correction factor for heating effect versus de-
gree-day value [15]
RESULTS & DISCUSSION
Infrared radiation is the same kind of radiation as radiation from the

sun. A heat source at high temperature emits infrared waves that are sub-
sequently absorbed by a colder object [9]. Thus, the heat is transferred in
essence by electromagnetic radiation, without the aid of an intermediary.
In high temperature resistance ovens, heat is also transferred to a large ex-
tent by radiation. However, for infrared heating, it is typical that the heat
source irradiates the object to be heated directly. Sometimes reflective sur-
faces (mirrors) are used to focus or direct the rays [9].
Figure 13 shows the temperature distribution versus distance (ce-

ramic, catalystic).
Air Renewal Rate

The air renewal of the building, whether natural (by opening doors
and windows or the permeability of the building envelope) or forced, di-
lutes the combustion gases released by the heating system, thus maintain-
ing the carbon dioxide and humidity contents below given prescribed lev-
els [8].
Environmental Impact
A pyrometer (see Figure 14) was used to measure the gaseous emis-
sion of an infrared heater. The gaseous emissions were an almost zero
reading, which is consistent with Figures 15 and 16.
CH4 + 2 (O2 + 4 N2) → CO2 + 2 H2O + 8N2 + heat

C3H8 + 5 (O2 + 4 N2) → 3 CO2 + 4 H2O + 20 N2 + heat
CONCLUSION
This article presents a catalyst infrared heater with dimensions of:

height 71cm, width 152cm, and thickness 30cm.
The following observations and conclusions were noted:
• Flameless infrared catalystic heater

• Efficiency rate 98%
• Saving of up to 50% vs. traditional heating systems (investments,
costs, energy savings, maintenance)
Figure 13. Temperature distribution versus distance (ceramic, catalystic)

43
Figure 14.
Pyrometer
Figure 15. CO2 and H2O concentrations as a function of the air renewal rate
• Instant warmth emission (radiation after 4 minutes)

• No hazardous gases such as CO & NOx
• No need for burner, chimney, heat distribution system (air & water)
• Temperatures are much lower than in flame combustion
• No risk of igniting explosives, vapours evaporating from solvent-
based products
• Very fast effect in heating; no need to start the heating system hours
earlier
Figure 16. Curve of a catalytic and non-catalytic reaction
• Convenient heating—relaxed, with humidification effect

• Ecological, with lower emissions
• Catalytic heating can be used for a wide variety of curing applica-
tions on metals, wood, and even plastics
• Extremely low exhaust-gas emissions—i.e., not measurable (CO,
NOx)
• Negligible exhaust gases can be emitted into the working environ-
ment.
References
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lasso
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anglais_int.pdf
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plied and installed by,” Finishing, Jan-Feb 2007 Issue.
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————————————————————————————————
ABOUT THE AUTHOR
Mohammed Al-Dabbas is a mechanical engineer with a master’s de-
gree in oil shale combustion and a Ph.D. in mathematical modeling of oil
shale combustion. He worked in the renewable energy department of the
Ministry of Energy from 1992 until December 2004 as head of the oil shale
section and is now an assistant professor in the Mechanical Engineering De-
partment of Mutah University, Karak, Jordan. His research interests involve
solar energy, wind, geothermal energy, oil shale combustion, and hydrogen.
Currently tasked with leading research in solar chimney, hho in diesel en-
gines, industrial problems and oil shale, he is also interested in POP proj-
ects, especially dioxin and furan. Dr. Al-Dabbas has published more than 10
papers in these fields. Contact information includes:
Mutah University
Faculty of Engineering, Mechanical Engineering Department
Mutah-Karak-Jordan, Assistant Professor
Mobile: 00962-795580449
Tel: 00962-3-2372380
P.O. Box: 7
Zip code: 61710
Fax: 00962-3-2375540
E-mail: madabbas@yahoo.com
madabbas@mutah.edu.jo
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Heating by Catalytic Gas Infrared Rays

Infrared (IR) is a form of electromagnetic radiation that has a wave-

frared radiation is created when objects are heated at temperatures not

• Gas flow meter

Keywords: Infrared heating, catalytic, relative humidity, radiation, py-

Heat supply problems are caused by the growth of fuel prices on a

conditions presented in most commercial and industrial applications [2].

Infrared heating systems can serve three basic functions [4]:

creates convection currents that heat the air above it.

HOUSEHOLD ELECTRIC HEATERS

Infrared Catalyst Heater

Figure 2. Comparison between heaters and room temperature [5]

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Figure 3a. Real image of Figure 3b. Drawing of

catalyst heater catalyst heater [6]

Figure 4a. Real image of Figure 4b. Construction

support (catalyst) for the catalytical combustion. The temperature gives

Gas Catalytic Infrared Heating

Figure 6. Top view of catalyst heater [6]

Figure 7. Internal parts of catalyst heater [6]

gases with oxygen or air to produce heat. There is no flame to create a

– Very small, open pores

Gas catalytic infrared heaters, producing maximum wavelengths in

Figure 8. The fundamental of catalystic

How the Catalytic Principle Works

The Catalytic Principle

The absorption of radiant energy by various materials is a property

Figure 9. Simplified catalystic heater diagram

Figure 10 shows the reactant of combustion by using a catalyst and

1. Very low activation energy

RESULT & DISCUSSION

Infrared radiation is the same kind of radiation as radiation from

Figure 10. The reactant of combustion

subsequently absorbed by a colder object. Thus, the heat is transferred in

Wien’s law [9]

The Stefan-Boltzmann law is used to find the total power density of

q= 0.8 × (5.7 x 10-8 W/(m2K4)) × (418+273.15 k) = 10.46 (kW/m2)

This result shows that the wavelength at which the monochromatic

P = σ •e’ • A1 • F12 • (T14 −T4) [W]

By taking dimensions of cat-ray as height = 28 inches (71.1 cm),

ferred energy between two bodies can be calculated as follows:

P = (5.73 x 10–8W/(m²K4) • (0.8)•

Heating Power to Install

Figure 12. A radiant heating systems using energy three times

Size of hall: 30 m x 33 m = 990 m2

Volume to be heated: 990m2 x 4 m = 3960 m3

External walls: Perimeter = 126 m

Heat loss by conduction:

Doors 72 5.0 360

Loss by heat conduction: