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Endothermic Generators

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Endothermic gas generators are used to produce a low cost endothermic gas that is used in heat processing and treating furnaces and other protective surface treatments. They are one of the primary types of equipment used for heat treatment. These generators are specially designed generators which generate a special type of gas to be used as atmosphere gas during heat treatment. The endothermic gas thus produced can also be as atmospheric gas for carburizing metals and other industrial applications.

The process

An endothermic atmosphere is produced by endothermic generators at a low cost by using any regular fuel gas like natural gas, propane or butane.

The atmosphere is created by mixing a hydrocarbon gas with air. The mixed gas is passed through a heated steel chamber filled with a catalyst. The process requires external heat. This heat is provided by electrical heaters or fuel burning around the chamber. Heating the mixed gas in the presence of a catalyst makes the gas to break down or crack into several simpler gases, mainly hydrogen, nitrogen, and carbon monoxide. Under controlled conditions when the generator heats fuel gas and air, a rich or lean endothermic gas is produced. This "cracked" gas is then cooled rapidly to prevent sooting and the formation of carbon dioxide.

Composition of Endothermic Gas

Operating on natural gas, propane, butane or methane, the reaction of air and fuel on the catalyst produces endothermic gas of the following composition:

Property	Value
CO	28 to 30%
H2	20 to 25%
CO2	0.1 to 0.5%
N2	Balance
Dew point	(-) 5^oC

Principal Components of an Endothermic Generator

Heating chamber: The chamber is used to supply heat by combustion or electric heating.
One or more cylindrical retorts in the heating chamber: These retorts are usually vertical with several small, porous ceramic pieces, infused with nickel as a catalyst for the reaction.
A cooling heat exchanger: This is used to cool the reaction products to a temperature that will not let the reaction to proceed further.
The control system: The system maintains the reaction temperature. It also adjusts the gas/air ratio to create the required dew point.

Applications of Endothermic Gas Generators

Gas carburizing
Carbo-nitriding
Carbon restoration in steel
Hardening/Annealing
High temperature brazing
Sintering of high carbon and alloy powdered compacts
Reduction of metal oxides

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