Carbon monoxide (CO) is one of the most critical hazards in confined and emergency breathing environments. Colorless, odorless, and highly toxic, CO poses an immediate risk in fire incidents, industrial accidents, and oxygen-deficient spaces. For escape masks and respirators, reliable removal of CO is not optional—it is a fundamental safety requirement.

 

DEAI CHEM’s 12×20 mesh Hopcalite Catalyst has been developed and validated specifically for filter canisters used in escape masks and respirators, where controlled airflow, limited space, and predictable reaction performance are essential.

 

 

 

 

Catalyst Composition and Design Rationale

 

 

The 12×20 mesh Hopcalite Catalyst is a manganese dioxide–copper oxide (MnO₂–CuO) granular catalyst, engineered to promote rapid oxidation of carbon monoxide into carbon dioxide under ambient conditions.

 

The selected mesh size provides a balanced combination of:

• Adequate contact time for CO oxidation
• Controlled pressure drop suitable for breathing applications
• Stable mechanical strength under pulsed airflow

 

While DEAI CHEM also offers Hopcalite catalysts in 4×8, 8×14, and 10×16 mesh sizes, long-term application experience shows that 12×20 mesh is particularly well suited for respirator and escape mask canisters, where compact design and breathing resistance must be carefully managed.

 

Customized particle size distributions can also be provided to match specific system requirements or regulatory standards.

 

 

 

 

Operating Principle in Breathing Air Systems

 

 

In a properly designed, dry air filtration system, the catalyst promotes the oxidation reaction:CO → CO₂

 

This reaction proceeds efficiently at ambient temperature, without external energy input. As contaminated breathing air passes through the catalyst bed, carbon monoxide is converted into carbon dioxide before reaching the user, providing a critical layer of protection in emergency and life-support scenarios.

 

Typical applications include:

• Escape masks for fire and industrial evacuation
• Respirators used in mining and confined spaces
• Compressed breathing air systems
• Cryogenic gas purification units

 

 

 

 

Key Physical and Mechanical Properties (12×20 Mesh)

 

 

The 12×20 mesh Hopcalite Catalyst is manufactured to meet the mechanical and performance requirements of safety-critical filtration systems:

• Bulk density: 0.95–1.20 kg/L
• BET surface area: 200 m²/g
• Weight loss: ＜ 1%
• Ball milling strength: 94.5%

 

These parameters support consistent catalytic activity, low dust generation, and resistance to attrition during handling and operation.

 

 

 

CO Performance Validation (Internal Reference Testing)

 

 

DEAI CHEM conducts in-house performance testing to evaluate catalyst behavior under controlled conditions. For the 12×20 mesh Hopcalite Catalyst, CO removal was assessed using an artificial lung pulse system:

• Pulse rate: 20 breaths per minute
• Flow rate: 30 L/min
• Inlet CO concentration: 0.25%
• Catalyst charge: 85 g Hopcalite + 85 g desiccant

 

Under these conditions:

• Breakthrough concentration was defined at 200 ppm CO
• Minimum effective duration achieved: ≥ 45 minutes

 

These results serve as internal reference data. Actual performance requirements vary depending on customer standards, canister design, airflow profiles, and regulatory frameworks.

 

DEAI CHEM routinely supports customers by supplying catalyst samples and technical data for customer-specific validation and certification testing, ensuring compatibility with their final filtration systems.

 

 

 

 

Supporting Safety-Critical Filtration Projects

 

 

Escape masks and respirators operate under strict performance expectations, often governed by national or international safety standards. Catalyst selection plays a decisive role in meeting those requirements.

 

With long-term production experience, controlled quality parameters, and application-focused particle size design, DEAI CHEM’s 12×20 mesh Hopcalite Catalyst continues to support CO removal solutions where human safety depends on predictable performance.

 

For project-specific recommendations, sizing guidance, or test support, DEAI CHEM provides technical assistance throughout the filter development and qualification process.