Overview

 

 

Compressed breathing air systems are critical safety components in industrial, firefighting, mining, and emergency response applications. One of the most serious risks in compressed breathing air is the presence of carbon monoxide (CO), which can originate from compressor exhaust, oil degradation, or incomplete combustion processes.

 

DEAI CHEM Hopcalite Catalyst, available in 4×8 mesh and 8×14 mesh, is specifically designed for CO removal in compressed breathing air filter systems, providing stable catalytic performance, long service life, and compatibility with standard industrial filter designs.

 

 

 

 

Typical Compressed Breathing Air Filter Diagram

 

 

A standard compressed breathing air filter system is typically configured in a multilayer purification structure, ensuring that each filtration medium operates under optimal conditions.

 

Typical layer configuration:

 

1. Molecular Sieve Layer (Top Layer)
Removes moisture and reduces dew point, protecting downstream filtration media.

 

2. Activated Carbon Layer (Middle Layer)
Adsorbs oil vapor, hydrocarbons, and trace organic contaminants.

 

3. Hopcalite Catalyst Layer (Bottom Layer)
DEAI CHEM Hopcalite Catalyst (4×8 or 8×14 mesh) oxidizes carbon monoxide (CO) into carbon dioxide (CO₂) through catalytic reaction.

 

This structured arrangement is widely adopted in compressed breathing air systems to ensure safety, reliability, and long-term operational stability.

 

 

 

 

Role of Hopcalite Catalyst in CO Removal

 

 

Hopcalite Catalyst is a well-established catalytic material for low-temperature CO oxidation. In compressed breathing air systems, it functions without external energy input, continuously converting CO into CO₂ as air passes through the catalyst bed.

 

Key functions include:

 

✅ Continuous CO oxidation under ambient operating conditions
✅ Stable performance in long-term breathing air applications
✅ Compatibility with standard compressed air filter housings

 

 

DEAI CHEM supplies Hopcalite Catalyst in granular formats optimized for industrial airflow and pressure drop requirements.

 

Granular Sizes: 4×8 Mesh and 8×14 Mesh

 

DEAI CHEM offers Hopcalite Catalyst in 4×8 mesh and 8×14 mesh to meet different system design requirements:

•4×8 mesh:
Commonly applied in systems requiring lower pressure drop and higher gas throughput.

 

•8×14 mesh:
Suitable for applications demanding finer gas–solid contact and compact filter designs.

 

 

Both granular sizes are widely used in compressed breathing air filter systems and air purification equipment.

 

 

 

 

Moisture Control and Operating Conditions

 

 

Moisture is a critical factor affecting Hopcalite Catalyst performance. Proper system design ensures that the catalyst operates under controlled humidity conditions.

 

• The catalyst contains no free moisture when dried at 120°C
• Under weight loss testing (3 hours @ 180°C), moisture content is below 1%
• Recommended operation under moisture-free air conditions (−40°C dew point)

 

Effective upstream drying significantly enhances catalyst stability and service life.

 

 

 

 

Service Life and Replacement Cycle

 

 

Under standard operating conditions, DEAI CHEM Hopcalite Catalyst typically provides a service life exceeding 5 years in CO removal applications.

 

Service life depends on:

• Operating temperature
• Environmental humidity
• System configuration
• Absence of catalyst poisons (e.g., sulfur compounds, silicones, halogens, oil aerosols)

 

 

When operated under non-humid, moisture-free air conditions (−40°C dew point) and without exposure to catalyst poisons, the replacement cycle is generally over 5 years, subject to actual system design and operating conditions.

 

 

 

 

Industrial Experience and Application Scope

 

 

DEAI CHEM has extensive experience supplying Hopcalite Catalyst for compressed breathing air systems across multiple international markets. The catalyst has been successfully applied in:

 

• Industrial compressed breathing air filter systems
• Emergency and safety air supply equipment
• Air purification systems requiring reliable CO removal

 

 

This application experience supports consistent quality, stable supply, and long-term technical support.

 

 

 

 

Conclusion

 

 

The Compressed Breathing Air Filter Diagram with DEAI CHEM Hopcalite Catalyst (4×8 & 8×14 mesh) reflects a proven and widely accepted approach to CO removal in breathing air systems.

 

Through optimized system configuration, controlled moisture conditions, and appropriate granular selection, DEAI CHEM Hopcalite Catalyst delivers reliable CO oxidation performance and long service life, supporting safe and compliant breathing air solutions worldwide.