Inside KLE-HEC-200: How a Multi-Metal Ozone Catalyst Handles COD 200-2000 mg/L Without Clogging

The brief behind the product

Shenzhen SINOKLE Technology holds more than twenty independent patents in ozone catalysis and oil-water separation. KLE-HEC-200 is its general-purpose multi-metal composite heterogeneous ozone catalyst, aimed at broad-spectrum industrial wastewater deep treatment where the plant needs degradation performance but cannot justify a precious-metal media budget. The design target is biochemical tailwater and pretreatment streams carrying COD 200-2000 mg/L.

It is normally deployed with CDFU cyclonic dissolved-air flotation and CDOF integrated ozone oxidation equipment, forming a chain of front-end physical impurity removal followed by catalytic deep oxidation. That combination is a direct response to the four complaints users raise about ordinary ozone catalysts: low activity, easy clogging, short service life and poor adaptability to changing water quality.

How the catalytic mechanism works

The carrier is produced by segmented precisely temperature-controlled sintering with atomic-deposition composite loading, giving a specific surface area above 250 m2/g. Its surface carries multi-component transition-metal active sites, optionally with low-content noble-metal synergistic modification and a hydrophilic modified surface layer.

Three effects follow. The multi-metal synergistic system sharply lowers the activation energy of ozone decomposition and rapidly generates hydroxyl radicals (OH), pushing oxidation efficiency to two to five times that of traditional ordinary media. The highly connected microporous structure adsorbs organic pollutants efficiently and keeps breaking the stable chemical bonds of dyes, phenols, antibiotics and halogenated hydrocarbons, mineralising them into CO2 and H2O while lifting the B/C biodegradability ratio. The atom-deposition super-hydrophilic layer blocks suspended solids, colloids and oil from adhering, so pores rarely scale or clog during 24 h continuous production.

Core performance indicators

• Appearance: gray spherical particles, 2-4 mm, customisable on demand.
• Compressive strength >= 1 MPa, single particle >= 100 N, annual wear rate <= 0.3%.
• Pore volume >= 0.3 ml/g; specific surface area > 250 m2/g; bulk density 0.7 t/m3.
• pH tolerance 2-12, tolerant of strong acid and alkali, broad-spectrum adaptability.
• Standard service life > 5 years, renewable by acid washing for reuse.
• Ozone decomposition utilisation rate >= 92%; overall COD removal rate >= 70% at incoming COD 200-2000 mg/L; color removal rate >= 92%.

Four field cases

Landfill leachate biochemical pretreatment

Municipal landfill leachate arrived at raw COD 3000-8000 mg/L with high humus, high color and very poor biodegradability. Using pretreatment plus KLE-HEC-200 ozone catalysis plus biochemistry, the plant ran ozone dosing at 350 mg/L, catalyst dosing at 9 g/L and hydraulic retention at 50 min. Catalytic unit COD removal reached 73%, effluent B/C rose from 0.08 to 0.37, and back-end biochemical load fell by 60%.

Printing-dyeing high-color deep upgrade

Biochemical effluent carried COD 320 mg/L at 300-fold color with residual reactive dyes, and conventional reagent decolorisation was generating heavy sludge. At ozone dosing 130 mg/L, catalyst dosing 6 g/L and hydraulic retention 30 min, color removal reached 93% and effluent COD held at or below 90 mg/L. No extra decolorising flocculant was needed and chemical sludge dropped by over 70%.

Fine-chemical combined wastewater retrofit

Feed swung between pH 4 and 10, incoming COD sat at 550 mg/L with trace halogenated intermediates, and the original ordinary ozone media was degrading below 40% efficiency. At ozone dosing 180 mg/L, catalyst dosing 7 g/L and hydraulic retention 38 min, COD removal reached 71% and halogenated toxic organics removal 91%, with no obvious activity decline across the pH swing.

Other streams

Pharmaceutical intermediate wastewater is treated to degrade bacteriostatic organics and stabilise downstream biochemistry. Petrochemical refining combined tailwater is polished to remove gum and trace dissolved oil before a membrane system. Power and metallurgy circulating discharge water is oxidised to break down organic slime, cutting bactericide and scale-inhibitor dosing, and VOCs exhaust-absorption waste liquid is oxidised so the liquid can be recycled.

What the complete set delivers

The standard configuration is CDFU cyclonic dissolved-air flotation followed by CDOF ozone catalytic oxidation loaded with KLE-HEC-200, delivered as skid-mounted modular equipment assembled and debugged in the factory. On site only piping and power connections are needed, and existing stations can be retrofitted online without a full shutdown. A two-stage CDFU pretreatment plus catalytic unit plus sand-filter variant adds fully automatic control that monitors COD, pH, ozone concentration and flow in real time and adjusts dosing, gas-water backwash and slag discharge automatically, with remote cloud monitoring instead of 24 h on-site attendance.

Operation is fully enclosed and pressurised: wastewater and ozone reaction exhaust travel through closed piping, tail gas is collected and catalytically decomposed, and residual ozone is destroyed before release, so there is no odour and no plant air-pollution risk.

Environmental and economic value

No heavy-metal ions leach during operation, so there is no secondary water pollution. Toxic refractory organics are mineralised, COD and color fall steadily, and decolorisation and flocculation-oxidation reagent dosing drops sharply, cutting hazardous chemical sludge output. Economically, ozone decomposition utilisation of at least 92% means smaller installed ozone power for the same effluent standard, while a catalyst life beyond five years with acid-wash regeneration that recovers over 90% of performance keeps replacement and O&M cost far below noble-metal alternatives.

SINOKLE backs the process with water testing, process customisation, installation and debugging, catalyst regeneration and annual inspection, supported by high-tech, specialised-innovative and ISO three-system qualifications.