Frequently Asked Questions

There’s a phenomenon called the Joule-Thomson (or JT) effect that causes the temperature of a gas to drop when its pressure is reduced in a valve or regulator. Low ambient temperatures increase the risk of freezing, but the driving factor is usually a combination of a high pressure cut and water content in the gas. Every 100 psi of pressure drop causes natural gas to lose 6-8° F, so even in very warm weather frozen equipment can still be a problem. The JT effect is happening inside the valve, so in a lot of cases insulation jackets can make the problem worse.

You can learn about Catco’s solutions for preventing freezing in valves and regulators here. Or you can contact us and we’ll be happy to help.

Catalytic heaters bring fuel and oxygen together in the presence of a hot catalyst. The result is a chemical reaction that produces infrared heat but no flame. In Catco heaters, the process looks like this:

1. The chemical reaction won’t take place unless the catalyst is at a high enough temperature. In Catco heaters, we preheat the catalyst with an electric heating element. A voltage is applied with either a hardwired power source or starting cables, and this raises the temperature so the reaction can begin.
2. Once the catalyst is hot, you turn on the fuel (either natural gas or propane). When the fuel comes into contact with the catalyst and the oxygen in the air, a chemical reaction takes place that releases energy in the form of infrared heat.
3. The catalyst isn’t consumed in the reaction, so once a heater is operating it can keep going as long as it has fuel and oxygen. This means after startup, the electricity from the preheating element is no longer needed.
4. All it takes to stop the reaction is cutting off the fuel supply.

Other infrared heaters, including some catalytic heaters used for camping or hunting, use a flame to preheat the catalyst and start the reaction. Catco heaters never use a flame during any part of their operation, from start-up to shutdown.

In most applications, several years. The catalyst isn’t consumed as part of the chemical reaction — with perfect fuel and a perfect environment, they would last forever. In the real world, the interaction between the catalyst, fuel, and oxygen gets disrupted and eventually starts to degrade.

How frequently they need to be replaced or remanufactured depends on the quality of the fuel and the harshness of the operating conditions. In oil and gas production where conditions are harsh, many operators do this every year. In gas utility applications where operating conditions tend to be more forgiving, we’ve had heaters operate in the field for longer than a decade.

The best way to ensure top performance and a long life for your heater is to make sure it has a clean, dry fuel supply and is protected from the elements. Catco has options for filters and drip pots to help deliver clean fuel to your heater, and we’re always here to answer questions if you’d like to contact us.

Catco heaters are rated for 6000 BTU/hr per square foot of heater face area. We assume a heating value of around 1000 BTU per standard cubic foot of fuel. To get the natural gas fuel consumption, divide the BTU rating by 1000. For example, a 3000 BTU/hr unit will consume 3 SCF per hour. You can see the BTU ratings of all Catco heaters on our catalytic heater product page.

Catco catalytic heaters have no moving parts so they’re pretty easy to maintain. The biggest issue we see is a heater getting wet. This can be caused by rain or snow, but it’s more common that a wet fuel supply is the problem. A few tips:

• The best thing you can do is make sure your heater has a clean, dry fuel supply. We have several options for filters and drip pots to help.
• It’s not uncommon for there to be some water in the line in a new installation. Aggressively purge fuel lines before installing your heater.
• If an area is being cleaned with high pressure air or water, it’s best to remove the heater beforehand. If that’s not practical, make sure the face is well-protected.
• If you’re storing your heater, make sure it’s protected from the elements.

If you have some specific questions about how to keep your heater performing its best, just contact us and we’re here to help.

Catco heaters are completely flameless from start-up to shutdown and are available with certifications from FM and CSA for use in hazardous locations.

As part of this certification process, Catco heaters are proven to be non-incendiary for Group D environments. While running at 100% output, Catco heaters have been directly exposed to natural gas, propane, heptane, gasoline, and other flammable gases and vapors. In each case, no ignition occurs.

Catco heaters have an impeccable safety record across four decades and hundreds of thousands of installations.

If you have some questions about our certifications or catalytic heater safety, please contact us.

Catco catalytic heaters are tough and reliable and have no moving parts, so maintenance is minimal. However, if your heater is equipped with a valve and thermocouple, it can be useful to keep spares on hand. You can get info on these products on our accessories page, or you can contact us to order some.

Depending on your industry and location, you might be a great fit for our network. Contact us if you’re interested in a partnership!

Yes, and the process is simple and easy. Simply contact us and one of our experts will work with you to get started. Visit our custom solutions page to learn more about our capabilities including custom-designed Heated Enclosure Packages, custom-configured Instrument Gas Heaters.

Contact us and we’ll guide you based on our decades of experience. The more of the following information you can give us, the more precise we can be:

• Desired temperature in the building
• Dimensions of the building
• Type of construction
• Minimum outside temperature
• Insulation type
• Types and numbers of doors and windows
• Air changes per hour

We have a nationwide network of partners that sells and stocks Catco products. Contact us and we’ll connect you with the right partner for your industry and application.