Ethylene oxide (EtO) plays a critical role in modern manufacturing, particularly in medical device sterilization, pharmaceutical production, and specialty chemical processes. Its effectiveness as a sterilant and chemical intermediate makes it difficult to replace in many applications. However, EtO is also a hazardous air pollutant, and increasing awareness of its health risks has intensified scrutiny around how facilities manage and control EtO emissions.
As regulatory expectations continue to evolve, operators are seeking emissions control solutions that are not only compliant but also reliable, energy‑efficient, and practical to operate over the long term.
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Ethylene Oxide Emission
Ethylene oxide is classified as a carcinogen, and even low‑level, chronic exposure has been linked to adverse health effects. As a result, regulatory agencies have tightened emissions limits and increased enforcement, particularly for facilities located near residential communities.
For manufacturers, this has introduced several challenges:
- Meeting increasingly stringent allowable emissions limits
- Demonstrating consistent destruction and removal efficiency (DRE)
- Ensuring emissions control systems perform reliably during startup, shutdown, and episodes of process variability
Facilities that once relied on legacy thermal or catalytic systems may now find those approaches insufficient, overly energy‑intensive, or difficult to operate under today’s standards.
Catalytic Oxidation: A Proven Approach to EtO Control
Catalytic oxidation is one of the most effective and widely adopted methods for controlling ethylene oxide emissions. In this process, EtO is converted into carbon dioxide and water vapor at significantly lower temperatures than those required for thermal oxidation, reducing fuel consumption and overall operating costs.
Catalytic systems are particularly well‑suited for EtO abatement because they:
- Achieve high destruction and removal efficiencies
- Operate at lower temperatures than thermal systems
- Reduce energy demand and operating expenses
- Deliver consistent performance over extended operating periods
At the core of these systems is the catalyst itself, a component that directly determines efficiency and long-term durability.
The Role of Catalyst Design and Performance
Not all catalysts perform the same under real‑world operating conditions. When evaluating catalytic solutions for EtO emissions control, facilities should consider several critical factors:
- Low-temperature activity: The ability to achieve high EtO conversion at lower operating temperatures
- Durability: Resistance to deactivation from process contaminants or thermal stress
- Pressure drop: Minimizing system resistance to reduce fan energy and maintain throughput
- Operational stability: Consistent performance across variable flow rates and concentrations
CARULITE® 500 catalyst, developed and manufactured by Carus, is engineered specifically to meet these demands. Its proven performance in EtO destruction applications helps facilities maintain regulatory compliance while improving system efficiency and operational reliability.
Expertise for EtO Emissions Control
Carus’ role in EtO emissions control is focused on the catalyst itself. While overall system design, integration, and commissioning are typically performed by engineering firms and emissions-control OEMs, Carus provides catalyst-specific expertise to support effective and reliable EtO abatement.
- Guidance on catalyst selection based on process conditions and EtO concentrations
- Technical input related to catalyst operating windows, temperature requirements, and expected performance
- Recommendations to help maintain catalyst activity and longevity under normal operating conditions
By clearly defining the catalyst’s role within the overall emissions control system, Carus helps OEMs, engineering partners, and end users apply catalytic solutions appropriately and with confidence
Looking Ahead
As regulations continue to evolve and expectations around emissions transparency increase, proactive EtO emissions management is no longer optional—it is a critical part of responsible operations.
By investing in proven catalytic abatement technology, such as Carulite 500 and partnering with experienced suppliers, facilities can reduce risk, improve efficiency, and demonstrate a clear commitment to protecting both people and the environment.
Interested in learning more about catalytic solutions for EtO emissions control?
Carus works with customers across industries to deliver reliable, high‑performance EtO abatement solutions backed by deep technical expertise and hands‑on support.
