SCR Catalyst

Dust Buster Catalyst

Specialized SCR Catalyst for high dust applications, such as coal power generation plants and FCCU units. Dust Buster provides a larger pitch than honeycomb and plate-type catalysts to provide proven pluggage resistance.

• SO2 to SO3 conversion is low at startup and maintains lower conversion throughout its life. Conversion is typically 2.5 times less than with a plate style catalyst.
• It can be regenerated to original performance and can be regenerated multiple times. It can also be recycled at end-of-life to save cost and reduce landfill.
• NEXTGEN Extruded catalyst from 100% titania material. No iron in or on catalyst walls. This absence of iron prevents undesired reactions with the catalyst that produces SO3.

Case Study of Dust Buster vs. Plate

METEOR Catalyst

Multi-function capabilities for DeNOx, CO and VOC. Combining catalyst functions allow for a smaller catalyst footprint inside of and SCR with lower pressure drop versus independent layers. Can be easily retrofitted into existing SCR’s.

M1: DeNOx and CO/VOC Control
M2: Ammonia Slip and CO/VOC Control
M3: CO/VOC Control

Catalyst Management, Reuse, and Regeneration

Management

CORMETECH SCR Catalyst Management services will determine an optimum catalyst replacement or addition plan through performance audits designed to determine the remaining potential of the field catalyst. An overall SCR catalyst management strategy will also consider the plant’s operating history, projected use of the SCR in the future, outage schedule, and other financial and operational factors. The final SCR catalyst replacement strategy must also carefully consider the fuel fired because catalyst layers often deactivate at different rates. This information may also be helpful to other units in the fleet that are burning the same fuel. The audit also allows the user to consider recent SCR catalyst technology advancements that may further improve system performance. In the past, replacement with an advanced catalyst has produced more than a 50% performance improvement compared to replacing with a new layer of the original SCR catalyst.

In other plants, the SCR catalyst management strategy may take advantage of the spare catalyst layer included in the original reactor design. For many users, adding a new or regenerated high performance catalyst to the existing reactor will be the best economic option compared to replacing an existing layer of SCR catalyst.

• Onsite review of field data (ie flow rates, NOx inlet/outlet, NH3 usage/slip, etc)
• Pulling samples for catalyst life testing
• AIG Tuning
• Troubleshoot SCR operation

Regeneration

The regeneration process removes catalyst deactivation compounds and restores catalyst activity back to the original OEM level. And since it reuses your existing catalyst modules, the cost of the regeneration is typically lower than a replacement.

As one of the first companies to develop catalyst regeneration, CORMETECH has refined the process with over twenty years of experience with our patented regeneration method. Our Selective Impregnation® process achieves a significantly lower SO2 to SO3 conversion ratio while maintaining a higher catalyst activity.

The modules go through a multi-stage process after arriving at the facility:

• Cleaning to remove fly ash and other particles which cause pluggage
• Immersion in a series of chemical baths to remove deposits that reduce performance
• Undergoes Selective Impregnation® , restoring full catalyst activity by infusing the module surfaces with oxides of base metals (V2O5 and either MoO3 or WO3)
• Recalcination, a heated drying process that re-establishes mechanical strength and fixation of the active metal oxides

CORMETECH’s Kings Mountain facility can process between 40 and 50 modules per day.

This process has been used for SCR Catalyst since 1997 and has resulted in reduced operations and management costs worldwide. Let CORMETECH do the same for you!

SCR Catalyst Reuse

SCR Catalyst reuse is an environmentally friendly, cost effective and closed-loop solution using patented separation and cleaning technology to convert used SCR catalyst into cleaned, reusable titanium feedstock.

CORMETECH is expanding its capabilities in total SCR catalyst lifecycle management to accept our customer’s used SCR catalyst modules, separating its components and processing the catalyst material to create controlled raw material for SCR catalyst manufacturing. This service provides power plant operators with a safe and responsible method to alleviate the burden and cost associated with discarding SCR catalyst at the end of its useful life. Go green.