Catalyst Management

Minimizing overall costs for a single SCR system or for large fleets requires an intimate knowledge of catalyst, its replacement, rejuvenation and regeneration cycles, and how a plant’s upstream and downstream equipment and fuels fired can play a factor in its performance. Effective catalyst management often means cutting ties with a “one size fits all” approach. The best and / or most cost-effective solution often results from flexibility in catalyst selection, methods of replenishment, and an informed management approach.

SCR-Tech develops catalyst management plans for its customers consistent with catalyst activity decay, ammonia slip and scheduled outages, with the understanding that some plants make a market in ash. SCR-Tech’s comprehensive catalyst management programs include performing inspections, AIG tuning, computer simulation and tracking of catalyst decay rates, evaluating the effects of fuels fired, providing catalyst test programs and guidance on catalyst interchangeability between units with options for new, brokered, rejuvenated and regenerated catalyst for either a single unit, a plant site, or the entire fleet. As part of its catalyst management program, SCR-Tech offers a customized catalyst regeneration plan scheduled around planned outages.

The Perpetual Cycle of SCR Catalyst Management

There are a considerable number of options for optimal catalyst management: add a layer; replace a depleted layer with new or regenerated catalyst; or mix and match plate, corrugated, or honeycomb catalyst in the same reactor. All of these options will change with year-round SCR operation.

No matter which catalyst type is being used, there are many possibilities for minimizing costs associated with a fleet of SCR systems. Other considerations include trying to match the use of catalyst to scheduled outages – the intervals between which will only get longer with the onset of year-round SCR operation. This alone may mean planning for catalyst replacement or replenishment in multiple layers.

There are also possibilities for managing or avoiding catastrophic catalyst failure. Pooling spare catalyst within the fleet and even within the industry at a central location can provide a safe margin for avoiding long, unplanned, and economically devastating outages. This strategy can be accomplished without a significant investment.

SCR-Tech has developed many programs that can evaluate nearly any catalyst management scenario. These programs can predict catalyst life, allow for the mixing and matching of different catalyst types, handle multiple fleet SCR systems, and evaluate site-specific economics associated with each scenario. They also provide risk assessment associated with extending catalyst life, based on previous experience. These assessments are always backed by independently verified third-party catalyst testing.

SCR-Tech Catalyst Management Benefits

Independently-verified data
Plant-specific control points
Confident compliance
Create credits
Maximize run-time
Mix regenerated catalyst type
Data-driven “what if” analysis