state of the art catalytic solutions for nox, co and voc · 2020. 11. 25. · scr inlet = gt...

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State of the Art Catalytic Solutions for NOx, CO and VOC

A&WMA West Coast Section

Virtual conference - November 19, 2020


CORMETECH, Inc.

Advancing emission catalyst technology since 1989

• Durham, NC – Manufacturing; Engineering & Laboratory Services

• Charlotte, NC – Headquarters & Laboratory

• Kings Mountain, NC – Regeneration

• Cleveland, TN – Manufacturing


Products and Services

• Catalyst Development & Manufacture

• Laboratory testing

• Field Service• Complete Inspections

• Sample pulls

• Cleaning (SCR & CO catalyst)

• Field Installation and Repair

• AIG Tuning

• Perimeter seal repair and Hatch upgrades

• Engineering• AIG design

• System upgrades

• Fixed sampling grids


Challenges

• Higher Performance Units

• Retrofits – how does it fit

• Operating Temperature

• Minimizing dP

• Mixing Distance

• How long do I need it to last

• NH3/NOx distribution vs Performance

• What happens if I have to clean the catalyst


Where To Start?


Cormetech Module Options

Vertical Module (Up or Down) Standard Horizontal Module Canister Style

Standard Part or can be

150 x 150 looseElite™ Module


EliteTM Platform

• RESULT• Step-change reduction in pressure drop: 60–75% Lower!

• Vastly improved emission control solution capability

• Innovative seal improvements

+ +

Pleated Module Advanced Catalyst Integrated Seal

Combines three new tools


Current Experience – ELITE™

• ELITE™ module’s many benefits• Greater pressure drop flexibility vs Advanced & Standard construction

• Improved access to catalyst face for easier maintenance & cleaning if required

• Handling/Installation and sealing same as previous module designs

• Less costly than Advanced Module (depending on design)

• Improved sealing – Traditional construction uses felt packing between catalyst elements which can fail over time. ELITE™ elements are cemented together. Felt packing only exists between element & steel interface. This is located behind retention bends to prevent loss

• ELITE™ supply experience (July 2020) – 187 units


CORMETECH Catalyst


Catalytic Options

• Standard SCR Catalyst Products• ST – Standard Temp (combined cycle/process units typ)

• ET – Extended Temp (small simple cycles typ)

• MT – Medium Temp (larger simple cycles typ)

• HT – High Temp (simple cycles-limited use typ)

• ELITE™ - Add more capacity / lower dP

• METEOR™v1 - Multi-pollutant (NOx/CO/VOC)

• METEOR™v2 - Selective Decomposition NH3

• METEOR™ v3 – Oxidation (CO/VOC)

• Hi NO2 – Elevated NO2/NOx ratio (>50%)


METEOR™ (M1) NOx CO & VOC Performance

▪ DeNOx and CO oxidation → high conversion rates over wide temperature range

▪ PGM loading can be adjusted to

optimize performance at

low/high temperatureTest

ConditionsNOx = 25 ppm

CO = 25 ppmO2 = 15%

H2O = 7%

NH3 slip 3 - 7 ppm

Constant SV


METEOR™ (M1) SO2 Oxidation and Sulfur Durability

Exposure tests show SO2 has no significant impact

on CO oxidation. Field experience supports

SO2 oxidation tests show oxidation rate similar to

traditional SCR catalyst resulting in lower SO3

content downstream


METEOR1™- Multi-Pollutant CatalystFull-Scale Installation

▪ Plant’s motivation for METEOR™ installation:

▪ Greater operating load flexibility during off-peak hours

▪ Plant limitation ~65% load

▪ Field testing validation: measured SCR inlet and outlet gas composition

▪ SCR inlet = GT exhaust gas.

▪ Fresh catalyst achieved ~99% CO oxidation at 36% GT load point.

▪ DeNOx achieved target value. NH3 slip is very low due to the fresh catalyst state.

GT Exhaust Gas METEOR™ SCR Catalyst Performance

GT Load

SCR Temp

GT Exhaust CO

GT Exhaust NOx

SCR Outlet CO

SCR Outlet NOx

SCR Outlet NH3 Slip

(oC) (ppm) (ppm) (ppm) (%) (ppm) (%)

98% 342 0.5 29.4 0.0 100 7.8 74 0.7 76% 334 0.6 32.8 0.0 100 6.7 80 0.7 36% 322 172 44.0 2.2 98.8 6.7 85 0.5


METEOR 2 – NH3 DestructionFull Scale Installation

• Existing Combined Cycle w/ Traditional CO Catalyst & SCR Catalyst

• Older style AIG. Dense spacing but one sided.

• Unit modifications required new permit

• New targets NOx-92%, CO-90%, NH3-2

• Cormetech METEOR 1&2 added

• AIG upgraded but METEOR 2 allowed for lower sensitivity to NH3/NOx distribution

SDA – Selective Decomposition of NH3

0.5

1.0

1.5

2.0

2.5

3.0

0% 2% 4% 6% 8% 10% 12% 14% 16%

NH3/NOx RMS

Rela

tiv

e C

ata

lyst

Su

rfac

e A

rea

Constant average NH3 slip = 2 ppm (end of life condition)

Surface area reference basis is standard catalyst at 90% DeNOx and 5% RMS

Standard Catalyst

at 99% DeNOx

Standard Catalyst

at 95% DeNOxStandard Catalyst

at 90% DeNOx

SDA Catalyst

at 90% DeNOx

SDA Catalyst

at 95% DeNOx

SDA Catalyst

at 99% DeNOx


METEOR 3 – CO & VOC Oxidation

CORMETECH METEORTM M3:

• Typical Ceramic TiO2 Substrate

• Higher Performance at Lower Precious Metal Loadings

• Module or Canister Customizability

• Sulfur Durable


METEOR 3 – Ramp Rates

Increasing PGM Loading

Oxidation catalyst can have a very low light-off temperature for CO oxidation.


Thank You

CORMETECH Inc.Brian Helner

[email protected]

state of the art catalytic solutions for nox, co and voc · 2020. 11. 25. · scr inlet = gt...

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