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The reaction kinetics over a V2O5−WO3/TiO2 catalyst which can describe the NH3 slip from a selective catalytic reduction (SCR) reactor as well as the maximum conversion of NO over a wide range of reaction temperatures was developed to design the SCR process. The modeling of the reactor based upon the kinetics developed in the present study was successfully accomplished by the inclusion of the effect of diffusion resistance in the honeycomb reactor model. The honeycomb reactor model could directly employ the kinetic parameters obtained from the kinetic study over a packed-bed flow reactor. The model could also predict the effects of the catalytic wall thickness on the honeycomb reactor and the pore structure of the catalyst on the NO removal activity and NH3 slip, regardless of the types of the honeycomb, washcoated or extruded. The present study also identified that the diffusion resistance in the honeycomb reactor plays a critical role in the design of the commercial-scale SCR reactor despite the relatively thin catalyst layer of the reactor. Moreover, the diffusion effect was more significant for a CuHM catalyst primarily containing micropores than for a V2O5−WO3/TiO2 catalyst primarily containing mesopores. The flow pattern and the NH3 distribution in the commercial-scale honeycomb reactor are also important for a high performance of NO removal. Good distribution of the flow by the guide vanes installed in the reactor can improve the NO removal activity by more than 10% of NO conversion.

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