Analytical management of SCR catalyst lifetimes and multipollutant performance

Abstract

Selective catalytic reduction (SCR) catalysts are deactivated by several mineral and metallic trace elements at highly variable rates determined by fuel quality and furnace firing conditions. With a loss in activity, NO is reduced over a longer inlet length of the SCR monolith, which leaves a shorter trailing section to sustain the most favorable conditions to oxidize Hg 0 and SO 2 . Since virtually no operating SCR was designed for Hg oxidation and since different monoliths are routinely combined as layers in particular units, the Hg oxidation performance of any SCR fleet is largely unmanaged. The analysis in this paper directly relates a measurement or manufacturer's forecast on the deterioration in NO reduction with age to corresponding estimates for oxidation of Hg 0 . It accommodates any number of catalyst layers with grossly different properties, including materials from different manufacturers and different ages. In this paper, the analysis is applied to 16 full-scale SCRs in the Southern Company fleet to demonstrate that catalyst deactivation disrupts even the most prominent connections among the Hg 0 oxidation performance of commercial SCRs and the behavior of fresh catalysts at lab, pilot, and even full scale.Implications: Catalyst deactivation confounds even the most prominent connections among the Hg 0 oxidation performance of commercial SCRs and the behavior of fresh catalyst at lab, pilot, and even full scale. The halogen dependence has been emphasized throughout the literature on catalytic Hg 0 oxidation, based on a large database on fresh catalysts. But for deactivated catalysts in commercial SCRs, the number of layers is much more indicative of the Hg 0 oxidation performance, in that SCRs with four layers perform better than those with three layers, and so on. The new qualified conclusion is that Hg 0 oxidation is greater for progressively greater HCl concentrations only among SCRs with the same number of layers, even for an assortment of catalyst design specifications and operating conditions. PAPER HISTORY

Kinetic and Mass Transfer Effects of Fly Ash Deposition on the Performance of SCR Monoliths: A Study in Microslab Reactor

“…26−29 In stationary applications, alkaline elements (K, Ca, Na, Mg) have been recognized as major poisons, that influence both the acidity 30 and the redox properties of the catalyst; 23,31 alkaline poisons have been reported to be detrimental to both the DeNO X 4,21 and the Hg-oxidation performances. 4,9,11,12,22 As, 13,14 S, 31,32 and P also typically accumulate with time on stream, with formation of sulfates and phosphates. The sulfation of V/TiO 2 catalysts has been demonstrated to improve the DeNOx performance in both short 33 and long-term 34 treatments; however, the formation of sulfate deposits can reduce the catalyst surface area and porosity by pore clogging, and can mask the active sites.…”

“…Fly ash deposition is a known major factor of deactivation; ,− the formation of volatile inorganics from stationary boilers and diesel engines, the mechanism of condensation (in combination with soot growth), and the deposition on porous solids has been recently reviewed in the literature. − In stationary applications, alkaline elements (K, Ca, Na, Mg) have been recognized as major poisons, that influence both the acidity and the redox properties of the catalyst; , alkaline poisons have been reported to be detrimental to both the DeNO X , and the Hg-oxidation performances. ,,,, As, , S, , and P also typically accumulate with time on stream, with formation of sulfates and phosphates. The sulfation of V/TiO 2 catalysts has been demonstrated to improve the DeNOx performance in both short and long-term treatments; however, the formation of sulfate deposits can reduce the catalyst surface area and porosity by pore clogging, and can mask the active sites .…”