Power Industry Webinar Production & Promotion

Optimizing SCR Catalyst Performance: A Deep Dive into Regeneration Strategies with CORMETECH

Selective Catalytic Reduction (SCR) is the predominant technology for NOx reduction in utility and industrial power plants, successfully eliminating over 5 million tons of NOx annually since the late 1990s. In these plants, effective SCR catalyst management plays a crucial role in minimizing lifecycle operating costs related to emissions control. Catalyst modules experience reduced activity due to challenges such as poisoning, plugging, or masking, and when this happens targeted layers within the SCR reactor are typically replaced with fresh catalyst.

Nevertheless, these deactivation mechanisms are often reversible through regeneration processes that eliminate catalyst deactivation compounds, restoring the catalyst's activity to its original OEM level. Regeneration reuses existing modules which not only ensures environmental compliance but also diminishes the necessity for ultimate recovery or disposal.

Pioneering catalyst regeneration, CORMETECH, recognized as one of the largest SCR catalyst regenerators globally, has perfected the process over two decades, utilizing a patented regeneration method. CORMETECH's Selective Impregnation® process achieves a much lower SO2 to SO3 conversion ratio and maintains higher catalyst activity. Additionally, extruded catalyst material can be recycled, contributing to the production of new catalysts.

Specific topics will include:

  • Overview of the multi-stage regeneration process after deactivated modules are received

    • Cleaning to remove fly ash and other particles causing pluggage
    • Immersion in a series of chemical baths to remove deposits that reduce performance
    • Selective Impregnation® to restore full catalyst activity
    • Recalcination, a heated drying process that re-establishes mechanical strength and fixation of the active metal oxides
  • Compared to plate and corrugated catalyst types, why honeycomb catalyst is best suited for regeneration
  • How decayed and non-regenerable catalyst material is ground and packaged for use in manufacturing new catalyst