CO and VOC oxidation catalyst performance degrades over time, so proper planning for catalyst replacement is essential to ensuring reliable plant emissions performance. Since it can take up to several months to specify, design, engineer, manufacture, and deliver a replacement CO catalyst charge, accurately determining when a catalyst will reach end of life is critical for outage scheduling and budget planning.
Routine catalyst testing is the most accurate way to determine when an oxidation catalyst will no longer be able to provide the required CO or VOC conversion performance. Environex can maximize the life of your CO catalysts and minimize the plant lifecycle operating costs associated with CO emissions control by implementing a proactive catalyst testing plan.
Environex has the independent perspective and deep industry experience needed to maximize the life of your CO catalysts. Since our laboratory opened in 1997, we have tested over a thousand CO catalyst samples, covering formulations from all of the major manufacturers. Our experience ranges from combined cycle and cogeneration facilities to high temperature peaking plants and biomass applications (amongst others). Environex helped EPRI develop the protocol for testing SCR and CO catalysts from gas turbines.
CO catalyst testing includes a combination of performance testing, chemical analysis, and physical analysis. Performance testing determines the CO removal potential of the catalyst relative to the plant CO removal requirement. The chemical and physical analyses are used to identify the causes of catalyst performance loss. The tests that are used for CO catalysts are easily extended to VOC catalyst testing. SO2 to SO3 and NO to NO2 oxidation testing are also available.
In many cases, it is possible to restore CO catalyst performance after the cause of deactivation is identified. CO catalyst rejuvenation studies identify wash solutions that can reverse catalyst deactivation and quantify the extent to which catalyst performance can be improved. Catalyst rejuvenation is often a cost effective means of extending catalyst life and preventing premature catalyst replacement.
Baseline testing of CO and VOC catalysts provides an important benchmark for planning future catalyst management activities. Performance testing of a baseline sample allows for the most accurate tracking of catalyst performance loss for your specific batch of catalyst. Chemical and physical analyses of a baseline sample enable you to track contaminant levels and monitor catalyst deactivation mechanisms as the catalyst ages.
If your catalyst fails prematurely, it is important to identify the causes of failure so that they do not become an ongoing problem. Failure analysis testing identifies the causes of catalyst failure and the extent to which they have caused performance loss. It may be possible to eliminate or mitigate the causes of failure once they are identified. If this is not possible, alternate catalyst formulations or designs that are more resilient to performance loss may be identified.