Catalyst Testing is the Cornerstone of an Effective SCR Management Program
Active SCR management is the key to reliable performanceSelective Catalytic Reduction (SCR) catalysts deactivate over time and must be actively managed to ensure reliable emissions performance. SCR Catalyst Testing is the most reliable way to determine when your catalyst will no longer be able to provide the required NOx conversion performance. Each catalyst is a custom-engineered product that takes several months to design, engineer, manufacture, and deliver to your facility. Knowing when your catalyst will reach end of life is critical for timely budget planning and replacement scheduling, and to avoid costly expedite charges.
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Proactive testing plans deliver resultsRoutine SCR catalyst testing takes the guesswork out of determining when the catalyst will reach end of life. Testing also identifies any deactivation mechanisms that are causing accelerated catalyst performance loss. Environex can maximize the life of your SCR catalysts and minimize the plant lifecycle operating costs associated with SCR systems by implementing a proactive SCR catalyst testing plan.
Choose Independence and ExperienceEnvironex brings an independent perspective and over 25 years of industry experience to your SCR management program. The Environex laboratory, which has been in operation since 1997, has tested many thousands of catalyst samples, from all of the major catalyst suppliers. Our experience includes high-temperature catalysts from peaking plant applications, conventional combined cycle and cogeneration plant catalysts, high dust catalysts from coal and biomass fired-plants, refinery SCR catalysts, and many more.
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How we test the catalyst
Catalyst Performance TestingSince the SCR reaction is temperature dependent, SCR catalyst performance testing is done across a range of temperatures and ammonia flows to simulate actual plant operating conditions. These ranges are selected based on the unique operating profile of your facility. This allows our engineers to make the most accurate projection of remaining catalyst life.
Chemical and Physical TestingChemical analysis and physical analysis support the catalyst performance testwork. The most common deactivation mechanisms for SCR catalysts are poisoning, fouling, and thermal damage. The physical and chemical analyses help pinpoint causes of catalyst performance loss. In many cases, it is possible to mitigate or eliminate causes of accelerated catalyst performance loss after they are identified.
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Failure AnalysisIf 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.
Baseline Catalyst TestingBaseline testing of SCR 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.
Operating Data Analysis and Site InspectionThe accuracy, quality of insight, and maintenance recommendations provided by an Environex full system evaluation deliver value that is unmatched in the industry. Our engineers travel onsite to inspect the bulk catalyst, catalyst housing and seals, reagent injection system, and other system components. We take catalyst samples at various locations to “map” bulk catalyst activity. The samples are tested across a full range of operating conditions in our lab to simulate all plant operating conditions and identify the limiting case for your system. Our engineers marry up the catalyst test results, system inspection observations, and plant operating data analysis to deliver a comprehensive evaluation of catalyst system operation. This allows us to provide accurate catalyst life projections, identify problems before they bring the plant offline, and guide maintenance plans.
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