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State of the Art Catalytic Solutions for NOx, CO and VOC
A&WMA West Coast Section
Virtual conference - November 19, 2020
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
CORMETECH, Inc.
Advancing emission catalyst technology since 1989
• Durham, NC – Manufacturing; Engineering & Laboratory Services
• Charlotte, NC – Headquarters & Laboratory
• Kings Mountain, NC – Regeneration
• Cleveland, TN – Manufacturing
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
Products and Services
• Catalyst Development & Manufacture
• Laboratory testing
• Field Service• Complete Inspections
• Sample pulls
• Cleaning (SCR & CO catalyst)
• Field Installation and Repair
• AIG Tuning
• Perimeter seal repair and Hatch upgrades
• Engineering• AIG design
• System upgrades
• Fixed sampling grids
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
Challenges
• Higher Performance Units
• Retrofits – how does it fit
• Operating Temperature
• Minimizing dP
• Mixing Distance
• How long do I need it to last
• NH3/NOx distribution vs Performance
• What happens if I have to clean the catalyst
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Where To Start?
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Cormetech Module Options
Vertical Module (Up or Down) Standard Horizontal Module Canister Style
Standard Part or can be
150 x 150 looseElite™ Module
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EliteTM Platform
• RESULT• Step-change reduction in pressure drop: 60–75% Lower!
• Vastly improved emission control solution capability
• Innovative seal improvements
+ +
Pleated Module Advanced Catalyst Integrated Seal
Combines three new tools
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Current Experience – ELITE™
• ELITE™ module’s many benefits• Greater pressure drop flexibility vs Advanced & Standard construction
• Improved access to catalyst face for easier maintenance & cleaning if required
• Handling/Installation and sealing same as previous module designs
• Less costly than Advanced Module (depending on design)
• Improved sealing – Traditional construction uses felt packing between catalyst elements which can fail over time. ELITE™ elements are cemented together. Felt packing only exists between element & steel interface. This is located behind retention bends to prevent loss
• ELITE™ supply experience (July 2020) – 187 units
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
CORMETECH Catalyst
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
Catalytic Options
• Standard SCR Catalyst Products• ST – Standard Temp (combined cycle/process units typ)
• ET – Extended Temp (small simple cycles typ)
• MT – Medium Temp (larger simple cycles typ)
• HT – High Temp (simple cycles-limited use typ)
• ELITE™ - Add more capacity / lower dP
• METEOR™v1 - Multi-pollutant (NOx/CO/VOC)
• METEOR™v2 - Selective Decomposition NH3
• METEOR™ v3 – Oxidation (CO/VOC)
• Hi NO2 – Elevated NO2/NOx ratio (>50%)
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METEOR™ (M1) NOx CO & VOC Performance
▪ DeNOx and CO oxidation → high conversion rates over wide temperature range
▪ PGM loading can be adjusted to
optimize performance at
low/high temperatureTest
ConditionsNOx = 25 ppm
CO = 25 ppmO2 = 15%
H2O = 7%
NH3 slip 3 - 7 ppm
Constant SV
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METEOR™ (M1) SO2 Oxidation and Sulfur Durability
Exposure tests show SO2 has no significant impact
on CO oxidation. Field experience supports
SO2 oxidation tests show oxidation rate similar to
traditional SCR catalyst resulting in lower SO3
content downstream
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METEOR1™- Multi-Pollutant CatalystFull-Scale Installation
▪ Plant’s motivation for METEOR™ installation:
▪ Greater operating load flexibility during off-peak hours
▪ Plant limitation ~65% load
▪ Field testing validation: measured SCR inlet and outlet gas composition
▪ SCR inlet = GT exhaust gas.
▪ Fresh catalyst achieved ~99% CO oxidation at 36% GT load point.
▪ DeNOx achieved target value. NH3 slip is very low due to the fresh catalyst state.
GT Exhaust Gas METEOR™ SCR Catalyst Performance
GT Load
SCR Temp
GT Exhaust CO
GT Exhaust NOx
SCR Outlet CO
SCR Outlet NOx
SCR Outlet NH3 Slip
(oC) (ppm) (ppm) (ppm) (%) (ppm) (%)
98% 342 0.5 29.4 0.0 100 7.8 74 0.7 76% 334 0.6 32.8 0.0 100 6.7 80 0.7 36% 322 172 44.0 2.2 98.8 6.7 85 0.5
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
METEOR 2 – NH3 DestructionFull Scale Installation
• Existing Combined Cycle w/ Traditional CO Catalyst & SCR Catalyst
• Older style AIG. Dense spacing but one sided.
• Unit modifications required new permit
• New targets NOx-92%, CO-90%, NH3-2
• Cormetech METEOR 1&2 added
• AIG upgraded but METEOR 2 allowed for lower sensitivity to NH3/NOx distribution
SDA – Selective Decomposition of NH3
0.5
1.0
1.5
2.0
2.5
3.0
0% 2% 4% 6% 8% 10% 12% 14% 16%
NH3/NOx RMS
Rela
tiv
e C
ata
lyst
Su
rfac
e A
rea
Constant average NH3 slip = 2 ppm (end of life condition)
Surface area reference basis is standard catalyst at 90% DeNOx and 5% RMS
Standard Catalyst
at 99% DeNOx
Standard Catalyst
at 95% DeNOxStandard Catalyst
at 90% DeNOx
SDA Catalyst
at 90% DeNOx
SDA Catalyst
at 95% DeNOx
SDA Catalyst
at 99% DeNOx
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METEOR 3 – CO & VOC Oxidation
CORMETECH METEORTM M3:
• Typical Ceramic TiO2 Substrate
• Higher Performance at Lower Precious Metal Loadings
• Module or Canister Customizability
• Sulfur Durable
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METEOR 3 – Ramp Rates
Increasing PGM Loading
Oxidation catalyst can have a very low light-off temperature for CO oxidation.
CORMETECH, Inc. © 2018 We reserve all rights in this document and in the information contained herein. Reproduction, use or disclosure to third parties without expressed consent from CORMETECH, Inc. is strictly forbidden.
Thank You
CORMETECH Inc.Brian Helner