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Catalysts for Environmental Strategies

Catalyst Cleaning and Regeneration

SCR-Tech’s catalyst cleaning and regeneration processes have been successfully applied to

more than 62,000 m3 of SCR catalyst of all types and brands.

Since March 2003, SCR-Tech has offered U.S. power plant operators a proven and more

cost-effective alternative to catalyst replacement in the form of catalyst regeneration, as well

as a means to eliminate the costs and environmental concerns associated with disposing of

deactivated catalyst as hazardous waste.

SCR-Tech’s breakthrough catalyst regeneration technology is the only commercial process

capable of restoring the activity level of spent catalyst back to its original specifications and

NOx reduction performance.

SCR-Tech’s catalyst regeneration technology has been successfully applied in Germany since

1997, and since 2003 in the United States. In Germany, catalyst regeneration has captured

more than 70% of the catalyst replacement market. There, the three largest municipal

utilities, the second, third and fourth largest investor—owned utilities, and the largest IPP all

use catalyst regeneration throughout their entire fleets of SCR systems to minimize

operating and maintenance costs.

Catalyst cleaning and regeneration has been performed on all catalyst types, including plate,

honeycomb and corrugated configurations, and spanning all major catalyst manufacturers

(Argillon / Siemens, Johnson Matthey, BASF, BHK- Hitachi, CERAM, Cormetech, Engelhard,

Haldor Topsøe, Kawasaki, and KWH).
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This comprehensive experience has validated the ability of our technology to achieve

maximum NOx reduction performance while reducing overall NOx compliance costs for the

power generating facility. Our regeneration process has even been demonstrated in certain

cases to increase catalytic activity beyond original by as much as 25%, providing the

potential for additional economic upside.

Independent Testing

SCR-Tech’s cleaning and regeneration processes are verified independently by third party

testing in accordance with EPRI and VGB Guidelines for the Testing of DeNOx Catalyst.

We can provide customers with the assurance that the work done by SCR-Tech is of the

highest quality in the world.

Reducing the SO2-SO3 Conversion Rate

The use of regenerated catalyst has also been demonstrated to have lower SO2 oxidation

rates while still maintaining original catalytic activity levels and NOx reduction performance

in certain applications. We are continuing R&D studies that focuses on constantly improving

the regeneration process (higher activity, lower SO2 conversion, higher mercury oxidation,

longer life, etc.).

Early in 2006, SCR-Tech completed a jointly funded study with AEP and Southern Company

focused on evaluating and minimizing the conversion of SO2 to SO3 during SCR system

operation.

As part of the joint development program, the three companies worked together to test and

quantify the SO2 to SO3 conversion rates demonstrated by SCR catalyst regenerated under

a variety of conditions, and to benchmark the performance of regenerated catalyst against

new and deactivated catalyst. The goal of the program was to demonstrate that it is possible

to achieve maximum restoration of catalytic activity while simultaneously minimizing the

conversion of SO2 to SO3.

Results from this study demonstrate that the use of regenerated catalyst can significantly

lower SO2 oxidation rates in some applications. Unused plate and honeycomb catalyst

modules were regenerated to compare the oxidation rate and catalytic activity before and

after regeneration. In the case of regenerated honeycomb catalyst, for example, SO2

oxidation rates were measured as low as 0.1 percent, which is comparable to the conversion

rates achieved only through the use of more costly, ultra-low conversion catalyst.

Importantly, the regenerated catalyst achieved these significant reductions in SO2

conversion while still maintaining original catalytic activity levels and NOx reduction
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performance, whereas the use of ultra-low conversion catalyst has been reported to be

associated with a loss in catalytic activity.

Details and results of this study were published in a an article entitled New Life for Old

Catalyst which appeared in the March 2006 edition of Power Engineering magazine.

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