Catalyst Regeneration
Catalyst Cleaning and Regeneration
Evonik Steag utilizes a patented deionized (DI) water-based process to remove the physical materials which plug or blind the catalyst layers. In the event of chemical deactivation, after the removal of the catalyst poisons or deactivation causes, Evonik Steag adds chemicals used in the original manufacturing of the catalyst to the regeneration process thereby restoring the catalyst it to its original activity level.
Evonik Steag has cleaned and regenerated several layers of catalyst a number of times and has found that there is no changed in the deactivation rate between new catalyst and cleaned and/or regenerated catalyst.
In January 2007, Evonik Steag relocated to its new headquarters and catalyst regeneration facility in Kings Mountain, NC to better serve our North American clients. Our catalyst storage facility is fully operational and the regeneration plant will start operations in second half of 2007.
 |
 |
Catalyst regeneration tank at Evonik Steag’s
Weiher Power Plant in Germany |
First catalyst modules to be regenerated at Evonik Steag`s new regeneration plant in Kings Mountain, NC arrive from the AES Somerset Plant.
|
Evonik Steag’s Patented Regeneration Technology is Based on Effective
|
• Removal of physical restrictions (blinding layers, fly ash and LPA)
• Removal of catalyst poisons (As, P, NA, K, CaSO4, etc.)
• Protection of the catalyst’s components providing structural integrity and mechanical
strength (i.e. WO3)
• Full activity restoration through replenishment of the catalyst’s active components
(V2O5, MoO3, WO3) |
Evonik Steag’s Patented Processes
- The patented processes are fully flexible and can adapt to the catalyst deactivation causes and the client’s space limitations and budget considerations.
| • Cleaning |
= |
Removal of physical restrictions |
| • Rejuvenation |
= |
Removal of catalyst poisons without the need for replenishing catalytically active compounds – can often be done on site |
| • Regeneration |
= |
Removal of catalyst poisons plus addition of catalytically active ingredients – must be done off site |
 |
 |
Catalyst before cleaning – deactivated
and plugged |
Catalyst after cleaning – Using Evonik Steag’s patented DI-water process
|
Background
Evonik Steag found that the flue gas from burning a variety of bituminous coals, and certain secondary fuels such as bone meal, gradually deactivated the installed catalyst due to fly ash and large particle ash plugging and/or the formation of blinding layers on the catalyst surface.
Chemical deactivation also results from catalyst poisons such as arsenic, phosphorus and earth alkali metals which chemically react with the catalytically active ingredients of the catalyst, thus rendering them ineffective.
In 1997 Evonik Steag developed a catalyst cleaning and regeneration process which has been a major factor in reducing the O&M costs for our own fleet of SCRs.
|