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 takes at least several months (and possibly longer due to supply chain issues) 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 reliable way to determine when an oxidation catalyst will no longer be able to provide the CO or VOC conversion performance needed to stay in compliance. Testing can also identify whether or not your catalyst is a good candidate for rejuvenation to extend operating life. Environex can maximize the life of your oxidation catalysts and minimize the plant lifecycle operating costs associated with CO and VOC emissions control by working with you on an effective catalyst testing plan.
Environex has the independent perspective and depth of experience to maximize the life of your CO and VOC catalysts. Since our laboratory opened in 1997, we have tested thousands of oxidation catalyst samples, covering formulations from all major manufacturers. Our experience ranges from combined cycle and cogeneration facilities to high-temperature peaking plants and biomass applications (among others). Environex served on the EPRI committee to develop the protocols for testing SCR and CO catalysts from gas turbine applications.
Environex’s CO catalyst testing includes a combination of performance testing, chemical analysis, and physical analysis. Performance testing determines the CO removal potential of the catalyst, which is used to project the remaining catalyst life. The chemical and physical analyses are used to identify the causes of catalyst performance loss. Once we measure the extent of performance loss and identify the causes, we can determine if your catalyst is a good candidate for rejuvenation.
Beyond routine CO/VOC catalyst testing for catalyst lifecycle management, there are additional ways that Environex’s CO catalyst testing capabilities can enhance your catalyst management program:
Rejuvenation Studies: In many cases, it is possible to restore CO catalyst performance once the cause of deactivation is identified. CO catalyst rejuvenation studies identify methods that can reverse catalyst deactivation and quantify the extent to which catalyst performance and life can be improved. Catalyst rejuvenation is often a cost-effective means of extending catalyst life and lowering lifetime operating costs.
Baseline Testing: Baseline testing of CO and VOC catalysts establishes important benchmarks 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 catalysts. Chemical and physical analyses of a baseline sample enable you to track contaminant levels and monitor catalyst deactivation mechanisms as the catalyst ages.
Failure Analysis: 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 the deactivation mechanisms your catalyst is experiencing may be identified.
The tests that are used for CO catalysts are easily extended to VOC catalyst testing. SO2 to SO3 and NO to NO2 oxidation testing programs are also available.