PROCESS

Selective catalytic reduction (SCR) is a post combustion NOx emission reduction system.
Vaporized ammonia injected into the flue gas stream acts as a reducing agent in the presence
of a catalyst, achieving NOx emission reductions as high as 95%. The NOx and ammonia
(NH3) reagent react to form nitrogen and water, reagent stoichiometry of
approximately 1.0 (moles of NH3 per mole of NOx reduced) and with design ammonia slip
values range from 2 to 10 ppm​.

An exothermic reaction occurs as ammonia and NOx flow over the catalyst forming
nitrogen and water vapor.

The potentially troublesome reaction is

oxidation of S02 to S03 and the subsequent reaction of S03 with unreacted ammonia to
form ammonium bisulfate ,SO2 to SO3 conversion rate increases at above approx-
imately 700° F.

At above 700°F SO2 converts to SO3 which reacts with NH3 to form ammonium sulfate/
bisulfate salts.
Boiler firing coal with sulfur content, ammonia injection to be limited between 660 to 700 ° F.
Ammonia reagent for SCR systems should be injected at temperatures above
approximately 570° F for effective ammonia reactivity and to help prevent the formation
of ammonium salts.
Ammonium bisulfate is a sticky substance that can deposit on catalysts, air heater
baskets, heat recovery steam generators, and other downstream equipment.
The salt particle
diameters are on the order of 1 to 3 microns and contribute to PM10 (particulate matter <10
microns) emissions.
This is not applicable if SCR is operating >570° F.
The ammonium salts could deposit on air heater surfaces, necessitating more frequent
soot blowing and offline washes.
Depending on the design fuel's sulfur content, it may be necessary to limit ammonia slip to
below 5 ppm to minimize the potential for air heater fouling.
The oxidation of S02 to S03 could also necessitate a change in the minimum air heater outlet
temperature since the acid dew point temperature of the flue gas is directly
related to S03 concentration. As the S03 concentration increases, the acid dew point of the flue
gas increases, potentially increasing corrosion in downstream equipment.
An alternative to changing the air heater outlet temperature is to install enameled baskets that
are corrosion resistant.

The ammonia slip that exits the SCR system condenses onto the fly ash collected in
particulate removal equipment (electrostatic precipitator or fabric filter). The ammonia
content of the fly ash can have an impact on waste disposal or the potential for waste
product sales.
At elevated pH, ammonia in the fly ash is released, possibly leading to odorous emissions. In
addition, fly ash used for
fixation of FGD reaction products or as admixture for cement manufacturing or other pozzolonic
uses could result in spontaneous ammonia releases.

Reagent Consideration
SCR systems can use either anhydrous (pure) or aqueous (20% to 30% NH3 in
water mixture) ammonia reagents.
Anhydrous ammonia is clear in the liquid state and boils at -28° F.​ Liquid anhydrous
ammonia must be stored under pressure at ambient temperatures and accidental atmospheric
release of anhydrous ammonia vapor can be hazardous.

When ammonia is diluted with water to 20% to 30% volume (aqueous ammonia),
evaporation of ammonia gas from the fluid becomes negligible at ambient conditions.
However, an aqueous ammonia storage facility is three to four times larger than an anhydrous
ammonia storage facility. In addition, use of aqueous ammonia has the double disadvantage of
increased transportation costs and the evaporation of water.
Anhydrous ammonia is the preferred reagent as:
● Less expensive than aqueous ammonia
● More concentrated requiring less storage volume.
● Energy and equipment requirements for vaporization of anhydrous ammonia are
less

Anhydrous ammonia is stored in a pressure vessel rated for 250 to 300 psig.
Aqueous ammonia is generally stored in a tank rated for 25 to 30 psig.

Ammonia must be vaporized to cause a phase change from liquid to gas. The flow of ammonia
vapor is regulated by a control valve. The gaseous ammonia is diluted with air to approximately
a 2% to 5% mixture. The air provides a relatively constant flow rate for more efficient distribution
of ammonia in the flue gas.

Catalyst Design and Deactivation

The cost of catalyst is 20~30% of SCR capital cost.

Average life is 2~4 years
The type of catalyst and catalyst volume required are dependent on the following parameters:

● Flue gas temperature

● Inlet NOx conc.
● NOx emission limits
● Allowable ammonia slip
 ● Required catalyst life
● Oxygen content of flue gas
● Allowable S02 to S03 conversion rate
● Inlet dust loading
● Flue gas and NO^ distribution
The ​gas hourly space velocity​, the inverse of residence time (1/h), is the volumetric flow rate
of the flue gas (ft3/h) divided by the catalyst volume (ft3).
As the gas hourly space velocity increases, the contact time between the gas and catalyst
decreases, and the overall NOx reduction
potential decreases (increasing NOx emissions, potential ammonia slip, or both).

The ​catalyst pitch​ is defined as the cell wall thickness plus the flow channel width, which
affects the pressure drop through SCR.
As the catalyst pitch decreases, the system pressure drop increases.
Coal Burning plants with high-dust applications require the largest pitch to accommodate the
large amount of fly ash present in the flue gas. High-dust SCR catalysts have a catalyst pitch of
6 to 7.5 mm, while low-dust or tail-end catalysts have a catalyst pitch of 3.3 to 5 mm.

Area velocity (ft/h) is obtained by dividing the volumetric flow of the flue gas (ft3/h) by the
surface area of the catalyst (ft2).

Conversion of area velocity to space velocity can be made by dividing the space velocity by the
specific surface area of the catalyst. The specific surface area is the area of catalyst
surface divided by total catalyst volume (ft2/ft3).

The optimum temperature for NOx emission reduction for vanadium-titanium catalyst is
generally between 600 and 700° F( 550 to 780° F).
As temperatures drops below the optimum temperature range, NOx reduction efficiency
decreases rapidly and as temperatures increases above the range, S02 to SOx conversion
rates increase.
As a result, economizer design and operation may be affected by considerations related to
effective SCR operation.

The alkali metals and trace elements found in coal poison the catalyst, significantly affecting
reactivity and life. Known
poisons are listed below:
● Arsenic
● Beryllium
● Cadmium
● Calcium
● Chromium
● Copper
● Lead
 ● Manganese
● Mercury
● Nickel
● Thorium
● Uranium

Arsenic, forms gaseous arsenic oxide, can be deposited on catalyst surfaces, clogging small
pores of the catalyst, thereby limiting the transport of the ammonia—NOx mixture to the active
catalyst sites.
The poisons can chemically attack (neutralize) the active sites on the catalyst surface and
reduce catalyst effectiveness over time( continual process with catalyst exposure to flue gas).

As the catalyst becomes deactivated, more ammonia must be injected to maintain

NOx emission limits with risk of increased amount of ammonia slip.

Catalyst Management
Initial catalyst charge deactivates at a fairly uniform rate, with augmentation or replacement
necessary when catalyst activity has decreased to the point that outlet NOx emission
requirements cannot be achieved consistent with ammonia slip limits.
Since the activity levels are still significantly
high (50% to 75%) in the initial catalyst charge, it is best to add, rather than fully replace,
catalyst to more completely utilize remaining catalyst activity.
Accordingly, the reactor casing to have with the flexibility to accommodate the addition of future
catalyst layers which lowers life cycle costs for an SCR system.

Including a CMP in the SCR design is cost effective whenever it is feasible to add a spare layer.

Addition of a future catalyst layer increases the overall SCR system pressure drop. Therefore,
there is a tradeoff between the replacement catalyst cost and the increase in overall power
consumption that accompanies additional
pressure drop. Typically, this tradeoff strongly favors a CMP.

Catalyst Disposal/Recycling
New, fresh catalyst is generally not considered hazardous.
However, after years of operation on a coal- or oil-fueled boiler in the presence of flue gas, the
catalyst may absorb or collect enough of the
trace pollutants in the flue gas to be classified as hazardous.

Catalyst recycling is the preferred method for the ultimate removal of spent catalyst.
The user can form an agreement with the catalyst supplier stipulating that when new catalyst is
ordered, the catalyst supplier will accept the spent catalyst for final disposition.
Air Heater Impacts
Sulfur trioxide (S03) in the presence of ammonia forms ammonium sulfate and ammo-
nium bisulfate salts, which may foul air heater surfaces, leading to increasing pressure drops,
and possibly create the need for periodic offline cleaning.If condensation temperature occurs
between layers, tenacious deposits tend to build up.

With SCR catalyst, ammonia slip is very low

with fresh catalyst and increases slowly as the catalyst is deactivated.

Draft System Impacts

An SCR system installed in a high-dust location can add 3 to 5 in. wg of pressure drop
to the boiler system.

Precipitator Impacts
SCR has no detrimental effects on the
precipitator. In boilers with low S03 concentrations, the ammonia slip that does not react with
S03 acts to enhance the collectability of fly ash in the precipitator.

Waste Solids Handling and Disposal Impacts.

Ammonia slip from the SCR system condenses onto the fly ash collected in the electrostatic
precipitator, is absorbed in the FGD system, or exits the system through the stack.
At elevated pH, ammonia in the fly ash is released, possibly leading to odorous
emissions. Ammonia (NH3)concentrations >100 ppm (mass) in the fly ash result in noticeable
odor and may result in rejection of the ash for use in the cement industry.

SCR Configuration

High dust
Catalyst located at the outlet of the economizer
and upstream of the air heater.
Low dust
Catalyst located at the outlet of a hot-side ESP and upstream of the air heater .
Tail end
Catalyst located at the outlet of particulate removal and FGD systems and upstream of the stack
. GGH required and reheating of flue gas required for process reaction. Life of catalyst more.