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Many of today's existing SCR systems have been in operation for 10+ years.
Throughout this time, much experience has been gained by end users and system
suppliers alike. Through practical hands-on experience, ENERACTIVE offers a
complete array of SCR optimization services to improve the operation of existing
SCR systems.
SCR Inspections
One of the most important steps in identifying SCR performance problems is to
perform periodic internal inspections. These inspections can be very informative
in identifying problem areas with LPA screens, ash deposition or erosion in flues,
AIG pluggage, ash buildups and structural integrity. SCR reactors are thoroughly
inspected for catalyst issues such as LPA buildup, catalyst ash accumulation or
erosion, flow distribution, and catalyst cleaning evaluations (sonic horns,
sootblowers, etc.). During inspections, ENERACTIVE can also retrieve catalyst
samples and arrange for testing with the catalyst OEM or 3rd party testing company.
Inspections are summarized with detailed reports including photos, maps and recommendations
for improvements.
Flow Modeling
Gas flow modeling provides an in-depth understanding of problems within air quality control
systems, and a means to provide solutions to those problems. ENERACTIVE has in-house
expertise in both Computational Fluid Dynamics (CFD) and physical (scale) modeling. CFD is
sed to help identify and solve flow-related problems around LPA screens, reactor flow
distributions and thermal mixing performance. Physical modeling is used in a similar manner,
but also provides more in-depth understanding and optimizations in areas where CFD may not be
effective. ENERACTIVE will recommend which method is most appropriate for the system being
analyzed and provide in-depth results and performance improvements.
Reagent System Optimization
Urea or ammonia systems are critical in the operation of SCR systems. Poor performance can
result increased O&M costs, safety issues or costly downtime. ENERACTIVE has in an in-depth
understanding of all major types of ammonia systems including urea (dry or liquid), aqueous
or anhydrous. Urea to ammonia systems (hydrolysis or decomposition) can be evaluated objectively
with recommendations provided based on customer needs. Systems with either vaporizers or direct
injection of ammonia can be optimized along with ammonia components including unloading, storage,
forwarding, vaporizers, dilution air systems, dual-fluid atomizing lances, and ammonia injection
grids. ENERACTIVE has worked with all of the major urea/ammonia system suppliers and therefore
is able to provide the most competitive and efficient solution to any operating problem.
Ammonia Injection Grid Tuning
The distribution of ammonia and NOX in SCR systems is critical to performance and optimal utilization
of catalyst life. Excellent NH3/NOX distribution will enhance SCR performance and extend the useful life
of the catalyst within the reactor. Therefore, AIG tuning is a wise investment to maintain and optimize
SCR performance. ENERACTIVE provides comprehensive AIG tuning services in combination with overall ammonia
distribution evaluations.
Performance Testing
Overall SCR performance is typically evaluated by SCR performance testing. ENERACTIVE offers all types of
key SCR performance testing including NOX reduction, NH3/NOX distribution, ammonia slip, SO2 and mercury
oxidation and pressure drop using the appropriate EPA test methods. ENERACTIVE can also provide test
protocol development and test supervision when conducted by 3rd parties.
SCR Design and Management Services return to top
ENERACTIVE personnel have worked for SCR system suppliers, catalyst suppliers and testing companies. This
background provides us with a unique portfolio of SCR design services that allows ENERACTIVE to provide
unbiased, experience-based detailed design reviews of SCR systems.
Equipment Design
ENERACTIVE can provide SCR systems design review services including ammonia storage and handling systems,
ammonia vaporization and injection systems, control systems, reactor and flue design, catalyst loading and handling systems.
Specification Development & Proposal Evaluations
ENERACTIVE can assist our clients with complete specification development for critical SCR components including
catalyst, ammonia system equipment and testing services. These specifications will utilize our in-depth
experience to obtain the most reliable and cost-efficient components based on your system needs.
SCR Commissioning and Construction Management
ENERACTIVE can assist our clients with complete specification development for critical SCR components including catalyst, ammonia system equipment and testing services. These specifications will utilize our in-depth experience to obtain the most reliable and cost-efficient components based on your system needs.
SCR Catalyst Management Services return to top
ENERACTIVE provides catalyst management services for coal-fired or natural gas-fired SCR systems. Being that we
are not affiliated with any new catalyst manufacturer or regenerator, we will provide a complete, unbiased analysis
of catalyst purchase options taking into account:
Existing catalyst performanceand activity*
Catalyst pluggage issues and pitch
Catalyst types (plate, honeycomb or corrugated)
Pressure drop and ID fan capability
SO2 and mercury oxidation
Fuel types and fuel switching
Arsenic and limestone addition
Outage duration
Outage cycles
*Catalyst Activity Testing
Catalyst activity testing is a critical part of catalyst management. ENERACTIVE provides complete management of catalyst activity testing utilizing 3rd party testing facilities. Being that we are not affiliated with any catalyst manufacturer or regenerator, we will provide a complete, unbiased analysis of test results to assist in making critical catalyst management decisions. Full specifications are provided for obtaining cost-competitive testing from approved catalyst testing firms.
