Conventional wisdom would have required Plant A to replace four separate catalyst layers over a 3-year period. However, catalyst testing proved that NOx reduction targets could be achieved with only three replacements over the same period. Eliminating a single catalyst replacement, yielded a net savings of $1.4M over the 3-year period with the investment of $48k/year in a catalyst testing program.
Plant B operates their SCR system on a seasonal basis, which means the catalyst is exposed to less flue gas than it would be under year-round operation. In addition to the limited flue gas exposure, ICT’s catalyst testing revealed that deactivation rates for all three layers were slower than the standard trend. The findings were able to save Plant B $2M, over a 4-year period, with the implementation a $48k/year catalyst testing program. ICT was able to determine the absolute lifetime of the catalyst, which differed from what the manufacturer suggested, allowing Plant B to run the catalyst to the end of usable life with the confidence that they’re not going to risk a compliance issue.
ROI: 1,000% over a 4 year period
In 2017, the Plant C switched to a more cost-effective type of coal. But the witch had unintended consequences and reduced the DeNOx activity of individual layers by 40-70%.
In this case, ICT’s testing revealed the catalyst was decreasing in performance much more rapidly than expected following the fuel switch. Because they were regularly testing their catalyst, Plant C was able to move up their next catalyst replacement to prevent a compliance issue. They were also then able to change how they operated the plant to mitigate the arsenic poisoning as much as possible.