CATALYST MANAGEMENT

Sustainable performance across

the entire lifecycle.

CATLife® is our manufacturer-independent program for the lifecycle management of SCR systems, based on operating conditions, inspection findings, and catalyst test data. The goal is to reduce catalyst and operating costs, ensure compliance, and avoid costly surprises during overhauls.

THE CATLife® MODEL

Customer orientation as a core principle.

Less comprehensive approaches that rely heavily on original design conditions underestimate the influence of real-world operation and often lead to incorrect assessments of catalyst requirements and unnecessary cost increases. CATLife® puts real-world operation at the center: this allows the next catalyst event to be accurately predicted and expensive surprises during overhauls to be avoided. Close cooperation and a deep understanding of the operating characteristics of each emission control system are the fundamental principles of our work. Our services can be used individually or as part of a comprehensive service package, flexible and tailored to the needs of the operator.

Step by step

Collect data & condition: Operating data, mechanical condition, existing distributions, and current fuels as a starting point.
Test catalyst: Test results show changes in the deactivation rate; inspection results are incorporated into the evaluation.
Model & evaluate: Comparison of DeNOx requirements and real reactor potential against current and future compliance goals.
Predict & plan: Prediction of the next catalyst event, recommendation of the test interval, and support for budget planning.

EVIDENCE & EQUIPMENT

Experience, service network, and in-house laboratory.

CATLife® relies on decades of field experience and a highly specialized laboratory that examines catalysts regardless of design or manufacturer.

More than 650 customers worldwide trust CATLife® services.

Laboratory Capacities

■12 microreactors and 1 bench reactor for performance tests
■2 X-ray fluorescence spectrometers (XRF) for chemical analysis
■2 surface and porosity analyzers (including BET)
■Measurement of NOx activity, SOx conversion, CO oxidation, pore volume, and pore size distribution

Field Experience & Reporting

■AIG tuning on 20 to 30 grids per year since 2004
■Frame-by-frame inspection maps including associated systems
■Service life prediction and strategies for extending the operating life
■Centrally coordinated investigations and consistent reporting

CATALYST TECHNOLOGY

From cell geometry to the finished SCR module.

CATLife® bundles all services necessary for precise planning of catalyst use: from inspection and testing to replacement and extension strategies. Our services can be used individually or as a comprehensive package.

Catalyst Testing & Evaluation

Manufacturer-independent catalyst investigation in our own laboratory: activity trending (K/K₀), deactivation analysis & evaluation of mechanical properties.

CATLife® Model

Holistic assessment of real-world operation instead of the original design — for a precise prediction of the next catalyst event & sound budget planning.

Reactor Inspections

Frame-by-frame mapping of clogging, ash deposits, erosion & mechanical condition — including associated systems such as AIG, flow guidance & cleaning equipment.

Installation Support

Support during catalyst assembly — from planning and installation monitoring to documentation for further lifecycle management.

Data Analysis & Evaluation

Comprehensive analysis of DeNOx requirements & system performance: data trends, scenario-based evaluation & combustion analysis to assess real-world operation.

Katalysatormanagement_Mikroreaktor_800x800

Partial Load Studies

Analysis of catalyst behavior during partial load operation — basis for operational optimization & assessment of ammonia slip risks with variable load profiles.

Flow Model Management

Management & evaluation of flow models to optimize gas distribution across the catalyst — basis for AIG tuning & uniform NH₃ distribution.

Training & Commissioning

Training of operating personnel & support during commissioning — for a safe start-up & sustainable operational knowledge within your own team.

Regeneration & Procurement

Evaluation, procurement & quality assurance of catalyst regeneration: Homogeneously extruded catalysts allow for repeated regenerations & an extended service life.

AIG Tuning

Optimization of ammonia injection (AIG) on 20 to 30 grids per year since 2004 — tuning goal is the improvement of NOx distribution at the outlet and minimization of NH₃ slip.

Katalysatormanagement_Vermessung_800x800

CONTACT

How much service life is left in your catalyst?

Let's find out.

Whether it's a reactor inspection, manufacturer-independent catalyst test, or a strategy to extend the service life: our CATLife™ experts support your operation. Let's talk about it.

Contact experts