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 & assess condition: Operating data, mechanical condition, existing distributions, and current fuels serve as the starting point.
Test catalyst: Test results show changes in the deactivation rate; inspection results are incorporated into the evaluation.
Model & evaluate: DeNOx requirements and real reactor potential are compared against current and future compliance goals.
Predict & plan: We predict the next catalyst event, recommend the test interval, and support 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

We examine catalysts independently of the manufacturer in our own laboratory, including activity trending (K/K₀), deactivation analysis, and evaluation of mechanical properties.

CATLife™ Model

We assess real-world operation holistically instead of relying on the original design, enabling a precise prediction of the next catalyst event and sound budget planning.

Reactor Inspections

We map clogging, ash deposits, erosion, and mechanical condition frame by frame, including associated systems such as AIG, flow guidance, and cleaning equipment.

Installation Support

We support catalyst installation, from planning and installation monitoring to documentation for further lifecycle management.

Data Analysis & Evaluation

We carry out comprehensive analyses of DeNOx requirements and system performance, including data trends, scenario-based evaluation, and combustion analysis to assess real-world operation.

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Part-Load Studies

We analyze catalyst behavior during part-load operation as a basis for operational optimization and for assessing ammonia slip risks under variable load profiles.

Flow Model Management

We manage and evaluate flow models to optimize gas distribution across the catalyst, providing the basis for AIG tuning and uniform NH₃ distribution.

Training & Commissioning

We train operating personnel and provide support during commissioning to ensure a safe start-up and lasting operational knowledge within your own team.

Regeneration & Procurement

We evaluate, procure, and assure the quality of catalyst regeneration. Homogeneously extruded catalysts allow repeated regeneration and an extended service life.

AIG Tuning

Since 2004, we have been tuning 20 to 30 ammonia injection grids (AIG) per year. The goal is to improve NOx distribution at the outlet and minimize NH₃ slip.

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CONTACT

How much service life is left in your catalyst?

Let's find out.

Whether it's a reactor inspection, a 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