CATALYST MANAGEMENT
Sustainable performance across
the entire lifecycle.
CATLife® is our vendor-neutral program for the lifecycle management of SCR systems, based on operating conditions, inspection findings, and catalyst test data. Goal: Reduce catalyst and operating costs, ensure compliance, and avoid costly surprises during audits.
THE CATLife® MODEL
Customer collaboration as a core principle.
Less comprehensive approaches to catalyst management that rely heavily on original design conditions underestimate the influence of real-world operation and often lead to incorrect assessments of catalyst requirements and higher operator costs. CATLife® puts real-world operation at the center: this allows the next catalyst event to be accurately predicted and eliminates the risk of surprise catalyst needs. Client collaboration and developing a deep understanding of the operating characteristics of every application are the fundamental principles of CATLife®. 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
- Data collection and analysis: Ceram uses station operating data, inspection and field test results, and fuel analyses to assess current operating conditions and performance demands on the SCR as a complete system.
- Catalyst testing: Regular catalyst testing provides insights on catalyst deactivation. Evaluating the context of the catalyst test results, performing error analysis on testing tolerances, and assessing the primary modes of catalyst deactivation provides critical information for the accurate assessment of catalyst life.
- Model & evaluate: Comparison of DeNOx requirements and real reactor potential against current and future compliance goals. Catalyst options are evaluated based upon project specific circumstances to determine optimum, cost-effective strategies for every application.
- Predict & plan: We consolidate our analysis into client-focused deliverables emphasizing recommended catalyst replacement timing, long-term support of CAPEX planning, the evaluation of multiple operating scenarios, recommended catalyst testing intervals, and future recommendations to further refine the model.
Capabilities & Experience
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 Capabilities
- ■Semi-bench and Full-bench scale test reactors for measurement of NOx activity and SOx conversion
- ■Assessment of catalyst deactivation mechanisms through chemical composition analysis via X-ray fluorescence spectroscopy (XRF) and the evaluation of catalyst surface area and porosity (inclusive of BET analysis)
- ■CO (and VOC) oxidation (and ammonia destruction) testing capabilities.
- ■Mechanical strength and geometry characterization testing.
- ■Testing performed per industry standards inclusive of those established by VGB and EPRI
Field Experience & Reporting
- ■Longstanding field services program established in 2002 based upon decades of industry know-how
- ■Expertise in emissions control technology inclusive of SCR system start-up and the relationship between SCR performance and the performance of the complete air quality control system
- ■Hands-on experience across the spectrum of power generation and process applications of SCR technology
- ■Responsive, flexible scheduling managed through a single Ceram point of contact
- ■Client-focused reporting and deliverables tailored to client-specific needs
THE CATLife® SUITE OF SERVICES
Customer-centered, end-to-end service.
The CATLife® program offers all services necessary for capital and O&M optimization of an SCR system: from inspection and testing services to the development of cost-effective replacement and life-extension strategies. Our services can be used individually or as a comprehensive package.
Catalyst Testing & Evaluation
Ceram regularly tests catalyst from all predominant manufacturers at our test facility in Frauental, Austria. The accuracy of SCR catalyst testing is heavily subject to the quality of the of the lab- the Ceram laboratories have a proven track-record of performance.
CATLife® Model
Our catalyst management modeling program emphasizes the importance of real-world operating conditions and client collaboration to develop accurate projections of catalyst needs and cost-effective management strategies.
Reactor Inspections
Our inspections entail a frame by frame assessment of catalyst pluggage and mechanical condition of the catalyst, sealing system, catalyst cleaning devices, and associated systems such as the AIG and SCR ductwork.
Installation Support
We provide technical field support during installation to ensure a smooth installation process and successful performance following start-up.
Data Analysis & Evaluation
Our data analysis services entail comprehensive trending and evaluation of facility operating data. Results of our analysis provide useful insights into longterm system performance and support more effective O&M planning.
Partial Load Studies
We analyze SCR inlet conditions in conjunction with system performance to better optimize turndown capabilities and expand safe load ranges for SCR operation.
Flow Model Management
Our engineering team evaluates flow model results and provides technical guidance on solutions to ensure uniform flow distribution into the SCR and reduce the risk of particulate drop out and accumulation.
Training & Commissioning
We train operations and technical personnel and provide support during commissioning to ensure a safe start-up and lasting operational knowledge within your team.
Regeneration & Procurement
Evaluation, procurement & quality assurance of catalyst regeneration: Homogeneously extruded catalysts allow for repeated regenerations & an extended service life.
AIG Tuning
Since 2004, we have tuned over 200 ammonia injection grids (AIG). The goal of an AIG tuning is to improve the NH₃/NOx distribution in the system and minimize NH₃ slip.
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 developing a strategy to extend the service life of our catalyst: our CATLife™ experts can support your operation. Let's talk about it.
High-performance ceramic technologies for exhaust gas treatment, heat storage, and decarbonization.
Expertise in ceramic processing since 1921.
Gamserstraße 38 · 8523 Frauental a. d. Laßnitz
office@ceram-austria.com · +43 3462 2000-0
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