Dual Function Catalyst : Reduction of NOx & CO / VOC for Power and Refinery Units

Our history

DNX Haldor Topsoe development the first emission control catalyst to reduce NOx in 1982.

First CommercialOrders

First commercial orders were received in 1989 were for coal-fired power plants in Denmark and stationary engines operating in Turkey.

North AmericaFirst commercial orders were received in 2000 for coal-fired power plants, industrial applications and stationary engine applications in Hawaii.

North AmericaPasadena, TX plant first produced catalyst for delivery in January, 2002.

Purchased Stationary emissions control catalyst division purchased by Umicore from Haldor Topsoe in November, 2017.

DNX® & DNO ® catalyst - Production plantsHouston, Texas: Sole global stationary catalyst production site

Stationary Catalyst Product range

Channel size

• 2.7 - 10.0 mm

Wall thickness

• 0.3, 0.4, 0.6, 0.8 and 1.0 mm

Chemical compositions

• 10 different to optimizeactivity/SO2 oxidation

• Umicore DNX type catalyst• Trimodal pore structure

• Extruded and plate type catalyst• Homogenous micro pore

structure

Macro pore Poison Micro poresMacro pore Micro pores

Meso pores

Pore Structures

‘Dual Function’ catalyst productionThe “4th Step”

• Elements are impregnated a 2nd time with a proprietary precious metal solution

• The catalyst now contains Vanadium (DeNOx) and Palladium (CO/VOC), both active sites work simultaneously inside the element

• Element can be ‘partially dipped’ to a defined depth to accommodate a specific amount of oxidation

Compressor Turbine

Air Gas

SCR & CO catalyst320-360 °C

GT

C-8

02

Dual Function Catalyst

References

Dual Function References (329) • Reformers

• Boilers

• FCC Units

• Gas Turbines (HRSG and SC)

• Thermal Oxidizers

• Diesel and NG Engines (Up to 18 MW)

• Cement Plants

• Carbon Black

• Chemical Plants

• Biomass

FCC (Fluid Catalytic Cracker) Case Study

• Unit had issues meeting air permit for start-up and shut-down limits for CO emissions.

• Solved with layer of dual function catalyst placed in one reactor at most downstream layer, reduced thousands of ppm of CO down to double digit outlet. Upstream layers of traditional SCR catalyst used to reduce NOx.

Methanol Unit Case Study

• Gulf Coast methanol unit required CO/VOC oxidation.

• Conventional layer of NOx only catalyst followed by layer of dual function catalyst

• NOx Reduction : 97%

• CO Reduction : 90%

• VOC Reduction : 70+%

• Catalyst protected due to unique substrate with large porosity.

Benefits of a meso- and macro-pore

Flue gas flow

NO N2

NONO

Homogeneous pore system Tri-modal pore system

Macro-poreMeso-poreMicro-pores Micro-pore

Chromium

Renewables effect on Power Grid

Gas turbines are running different than intended design.

Results:

High CO values due to ramping up and down when renewables come online.

High ratio NO2(60-90%) of NOx which will effect catalytic activity when run at low loads.

New hydrogen fuels may produce 2-3x NOx than conventional NG fuels.

Performance Advantages of Dual Function Catalyst in a HRSG

Optimized Dual Function Arrangement

• Lowest specific system pressure drop

• Lowest SO2 oxidation

• Lowest NO oxidation

• Easiest installation

• Lower NH3 slip

• Can utilize frameless module design

• Liquid ammonia injection

• Weight Savings

Compressor Turbine

Air Gas

SCR & CO catalyst320-360 °C

GT

C-8

02

Dual Function Catalyst

Story: DNX® GTC-802 Installation, Wolf Hollow Unit 2

DNX® GTC-802

Prior to installation in Unit 2 at Wolf Hollow

Operating Performance - Wolf HollowINITIAL START-UP

LM-6000 Dual Function Retrofit – Anchorage, AK

LM6000 in OTSG configuration

• HRSG temperatures in regular mode ~700F

• Running ‘dry’ temperatures reach 920F

• Vertical up flow with conventional CO/VOC catalyst & Umicore NOx only catalyst downstream.

Required Reductions:

• 90% NOx Removal

• 90% CO Removal

• 75% VOC Removal

LM-6000 Dual Function Retrofit – Anchorage, AK

• Removed CO catalyst – recovered scrap value and used towards purchase of dual function catalyst charge.

• Exceed required emissions reductions.

• Saved 2.0 in W.C. pressure drop with removal of CO catalyst and increased overall unit power output.

• Lowered overall ammonia consumption.

• NOTE:

- NOx reduction ~>90% is limited by NH3/NOxmaldistribution, the lower the RMS value the better the mixing

- CO/VOC reduction can be controlled by adding more catalyst volume and/or higher temperatures.