Comply without compromise

DNX SCR catalysts and

®

technologies
High-performance DeNOx catalysts
and efficient SCR system designs
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Umicore is a global materials technology and

recycling group with over 11,000 employees
and a turnover of €17.5 billion in 2019. We
generate the majority of our revenues and
dedicate most of our R&D efforts to clean
technologies. These include emission control
catalysts, materials for rechargeable batteries
and recycling.

Umicore’s overriding goal of sustainable

value creation is based on an ambition to
develop, produce and recycle materials in
a way that fulfils its mission: materials for
a better life.
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Comprehensive solutions
for DeNOx applications
Reduce NOx by up to 99% with proven Umicore technology

Complying with emission standards without compromising performance or profitability is

a challenge many industries are facing.

With decades of broad experience, Umicore DNX® SCR applications, our high-efficiency solutions can reduce
catalysts and system designs are meeting the challenge NOx by up to 99% with maximum reliability, even
for customers around the world. For stationary when operating under severe conditions.

The scope of SCR DeNOx

products and services
Stationary
UMICORE Waste Biomass
incineration and marine fired boilers
SCR DENOX engines

General Coal, oil Gas turbines FCC units,

industrial and gas fired single and crackers, heaters
processes boilers combined and other
cycle processes

Benefits at a glance: Our Services include:

1. Our SCR process designs have been implemented at • SCR system management including onsite inspections,
over 2,000 sites worldwide performance assessments, and assistance with
catalyst regeneration or disposal
2. Our engineering services make sure the value of
investments is maximized • Catalyst sample retrieval, activity testing, accumulated
poison analysis and remaining service life projection
3. CFD and cold flow modeling enable us to ensure low
pressure drop, efficient ammonia mixing, and uniform • On-site advisory services during installation etc.
gas distribution
• On-site troubleshooting, including emissions testing
4. Our technical services help optimize performance and and AIG tuning
manage catalyst replacement
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DNX® SCR catalysts

Proven solutions for all industrial applications

Umicore DNX® catalysts are widely recognized for their superior NOx removal capabilities
and extremely low SO2 oxidation rate.

A fiberglass-reinforced titania carrier and corrugated shape secure exceptional mechanical strength and low gas
pressure loss. A wide range of pitch sizes and chemical formulations mean we can provide the optimal catalyst
for all applications.

NOx reduction

Our DNX® catalysts remove NOx in exhaust gases existing and upcoming regulations on mercury emissions.
from boilers, combustion turbines, gas and diesel
The DNX® dual function DNO and GTC series add powerful
engines, incinerators, refineries, and chemical units.
CO and VOC oxidation to our proven DeNOx capabilities
To handle dust-laden gases from coal-fired boilers in combustion turbine applications, FCC units, biomass,
and poisonous components in fly ash and flue gas – engines, cement and other industrial systems and
including biofuels – we offer special high-dust catalyst fueled power plants such as wood-burning plants. Unlike
formulations. Long-term experience with DNX® on traditional oxidation catalysts, Umicore’s dual function
coal-fired boilers has furthermore demonstrated more catalysts is unique in that it does not significantly
than 90% mercury oxidation, allowing users to meet increase SO2 oxidation, even at low SO2 concentrations.

Main benefits

• Up to 99% NOx removal with low

to zero ammonia slip

• Very low SO2 oxidation

• High tolerance for catalyst poisons

• Excellent, proven mercury oxidation

capabilities

• Long service life

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SCR system designs

Optimized technologies work hand in hand with our catalysts

For any DeNOx catalyst to perform optimally, systems for ammonia injection and mixing need to be designed
just right. Developed to bring out the very best in our DNX® catalysts, our system designs complete the DeNOx
picture no matter which application.

A specially designed gas mixing system

Our licensed specially designed gas mixer

ensures superior mixing efficiency and very low
pressure loss. Used with success in SCR units on
coal-fired power plant boilers and at oil refineries,
where NOx reduction requirements exceed 95%,
our specially designed mixer is a great example of
how our technologies enhance our market-leading
catalyst performance.

Complete technology package

From the first feasibility study to the final commissioning, Umicore offers complete technology packages which
include our DNX® catalysts plus a Basic Engineering Package comprising of:

• Drawings of catalyst, catalyst arrangement, and • Process flow diagrams plus piping and instrument
sealing system diagrams

• CFD and physical flow model verification with test • Process description, including control principles
report including drawings
• Performance test procedure
• Process specifications and drawings of the reactor,
ammonia injection and mixing systems, and • Review of a system design
ammonia flow control unit

By supplementing DNX® catalysts with a Basic Engineering Package, Umicore makes sure that all SCR processes
are guaranteed with high performance.
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CASE
DNX® catalyst removes load constraints in gas turbine operation

THE CHALLENGE THE SOLUTION

Located in Hood County, Texas, Exelon Corporation’s Wolf Instead of a conventional CO oxidation system, Exelon
Hollow Generating Station was constructed and went management decided to install Umicore’s dual function
commercial in 2003. The power island consists of two MHI DNX® GTC-802 combined SCR/CO catalyst in the two units
501G turbines firing natural gas only, two Deltak HRSGs at Wolf Hollow. The catalyst was installed in October
and one MHI steam turbine, and has a rated net capacity 2014, replacing the existing charge of Umicore SCR-only
of 720 MW. In recent years, the plant has seen a greater catalyst. Both units were shut down for about four days,
need to operate at partial load, not only at night, but also while the previous catalyst was replaced with a single
during the day. Originally designed with no system for layer of the DNX® GTC-802. At 500 mm deep, the layer
oxidizing CO to CO2, the plant’s minimum load limit has of new catalyst was only 25 mm deeper than the layer
been constrained by higher CO emission rates at reduced it had replaced, enabling the plant to oxidize 90% of the
load. The obvious solution – installing a conventional CO across the load range in addition to removing 90%
CO oxidation system upstream of the AIG – would have of NOx, without increasing pressure drop.
entailed significant modifications and a loss of maximum
output and thermal efficiency due to higher pressure drop.

THE OUTCOME
The unit’s performance has not changed since initial start-up. The CO oxidation rate remains at >96%, while DeNOx
removal is over 90% with very low ammonia slip. The SO2 to SO3 oxidation rate is 10 times lower than traditional platinum
catalyst at less than 1.0% – greatly reducing any chance of ABS fouling in the economizer section of the HRSG. Unlike
platinum/alumina catalysts, the GTC-802 is very tolerant to the presence of sulfur in the fuel, and will never require
acid washing to remove poisons. Finally, overall pressure drop is close to 50% lower than a traditional arrangement
with separate layers of CO and SCR catalysts. Needless to say, the customer is very pleased with the new solution.

Related technologies

Particulate filtration and NOx removal combined Discover the full range of Umicore catalysts and
In certain industries, dust, soot and other particulates technologies for emissions control
in off-gases are a problem that needs special Optimized performance often means ensuring that
consideration. Our solutions allow for integration of multiple technologies and components are tuned to
catalytic emission management in particulate filtration, each other. On the following pages are some related
reducing complexity and total cost of ownership. High offerings from Umicore.
efficiency catalytic filters offer new flexibility in meeting
existing and future emission requirements.
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CASE
The DNX® catalyst enables coal-fired power plant to overcome challenges posed by Texas lignite fuel

THE CHALLENGE THE SOLUTION

Texas lignite is a high ash, low BTU and very erosive Sandow Unit 4 uses a Combustion Engineering
coal, mined mostly in central and northeastern Texas. tangentially fired supercritical boiler, and has a
Luminant, the largest electricity producer in Texas, maximum continuous output of 640 MWe. After
wanted to install a SCR system in Unit 4 of its Sandow consulting with Umicore specialists, plant managers
plant, located near the city of Rockdale. However, plant decided to install DNX® in the SCR system – creating the
managers – and the industry at large – were concerned world’s first commercial application of a SCR system on
that the Texas lignite fuel would result in SCR catalyst a boiler burning Texas lignite fuel.
erosion and plugging.

THE OUTCOME
The system was deployed in early 2010, and Umicore has remained the only catalyst supplier for Unit 4 ever since.
Over years of operation, the SCR system has proven to be very reliable – with near zero catalyst erosion, no plugging
and lower than expected deactivation.

Why partner with Umicore:

The Umicore advantage lies not just in Partnering with us on a DeNOx solution
individual solutions, but in how our solutions provides the benefits of proven reliability and
work together. decades of industry experience.

We are a partner who – as catalyst provider, We have vast experience delivering DeNOx
technology licensor and service provider – has process designs, catalysts and proprietary
a unique ability to look at the big picture and equipment across the full range of industries
tailor solutions that are fully optimized to meet and specific applications.
exact needs.
 For inquiries and additional
information please contact

Umicore Catalyst USA LLC

17625 El Camino Real Suite 210

Houston, TX 77058
USA

Nathan White
Telephone: +1 281 684 8809
Email: [email protected]

Umicore Denmark

Kogle Allé 1
2970 Hoersholm
Denmark

Mikkel Nygaard Larsen

Telephone: +45 226 55 022
Email: [email protected]

Umicore Catalyst (China) Co.,Ltd Beijing Branch

优美科催化剂北京分公司

2302 room, West Tower, Prosper Center, 5

Guanghua Road, Chaoyang District, Beijing 100020
北京朝阳区光华路5号世纪财富中心西座2302室，邮编
100020

Ma Nan
Telephone: +86 139 110 62179
Email: [email protected]

http://secc.umicore.com