FERCo operates both a bench-scale and micro-scale catalyst activity testing facility. Testing has been performed on over 1000 individual samples, both commercial and R&D studies.
Current testing capabilities include:
FERCo owns and operates one of only independent catalyst activity testing laboratories in the United States. The bench scale facility can cover a temperature range from 320 - 900 F.
FERCo has a bench-scale facility in which we can evaluate the activity of traditional catalyst samples. The testing can be performed per either the VGB or EPRI catalyst testing guidelines. The facility also has R&D capabilities that expand upon traditional testing.
The test facility currently accepts bench scale catalyst samples, and rigorously controls flue gas temperature, flow rate, and gas compositions.
In addition to NOx activity, SO2 to SO3 oxidation and CO oxidation can also be measured. Tests have also been performed at varying NO/NO2/NOx ratios, as well as VOC's such as toluene, methane, propane, formaldehyde, isopropanol and hydrogen cyanide.
FERCo has a micro-scale facility in which we can evaluate the activity of small SCR catalyst samples. The test facility currently evaluates catalyst samples 1" diameter x 6" long, and is most useful for the tracking of gas turbine SCR and CO catalyst activity.
SCR Catalyst activity is determined by measuring NOx reduction at a NH3/NOx ratio of typically 1.2 to 1.5. Catalyst temperatures approaching 1000 F can be tested in this micro reactor.
The micro-scale reactor has tested activity in over 100 samples, comprising both dNOx and CO catalysts. Typically dNOx catalyst are tested at one condition, while CO measurements are taken over a nominal temperature range (ex. 200-700 F) to establish a "light-off" curve.
Traditional activity testing of catalyst samples is useful as a means of assessing catalyst life. However, as the opportunities for obtaining samples may be limited to the annual planned outages, using laboratory tests to determine catalyst replacement strategies may not be feasible. Limited activity data will limit the ability to make good decisions. As a solution to this, FERCo has developed the CatalysTrak®-Activity In Situ Test System, in which the Reactor Potential of the SCR can be accurately measured at any time, on-demand, without waiting for an outage to collect a sample.
The CatalysTraK® test system is easy to install. Each typical test location requires only two standard 4” ports, one upstream and one downstream of the catalyst layer. Test probes can be installed on as many locations per reactor as needed. All locations are managed by one control cabinet.