NOx Control for Industrial Facilities
Air quality regulations require NOx control systems that consistently meet permit requirements across varying operating conditions.
ALSYS Catalysts provides selective catalytic NOx reduction (SCR), N₂O decomposition, and ammonia oxidation systems for industrial facilities. Catalyst formulations deliver the performance and longevity required for continuous operation over many years.
With over 600 m³ of catalysts supplied in the last 5 years, ALSYS delivers catalyst solutions from feasibility testing through commissioning. ALSYS Engineering provides procurement, construction management, and startup support. Combined, this provides complete value chain coverage from technology selection through operational handover.
The ALSYS Advantages:
- High skills in catalytic processes and lab/pilot testing facilities to fine-tune the preferred solution to reach the customer’s expectations & constraints
- High level of customer engagement
- Local presence and close customer support
NOx Control System Capabilities
ALSYS catalyst systems are designed for reliable performance in industrial emissions control applications. Systems combine proven catalyst formulations with complete reactor engineering.
Proven Catalyst Performance
Formulations delivering consistent NOx reduction across varying load conditions, fuel types, and operating temperatures and pressures
Full System Integration
Complete SCR systems, including catalyst, reactor design, ammonia injection grid engineering, and controls integration.
Long Catalyst Life
Formulations optimized for resistance to poisons, thermal degradation, and mechanical breakdown.
Regulatory Compliance Support
Performance guarantees and documentation supporting air permit compliance and regulatory reporting requirements.
Lyon District Heating DeNOx Systems
ALSYS and partner Prossergy supplied two DeNOx SCR systems for biomass boilers serving Lyon’s district heating network. Systems treat emissions from renewable fuel combustion, meeting French air quality standards. Installation demonstrates SCR capability with biomass fuel, operating for years, and meeting permit requirements.
Catalyst Solutions for Industrial Air Quality Compliance
ALSYS Catalysts provides comprehensive solutions specifically designed to help industrial facilities meet complex air quality compliance standards. Crucially, these advanced catalyst systems are engineered to address major industrial emission challenges, including the vital reduction of nitrogen oxides (NOx), the decomposition of nitrous oxide (N₂O), and the effective control of ammonia slip.
Overview
Selective Catalytic Reduction (SCR) is a robust and widely used technology in industrial emissions control, specifically designed to reduce harmful nitrogen oxides (NOx). The process works by injecting a reducing agent, such as ammonia or urea, over a specialized catalyst, which converts the NOx into harmless nitrogen and water vapor. This essential chemical reaction is reliably achieved across a moderate temperature range, typically between 300 and 450°C.
ALSYS Catalysts provides complete, full-system integration for SCR, covering everything from catalyst supply to controls integration and reactor engineering. These advanced systems are deployed across various demanding applications, including biomass boilers, natural gas turbines, industrial process heaters, and waste-to-energy facilities. With a commitment to performance, ALSYS ensures long catalyst life, consistent NOx reduction across varying loads, and comprehensive regulatory compliance support.
ALSYS’ Track Record
ALSYS’ track record is built on providing complete Selective Catalytic Reduction (SCR) systems, encompassing catalyst supply, specialized reactor design, precise ammonia injection grid engineering, and sophisticated controls integration. This full integration ensures optimal performance and reliability for diverse industrial emissions control applications. The comprehensive approach covers the entire value chain from component technology to final operational controls.
These advanced systems are successfully supplied for various demanding applications. Such applications include biomass boilers, natural gas turbines, industrial process heaters, and waste-to-energy facilities. The Lyon district heating project, for example, serves as a clear demonstration of the technology’s effectiveness in a biomass-fuel application.
Overview
Nitrous oxide (N₂O) is a potent greenhouse gas produced primarily in industrial processes like nitric acid manufacturing, adipic acid production, and specific combustion processes.
To mitigate this, N₂O is reduced to nitrogen and oxygen through a catalytic decomposition mechanism, which takes place in a 400 – 600°C temperature window with ALSYS’ patented catalysts.
ALSYS’ Track Record
Catalyst formulations from ALSYS are specifically engineered for a very high N₂O decomposition rate (95%+), a reaction necessary to reduce the potent greenhouse gas nitrous oxide into harmless nitrogen and oxygen. These formulations feature exceptional thermal stability and resistance to common catalyst poisons. Furthermore, the geometry of the catalyst is precisely optimized to minimize pressure drop.
Overview
Industrial NOx control involves several core combustion and post-combustion techniques aimed at reducing nitrogen oxide emissions. These methods include implementing primary measures like low-NOx burners, staged combustion, and flue gas recirculation, as well as a post-combustion method called Selective Non-Catalytic Reduction (SNCR). Together, these proven strategies form a complete approach to managing air quality and emissions compliance.
ALSYS Engineering evaluates complete NOx control strategies, going beyond catalytic systems to include these conventional methods. Their approach involves a full evaluation, from initial feasibility studies to comprehensive engineering, which may result in recommendations for a hybrid system incorporating SCR, SNCR, and combustion optimization. This end-to-end service provides regulatory strategy support to ensure the selected solution meets all air permit requirements.
ALSYS’ Track Record
SCR systems sometimes allow a small amount of unreacted ammonia (known as ammonia slip) to pass through the catalyst bed. To mitigate this, downstream ammonia oxidation catalysts are utilized to convert the unreacted ammonia into harmless nitrogen and water.
ALSYS offers ammonia oxidation catalysts with high selectivity toward nitrogen and activity across a wide temperature range. These catalysts are designed with geometries that allow for seamless integration with existing ductwork and can be combined with SCR/ammonia slip catalyst designs for complete system optimization.
Overview
SCR systems, while highly effective, can sometimes result in a small amount of unreacted ammonia passing through the catalyst bed, a phenomenon known as ammonia slip. To mitigate this issue, downstream ammonia oxidation catalysts (i.e., NH3 slip catalysts) are used, which efficiently convert unreacted ammonia into harmless nitrogen and water.
ALSYS’ Track Record
For effective ammonia emission control, ALSYS provides advanced ammonia oxidation catalysts engineered for high selectivity toward nitrogen and reliable activity across a wide temperature range. This offers customers guaranteed performance and is combined with optimized catalyst geometries that ensure seamless, cost-effective integration into existing plant ductwork and SCR systems.
Questions About NOx Emissions Control
Find quick answers to common questions about Selective Catalytic Reduction (SCR) and other emissions control technologies.
3-5 years is typical for well-designed industrial systems. Some installations exceed 5 years, depending on operating conditions and maintenance.
Factors affecting life include:
- Catalyst poisons (sulfur, phosphorus, alkali metals from fuel)
- Operating temperature and thermal cycling
- Particulates causing erosion or plugging
- Mechanical stresses from improper support
ALSYS Catalyst formulations optimize poison resistance. For biomass applications with high alkali content, specialized formulations extend catalyst life beyond that of standard SCR catalysts.
Yes. Lyon installation proves this. Biomass creates challenges, including alkali metals from fuel, particulates requiring soot blowers, and temperature variation with load and fuel moisture.
Catalyst formulations resistant to alkali poisoning are essential. Reactor design includes soot blowers for ash removal. Temperature management ensures the catalyst stays in the active range (300-400°C).
ALSYS designs SCR systems specifically for biomass conditions. Technology enables biomass facilities to meet air quality standards while using renewable fuels.
Routine maintenance includes:
Ammonia injection system: Verify proper flow and distribution
- Catalyst inspection: Annual visual inspection for plugging or erosion
- Soot blowing: For high-particulate applications, daily or weekly cycles
- Instrumentation: NOx analyzers, temperature sensors, flow measurement
- Controls verification: Ammonia injection control loop calibration
Catalyst replacement occurs every 3-5 years based on performance monitoring. ALSYS provides replacement catalysts that match the original specifications.
N₂O has a global warming potential approximately 300 times that of CO₂. One ton of N₂O reduced is roughly equivalent to 300 tons of CO₂.
Chemical facilities with N₂O abatement systems qualify for carbon credits under various programs. Credit revenues can provide economic justification for catalyst investment.
Find the Right Solution for Your Emissions Control Requirements
Discuss your NOx or N₂O emissions with our catalyst team.