[{"data":1,"prerenderedAt":868},["ShallowReactive",2],{"site-footer-common":3,"glossary:plate-catalyst":45,"glossary-related:plate-catalyst":256},{"id":4,"extension":5,"footer":6,"meta":40,"navbar":41,"stem":43,"__hash__":44},"common\u002Fcommon.yml","yml",{"tagline":7,"links":8,"sections":9},"Acoustic cleaning intelligence for industrial fouling, soot, ash, dust and build-up.",[],[10,19,31],{"title":11,"links":12},"Product",[13,16],{"label":14,"to":15},"How it works","\u002F#product",{"label":17,"to":18},"Cost assessment","\u002F#hero",{"title":20,"links":21},"Company",[22,25,28],{"label":23,"to":24},"What we build","\u002F#about",{"label":26,"to":27},"Careers","\u002F#careers",{"label":29,"to":30},"Contact","\u002F#contact",{"title":32,"links":33},"Resources",[34,37],{"label":35,"to":36},"Blog","\u002Fresources\u002Fblog",{"label":38,"to":39},"Glossary","\u002Fglossary",{},{"links":42},[],"common","YocmZRy1AYfBbpgGVms-zhdiABlF8VTxHx6h4rDmZBA",{"id":46,"title":47,"aliases":48,"body":51,"category":236,"description":237,"extension":238,"meta":239,"navigation":240,"path":241,"relatedTerms":242,"seo":247,"sources":250,"stem":254,"term":47,"__hash__":255},"glossary\u002Fglossary\u002Fplate-catalyst.md","Plate catalyst",[49,50],"plate-type SCR catalyst","SCR plate catalyst",{"type":52,"value":53,"toc":228},"minimark",[54,74,79,102,106,187,190,194,201,205],[55,56,57,58,62,63,68,69,73],"p",{},"A ",[59,60,61],"strong",{},"plate catalyst"," uses an array of parallel steel plates coated with the active catalytic material (typically vanadium \u002F tungsten \u002F titanium oxides) instead of an extruded ceramic ",[64,65,67],"a",{"href":66},"\u002Fglossary\u002Fhoneycomb-catalyst","honeycomb",". The plates form open gas channels that are physically wider than honeycomb channels of equivalent surface area, making plate catalysts the preferred choice for high-dust ",[64,70,72],{"href":71},"\u002Fglossary\u002Fselective-catalytic-reduction","SCR"," duty.",[75,76,78],"h2",{"id":77},"where-plate-catalysts-are-specified","Where plate catalysts are specified",[80,81,82,86,93,99],"ul",{},[83,84,85],"li",{},"Coal-fired utility boilers with heavy fly-ash loading",[83,87,88,92],{},[64,89,91],{"href":90},"\u002Fglossary\u002Fwaste-to-energy","Biomass"," plants where ash includes large agglomerated particles",[83,94,95,98],{},[64,96,97],{"href":90},"Waste-to-energy"," plants with sticky chloride-laden ash",[83,100,101],{},"Iron-ore sintering plants and metallurgical off-gas SCR",[75,103,105],{"id":104},"trade-offs-vs-honeycomb","Trade-offs vs honeycomb",[107,108,109,127],"table",{},[110,111,112],"thead",{},[113,114,115,119,122],"tr",{},[116,117,118],"th",{},"Factor",[116,120,121],{},"Plate",[116,123,124],{},[64,125,126],{"href":66},"Honeycomb",[128,129,130,146,155,166,176],"tbody",{},[113,131,132,140,143],{},[133,134,135,139],"td",{},[64,136,138],{"href":137},"\u002Fglossary\u002Fcatalyst-pluggage","Pluggage"," resistance",[133,141,142],{},"Higher",[133,144,145],{},"Lower",[113,147,148,151,153],{},[133,149,150],{},"Geometric surface area per volume",[133,152,145],{},[133,154,142],{},[113,156,157,160,163],{},[133,158,159],{},"Catalyst volume per MW",[133,161,162],{},"Larger",[133,164,165],{},"Smaller",[113,167,168,171,174],{},[133,169,170],{},"Capital cost per layer",[133,172,173],{},"Similar",[133,175,173],{},[113,177,178,181,184],{},[133,179,180],{},"Vendor pool",[133,182,183],{},"Narrower",[133,185,186],{},"Broader",[55,188,189],{},"Plate catalysts have a longer effective life on dusty duty because pluggage is the dominant lifetime-limiting failure mode there.",[75,191,193],{"id":192},"cleaning-compatibility","Cleaning compatibility",[55,195,196,200],{},[64,197,199],{"href":198},"\u002Fglossary\u002Fsonic-horn","Sonic horns"," are particularly effective on plate catalysts because the open channels respond well to acoustic cleaning; the wide spacing means dislodged particulate has somewhere to go.",[75,202,204],{"id":203},"related-terms","Related terms",[80,206,207,212,217,223],{},[83,208,209],{},[64,210,211],{"href":71},"Selective Catalytic Reduction (SCR)",[83,213,214],{},[64,215,216],{"href":66},"Honeycomb catalyst",[83,218,219],{},[64,220,222],{"href":221},"\u002Fglossary\u002Fcorrugated-catalyst","Corrugated catalyst",[83,224,225],{},[64,226,227],{"href":137},"Catalyst pluggage",{"title":229,"searchDepth":230,"depth":230,"links":231},"",2,[232,233,234,235],{"id":77,"depth":230,"text":78},{"id":104,"depth":230,"text":105},{"id":192,"depth":230,"text":193},{"id":203,"depth":230,"text":204},"scr-sncr","A plate catalyst uses an array of parallel steel plates coated with the active catalytic material (typically vanadium \u002F tungsten \u002F titanium oxides) instead of an extruded ceramic honeycomb. The plates form open gas channels that are physically wider than honeycomb channels of equivalent surface area, making plate catalysts the preferred choice for high-dust SCR duty.","md",{},true,"\u002Fglossary\u002Fplate-catalyst",[243,244,245,246],"selective-catalytic-reduction","honeycomb-catalyst","corrugated-catalyst","catalyst-pluggage",{"title":248,"description":249},"Plate catalyst — open-channel SCR catalyst for high-dust duty","A plate catalyst uses parallel coated steel plates instead of extruded honeycomb. Wider gas channels make it preferred for high-dust SCR duty where pluggage risk is significant.",[251],{"title":252,"url":253},"Wikipedia — Selective catalytic reduction","https:\u002F\u002Fen.wikipedia.org\u002Fwiki\u002FSelective_catalytic_reduction","glossary\u002Fplate-catalyst","KtD8hBBUFAwCdfVepRrvTcQXDBoyEOyHfn74wTiQCFY",[257,416,570,719],{"id":258,"title":211,"aliases":259,"body":262,"category":236,"description":396,"extension":238,"meta":397,"navigation":240,"path":71,"relatedTerms":398,"seo":405,"sources":408,"stem":413,"term":414,"__hash__":415},"glossary\u002Fglossary\u002Fselective-catalytic-reduction.md",[72,260,261],"SCR system","SCR reactor",{"type":52,"value":263,"toc":391},[264,282,286,302,306,309,336,353,355],[55,265,266,268,269,273,274,277,278,281],{},[59,267,211],{}," is the dominant flue-gas NOx-control technology on coal-fired and gas-fired utility boilers, ",[64,270,272],{"href":271},"\u002Fglossary\u002Fheat-recovery-steam-generator","HRSGs"," in combined-cycle plants, ",[64,275,276],{"href":90},"waste-to-energy"," and ",[64,279,280],{"href":90},"biomass"," boilers, cement plants and major refining furnaces. Ammonia or aqueous urea is injected upstream of a catalyst bed; the catalyst lowers the activation energy for the reaction NOx + NH₃ → N₂ + H₂O, achieving 80–95% NOx reduction across the reactor.",[75,283,285],{"id":284},"reactor-layout","Reactor layout",[55,287,288,289,293,294,297,298,301],{},"A typical SCR reactor is a vertical or horizontal duct containing 2–4 layers of catalyst modules. Upstream of the catalyst sits the ",[64,290,292],{"href":291},"\u002Fglossary\u002Fammonia-injection-grid","ammonia injection grid (AIG)"," that distributes the ammonia evenly into the flue gas. Most installations operate in the ",[59,295,296],{},"high-dust"," position (between economiser and air heater) where catalyst temperature is around 300–400 °C; ",[59,299,300],{},"tail-end"," SCRs sit downstream of particulate control at lower temperatures, with the trade-off of needing flue-gas reheating.",[75,303,305],{"id":304},"fouling-and-cleaning","Fouling and cleaning",[55,307,308],{},"SCR catalysts foul in two ways:",[80,310,311,327],{},[83,312,313,317,318,277,322,326],{},[59,314,315],{},[64,316,138],{"href":137}," — fly ash, ",[64,319,321],{"href":320},"\u002Fglossary\u002Fpopcorn-ash","popcorn ash",[64,323,325],{"href":324},"\u002Fglossary\u002Flarge-particle-ash","large-particle ash"," wedge into the catalyst cells, blocking the gas path",[83,328,329,335],{},[59,330,331],{},[64,332,334],{"href":333},"\u002Fglossary\u002Fcatalyst-masking","Masking"," — a thin layer of deposit covers the active sites; gas flow continues but catalytic activity falls",[55,337,338,339,343,344,348,349,352],{},"Both reduce NOx-reduction efficiency, raise ",[64,340,342],{"href":341},"\u002Fglossary\u002Fammonia-slip","ammonia slip",", and shorten catalyst life. Cleaning options include steam ",[64,345,347],{"href":346},"\u002Fglossary\u002Fsteam-sootblower","sootblowers",", ",[64,350,351],{"href":198},"sonic horns"," and offline campaigns (vacuum \u002F water wash \u002F regeneration). Sonic horns are increasingly favoured because they continuously dislodge ash before it cements onto the catalyst face, without the steam erosion of mechanical sootblowing.",[75,354,204],{"id":203},[80,356,357,363,368,373,378,382,386],{},[83,358,359],{},[64,360,362],{"href":361},"\u002Fglossary\u002Fselective-non-catalytic-reduction","Selective Non-Catalytic Reduction (SNCR)",[83,364,365],{},[64,366,367],{"href":291},"Ammonia injection grid",[83,369,370],{},[64,371,372],{"href":341},"Ammonia slip",[83,374,375],{},[64,376,377],{"href":333},"Catalyst masking",[83,379,380],{},[64,381,227],{"href":137},[83,383,384],{},[64,385,216],{"href":66},[83,387,388],{},[64,389,390],{"href":198},"Sonic horn",{"title":229,"searchDepth":230,"depth":230,"links":392},[393,394,395],{"id":284,"depth":230,"text":285},{"id":304,"depth":230,"text":305},{"id":203,"depth":230,"text":204},"Selective Catalytic Reduction (SCR) is the dominant flue-gas NOx-control technology on coal-fired and gas-fired utility boilers, HRSGs in combined-cycle plants, waste-to-energy and biomass boilers, cement plants and major refining furnaces. Ammonia or aqueous urea is injected upstream of a catalyst bed; the catalyst lowers the activation energy for the reaction NOx + NH₃ → N₂ + H₂O, achieving 80–95% NOx reduction across the reactor.",{},[399,400,401,402,403,246,244,404],"selective-non-catalytic-reduction","denox","ammonia-injection-grid","ammonia-slip","catalyst-masking","sonic-horn",{"title":406,"description":407},"Selective Catalytic Reduction (SCR) — how the dominant NOx-control technology works","SCR is the dominant NOx-control technology on industrial combustion plant. Ammonia is injected upstream of a catalyst that converts NOx to nitrogen and water.",[409,410],{"title":252,"url":253},{"title":411,"url":412},"Power Engineering — SCR Catalyst Cleaning: Sootblowers vs. Acoustic Horns","https:\u002F\u002Fwww.power-eng.com\u002Foperations-maintenance\u002Fscr-catalyst-cleaningsootblowers-vs-acoustic-horns\u002F","glossary\u002Fselective-catalytic-reduction","Selective Catalytic Reduction","fmMCMd4NY3eZdSk_UYlbZ9ryi-9CR2Os6DivQjXEPCU",{"id":417,"title":216,"aliases":418,"body":421,"category":236,"description":558,"extension":238,"meta":559,"navigation":240,"path":66,"relatedTerms":560,"seo":563,"sources":566,"stem":568,"term":216,"__hash__":569},"glossary\u002Fglossary\u002Fhoneycomb-catalyst.md",[419,420],"honeycomb SCR catalyst","extruded catalyst",{"type":52,"value":422,"toc":552},[423,433,437,487,491,494,508,512,527,529],[55,424,57,425,428,429,432],{},[59,426,427],{},"honeycomb catalyst"," is a monolithic extruded ceramic block containing a dense grid of parallel square channels through which flue gas flows. The active catalytic material — typically vanadium pentoxide and tungsten trioxide on a titanium-dioxide carrier — is incorporated into the bulk ceramic. Honeycomb is the most common form of ",[64,430,431],{"href":71},"SCR catalyst",".",[75,434,436],{"id":435},"strengths-and-weaknesses","Strengths and weaknesses",[107,438,439,449],{},[110,440,441],{},[113,442,443,446],{},[116,444,445],{},"Strength",[116,447,448],{},"Weakness",[128,450,451,463,471,479],{},[113,452,453,456],{},[133,454,455],{},"Very high geometric surface area per unit volume",[133,457,458,459,462],{},"Channels susceptible to ",[64,460,461],{"href":137},"pluggage"," by ash",[113,464,465,468],{},[133,466,467],{},"Low pressure drop in clean condition",[133,469,470],{},"Brittle — handle with care during install \u002F replacement",[113,472,473,476],{},[133,474,475],{},"Mature, large supplier base",[133,477,478],{},"Channels are harder to clean than open structures",[113,480,481,484],{},[133,482,483],{},"Wide range of pitch options (3.5–7.4 mm typical)",[133,485,486],{},"Smaller pitch = more risk of pluggage",[75,488,490],{"id":489},"pitch-selection","Pitch selection",[55,492,493],{},"Pitch (centre-to-centre channel spacing) trades surface area against pluggage risk:",[80,495,496,502],{},[83,497,498,501],{},[59,499,500],{},"Smaller pitch (3.5–4.5 mm)"," — high surface area, used on clean gas streams (NGCC HRSGs, gas-fired duty)",[83,503,504,507],{},[59,505,506],{},"Larger pitch (6–7.4 mm)"," — used on dusty coal, biomass and WtE duty where pluggage risk dominates",[75,509,511],{"id":510},"layer-assembly","Layer assembly",[55,513,514,515,519,520,522,523,526],{},"Individual honeycomb blocks are loaded into a ",[64,516,518],{"href":517},"\u002Fglossary\u002Fcatalyst-layer-module","catalyst layer \u002F module"," and stacked 2–4 layers deep inside the SCR reactor. ",[64,521,199],{"href":198}," and steam ",[64,524,347],{"href":525},"\u002Fglossary\u002Fsonic-sootblower"," are positioned between layers to keep channels clear.",[75,528,204],{"id":203},[80,530,531,535,539,543,548],{},[83,532,533],{},[64,534,211],{"href":71},[83,536,537],{},[64,538,47],{"href":241},[83,540,541],{},[64,542,222],{"href":221},[83,544,545],{},[64,546,547],{"href":517},"Catalyst layer \u002F module",[83,549,550],{},[64,551,227],{"href":137},{"title":229,"searchDepth":230,"depth":230,"links":553},[554,555,556,557],{"id":435,"depth":230,"text":436},{"id":489,"depth":230,"text":490},{"id":510,"depth":230,"text":511},{"id":203,"depth":230,"text":204},"A honeycomb catalyst is a monolithic extruded ceramic block containing a dense grid of parallel square channels through which flue gas flows. The active catalytic material — typically vanadium pentoxide and tungsten trioxide on a titanium-dioxide carrier — is incorporated into the bulk ceramic. Honeycomb is the most common form of SCR catalyst.",{},[243,561,245,562,246],"plate-catalyst","catalyst-layer-module",{"title":564,"description":565},"Honeycomb catalyst — extruded SCR catalyst form factor","A honeycomb catalyst is an extruded ceramic block with parallel square channels, the most common SCR catalyst form. High surface area but susceptible to channel pluggage.",[567],{"title":252,"url":253},"glossary\u002Fhoneycomb-catalyst","_YfmRO7jrh-yc8ZLI7n3Nr5QKYo9e0uBw4yWiXy1uho",{"id":571,"title":222,"aliases":572,"body":575,"category":236,"description":709,"extension":238,"meta":710,"navigation":240,"path":221,"relatedTerms":711,"seo":712,"sources":715,"stem":717,"term":222,"__hash__":718},"glossary\u002Fglossary\u002Fcorrugated-catalyst.md",[573,574],"corrugated SCR catalyst","fibre-reinforced catalyst",{"type":52,"value":576,"toc":704},[577,589,593,615,619,685,688,690],[55,578,57,579,582,583,277,585,588],{},[59,580,581],{},"corrugated catalyst"," uses corrugated ceramic-fibre sheets coated with the active catalytic material, assembled into modules with alternating flat and corrugated layers to form gas-flow channels. The construction is lighter than ",[64,584,67],{"href":66},[64,586,587],{"href":241},"plate"," catalysts and is particularly common on tail-end SCR, marine duty and applications where catalyst weight matters.",[75,590,592],{"id":591},"where-corrugated-catalysts-fit","Where corrugated catalysts fit",[80,594,595,602,605,608],{},[83,596,597,598,601],{},"Tail-end ",[64,599,600],{"href":71},"SCRs"," downstream of FGD",[83,603,604],{},"Marine SCR for shipboard NOx control",[83,606,607],{},"Co-generation and industrial duty with weight constraints",[83,609,610,611,614],{},"Some ",[64,612,613],{"href":271},"HRSG"," installations",[75,616,618],{"id":617},"trade-offs","Trade-offs",[107,620,621,634],{},[110,622,623],{},[113,624,625,627,630,632],{},[116,626,118],{},[116,628,629],{},"Corrugated",[116,631,126],{},[116,633,121],{},[128,635,636,650,661,672],{},[113,637,638,641,644,647],{},[133,639,640],{},"Weight per unit volume",[133,642,643],{},"Lowest",[133,645,646],{},"Highest",[133,648,649],{},"Medium",[113,651,652,655,657,659],{},[133,653,654],{},"Mechanical robustness",[133,656,145],{},[133,658,649],{},[133,660,142],{},[113,662,663,666,668,670],{},[133,664,665],{},"Surface area",[133,667,649],{},[133,669,646],{},[133,671,145],{},[113,673,674,677,680,683],{},[133,675,676],{},"Cost",[133,678,679],{},"Variable",[133,681,682],{},"Lowest (mature supply)",[133,684,649],{},[55,686,687],{},"Corrugated catalysts are less common in heavy-duty coal and cement SCR but earn their place in specialised duty.",[75,689,204],{"id":203},[80,691,692,696,700],{},[83,693,694],{},[64,695,211],{"href":71},[83,697,698],{},[64,699,216],{"href":66},[83,701,702],{},[64,703,47],{"href":241},{"title":229,"searchDepth":230,"depth":230,"links":705},[706,707,708],{"id":591,"depth":230,"text":592},{"id":617,"depth":230,"text":618},{"id":203,"depth":230,"text":204},"A corrugated catalyst uses corrugated ceramic-fibre sheets coated with the active catalytic material, assembled into modules with alternating flat and corrugated layers to form gas-flow channels. The construction is lighter than honeycomb and plate catalysts and is particularly common on tail-end SCR, marine duty and applications where catalyst weight matters.",{},[243,244,561],{"title":713,"description":714},"Corrugated catalyst — fibre-reinforced SCR catalyst variant","A corrugated catalyst uses corrugated fibre-reinforced sheets coated with active material. Lighter than honeycomb, particularly common on tail-end SCR and marine duty.",[716],{"title":252,"url":253},"glossary\u002Fcorrugated-catalyst","CqZmhRTFIm1--3cXbXC4v9Aj1gEGQgae_3CZfSpkrC8",{"id":720,"title":227,"aliases":721,"body":725,"category":236,"description":854,"extension":238,"meta":855,"navigation":240,"path":137,"relatedTerms":856,"seo":859,"sources":862,"stem":866,"term":227,"__hash__":867},"glossary\u002Fglossary\u002Fcatalyst-pluggage.md",[722,723,724],"catalyst plugging","catalyst channelling","SCR catalyst pluggage",{"type":52,"value":726,"toc":849},[727,739,743,778,782,820,822],[55,728,729,731,732,734,735,738],{},[59,730,227],{}," is the physical blockage of ",[64,733,431],{"href":71}," channels by particulate material. Unlike ",[64,736,737],{"href":333},"catalyst masking"," (a thin surface blanket), pluggage fills the catalyst channels themselves, stopping gas flow through affected cells. The result is ΔP rise across the SCR, gas-flow maldistribution into the remaining open cells, and channelling effects that reduce overall NOx reduction.",[75,740,742],{"id":741},"sources-of-pluggage-material","Sources of pluggage material",[80,744,745,753,761,772],{},[83,746,747,752],{},[59,748,749],{},[64,750,751],{"href":324},"Large-particle ash (LPA)"," — slag fragments and agglomerated ash carried over from the boiler",[83,754,755,760],{},[59,756,757],{},[64,758,759],{"href":320},"Popcorn ash"," — porous low-density ash particles that wedge into honeycomb cells",[83,762,763,766,767,771],{},[59,764,765],{},"Ammonium-salt deposits"," — ",[64,768,770],{"href":769},"\u002Fglossary\u002Fammonium-bisulphate","ammonium bisulphate"," on tail-end SCRs at lower temperatures",[83,773,774,777],{},[59,775,776],{},"Refractory debris"," — fragments from upstream furnace or duct repairs",[75,779,781],{"id":780},"prevention","Prevention",[80,783,784,790,796,802,811],{},[83,785,786,789],{},[59,787,788],{},"LPA screens"," — coarse mesh screens upstream of the catalyst trap large particles",[83,791,792,795],{},[59,793,794],{},"Guard layers"," — sacrificial top catalyst layer with larger pitch absorbs the initial particulate",[83,797,798,801],{},[59,799,800],{},"Larger pitch on the top layer"," — wider cell openings on the first catalyst layer pass LPA through to a removable screen below",[83,803,804,810],{},[59,805,806,807,809],{},"Periodic ",[64,808,404],{"href":198}," cleaning"," — dislodges accumulating ash before it cements",[83,812,813,819],{},[59,814,815,816],{},"Steam ",[64,817,818],{"href":525},"sootblowing"," — for harder deposits",[75,821,204],{"id":203},[80,823,824,828,833,837,841,845],{},[83,825,826],{},[64,827,211],{"href":71},[83,829,830],{},[64,831,832],{"href":324},"Large-particle ash",[83,834,835],{},[64,836,759],{"href":320},[83,838,839],{},[64,840,377],{"href":333},[83,842,843],{},[64,844,216],{"href":66},[83,846,847],{},[64,848,390],{"href":198},{"title":229,"searchDepth":230,"depth":230,"links":850},[851,852,853],{"id":741,"depth":230,"text":742},{"id":780,"depth":230,"text":781},{"id":203,"depth":230,"text":204},"Catalyst pluggage is the physical blockage of SCR catalyst channels by particulate material. Unlike catalyst masking (a thin surface blanket), pluggage fills the catalyst channels themselves, stopping gas flow through affected cells. The result is ΔP rise across the SCR, gas-flow maldistribution into the remaining open cells, and channelling effects that reduce overall NOx reduction.",{},[243,857,858,403,244,404],"large-particle-ash","popcorn-ash",{"title":860,"description":861},"Catalyst pluggage — channel blockage that reduces SCR gas flow","Catalyst pluggage is the physical blockage of SCR catalyst channels by large-particle ash, popcorn ash or ammonium-salt deposits. It causes ΔP rise and gas-flow maldistribution.",[863],{"title":864,"url":865},"Airflow Sciences — SCR Catalyst Pluggage Reduction at Roxboro Unit 3","https:\u002F\u002Fwww.airflowsciences.com\u002Fsites\u002Fdefault\u002Ffiles\u002Fdocs\u002F2010_MEGA_Symposium_Roxboro_U3.pdf","glossary\u002Fcatalyst-pluggage","m2viiLe19KKcTBiDWhyUc38xPIzoOiMpL15r0i_ayHg",1782613751549]