Nationwide Boiler Inc., a leading provider of boiler solutions, highlights its advanced CataStak™ SCR system. This proven selective catalytic reduction (SCR) technology has transformed the mining industry by reducing nitrous oxide (NOx) emissions by up to 99%, offering a cost-effective, sustainable option for near-zero NOx performance while supporting decarbonization efforts.
CataStak™ SCR system. Image Credit: Nationwide Boiler Inc.
The CataStak™ SCR system is designed for versatility, capable of being installed both vertically or horizontally. Its adaptability makes it suitable for a wide range of equipment applications, including boilers, gas turbines, and fired heaters. The system's single-reactor housing accommodates NOx reducing catalyst and/or carbon monoxide (CO) oxidizing catalyst, providing a comprehensive solution for emission control.
At the heart of the CataStak™ SCR system is its advanced catalyst technology. Nationwide Boiler offers multiple catalyst options, including honeycomb, plate type, or pelletized, tailored to specific applications and equipment types. This unique catalyst design ensures high NOx or CO removal activity, low pressure drop, low sulfur dioxide (SO2) oxidation rate, and exceptional durability.
The catalyst's innovative features deliver significant benefits to mining facilities. It achieves high NOx or CO removal levels with minimal ammonia slip, ensuring optimal performance while maintaining environmental compliance. The low activity towards SO2 oxidation minimizes the risk of fouling downstream equipment, enhancing overall system efficiency. Additionally, the catalyst's high poison resistance guarantees a long and stable service life, reducing maintenance costs and downtime.
The CataStak™ SCR system also incorporates a state-of-the-art NOx reduction control system for precise ammonia flow control. This feed-forward control system ensures compliance is maintained throughout the modulating range of the unit, optimizing performance and efficiency.
Nationwide Boiler's commitment to flexibility is evident in the CataStak™ SCR system’s reagent delivery system. The system can utilize pure anhydrous ammonia, aqueous ammonia, or urea, adapting to various operational preferences and regulatory requirements. Nationwide Boiler’s urea-based CataStak™ SCR system provides the superior performance of SCR technology without the use of ammonia.
As the mining industry shifts toward the use of hydrogen as a fuel, the CataStak™ SCR system also plays a crucial role in reducing greenhouse gas emissions by controlling the increased NOx levels associated with the use of hydrogen and hydrogen-blended fuels. While hydrogen combustion eliminates CO emissions—the primary contributor to greenhouse gases—it does produce more NOx when compared to firing on natural gas. The CataStak™ combats this increase in NOx, reducing output to acceptable levels.
With its comprehensive features and proven performance in more than 250 installations, the CataStak™ SCR system represents a significant advancement in emission control technology. Nationwide Boiler continues to lead the industry in providing innovative, efficient, and environmentally friendly solutions for boiler operations across the mining industry.