EMERACHEM
Operators of gas-fired industrial boilers are continually looking at advanced technologies to meet their emission control goals. With increasing regularity, answers are found in the catalytic systems designed and manufactured by EmeraChem.
Industrial boilers are often installed in "non-attainment" areas. Nonattainment areas are regions within the country where the concentration of one or more criteria pollutants exceeds the level set as the federal air quality standards. Once the EPA announces that an area does not meet the health standard, the State works with businesses, local governments, and the public to reduce the emissions from sources contributing to the nonattainment status of the area. Hence, these boilers must incorporate proven oxidation catalyst technology to reduce CO and VOC emissions.
The EPA has finalized the Boiler Maximum Achievable Control Technology (MACT) Rule. The rule is intended to control emissions of hazardous air pollutants (HAP's) from industrial, commercial, and institutional boilers and process heaters. Fortunately, EmeraChem has products and solutions that meet current and future Boiler MACT regulations. It all starts with proprietary design and construction from the ground up.
• Bonded discrete cell density. Bonded discrete cell substrate.
• Highest catalytic surface area (<40% more than herringbone) yielding the lowest possible pressure loss.
• Prevents substrate nesting, blow-outs and exhaust bypass.
• 5 -10 Year mechanical integrity guarantee.
Operators of natural gas or diesel-fired boilers will reduce NOx, and PM emissions with EmeraChem's catalytic products as well. EMx™ is an effective multi-pollutant technology that reduces emissions to ultra-low levels without the use of ammonia. Since the introduction of EMx™, operators of electric generating facilities at universities, hospitals, airports and clean room manufacturing plants have employed this advanced ammonia free reduction technology (AFR) with extremely satisfactory results.
To properly equip an industrial boiler facility, all catalytic system designs start with the frame. The frame is made from structural steel tubes and other shapes and mounted in a casing (HRSG) furnished by the customer. Depending upon the application, the frame is constructed of either A36 carbon steel or 304 stainless steel. When completed, overall size dictates shipping the frame in up to six sections.
The frame is designed to fit within the casing, with allowance for thermal expansion. It is supported by bearing plates on the bottom and guided supports on the sides and top that will allow for thermal expansion without binding. The gap left between the frame and the casing is covered by overlapping bent seal plates, which slide across each other and within the hold down plate. This helps to maintain an airtight seal while allowing for thermal expansion of the frame.
The frame is specifically designed to eliminate exhaust gas bypass, a major factor that can affect conversion. Bypass is exhaust gas passing through gaps in the system rather than through the catalyst. Bypass can occur between the frame and the individual catalyst modules, and between the frame and the HRSG casing (liner). To prevent bypass, EmeraChem uses flat woven fiberglass gaskets between the frame and the catalyst modules. A bent seal plate prevents bypass between the frame and the HRSG casing liner plates. Bypass must be eliminated to prevent voiding the CO conversion warranty.