Catalytic Products International (CPI) installed a Selective Catalytic Reduction (SCR) system with integrated catalytic oxidization to control volatile organic compounds (VOC), carbon monoxide (CO), hydrogen cyanide (HCN), ammonia (NH3) and nitrous oxide (NOx) emitted from a high-temperature calciner. The CPI CONCORD NR 4.2 system, was engineered for a 4,200 scfm exhaust stream and incorporates both catalytic oxidation and SCR-based NOx reduction in accordance with the applicable federal performance standards for calciners.
- Process Type: Calciner
- Contaminants Controlled: VOC, CO, HCN, NH₃, process-generated NOₓ, and NOₓ formed via NH₃ oxidation
- Air Volume: 4,200 scfm
- Control Type: Catalytic oxidation + selective catalytic reduction (SCR)
- Destruction Rate of Efficiency (DRE): 90% VOC & NOx
- Particulate Pretreatment: Pulse-jet stainless steel baghouse for catalyst protection
- Installation: CPI supervised EPC performing install
The control system is designed to treat emissions from a mineral-processing calciner that is required to comply with 40 CFR Part 60, Subpart UUU (NSPS for Calciners and Dryers in Mineral Industries), including PM and visible emissions. CPI's SCR/oxidation system is engineered to operate continuously whenever the calciner is in service, aligning with permit conditions typical for calciner operations under federal NSPS.
Catalytic Oxidation & SCR Function
Catalytic oxidation was selected due to its low thermal energy requirements, suitability for multi‑pollutant abatement, and strong performance intreating dilute organic and inorganic air toxics. The behavior of VOCs, CO, and HAPs in catalytic systems is based on the ability of catalysts to achieve high destruction efficiencies at significantly lower temperatures than thermal oxidizers (typically 600–900°F vs.1,400–1,600°F) . This reduces auxiliary fuel consumption and prevents catalyst sintering.
Particulate Pretreatment & Catalyst Protection
- Dilution and fresh‑air purge dampers to maintain optimal inlet temperature and protect catalyst beds from overheating.
- Induced‑draft booster fans for proper system draft, ensuring compliance with minimum residence time and flow distribution principles described in oxidizer design standards .
- A vertical exhaust stack sized for adequate dispersion consistent with typical state permit modeling assumptions.
Catalytic Products International (CPI) has been “Enabling Clean Production™ Since 1969” and continues as a leading supplier of air pollution control equipment. CPI is at the forefront in providing industries including the chemical processing industry with solutions to their air pollution control needs.
Today, CPI partners with its customers as a trusted resource in resolving the most complex air pollution and energy conservation problems. We provide our customers with innovative and cost-conscious solutions to their most complex VOC, NOx, and Odor pollution challenges. Our equipment is also at work meeting energy conservation strategies and minimizing greenhouse gas (GHG) emissions.
