UltraCat Catalytic Filters are composed of fibrous ceramic materials mixed with nanobits of proprietary catalyst.
This new generation of light weight, ductile ceramic filter is highly efficient for multi-pollutant control, including the removal of NOx and submicron particulate, to extremely low levels.
Ceramic Catalyst Filters typically capture particulate to levels less than 0.001 grains/dscf (2.0 mg/ Nm3). MACT compliance levels are guaranteed. The unique structure of the filters keeps the collected particles on the surface. The embedded NOx catalyst is protected from blinding and poisoning.
NOX and Dioxin Control
The filter tubes have nanobits of proprietary catalyst embedded throughout the filter walls, which are about 3/4" thick (see illustration below). UltraCat Catalytic Filter Systems achieve excellent NOx removal at temperatures of 350°F and higher.
Operating range is approximately 350°F to 750°F. Aqua ammonia is injected upstream of the filters, reacting with NOx at the catalyst to form harmless nitrogen gas and water vapor, which then exits the system as clean gases.
The proprietary catalyst is highly resistant to sulfur poisoning and is protected from particulate contamination because it is embedded inside the filter walls. NOx removal is up to 95%. UltraCat Catalytic Filter Systems are also efficient at destroying dioxins, typically over 97%.
SO2, HCI, Acid Gas Control
UltraCat Catalytic Filter Systems can incorporate dry sorbent injection of hydrated lime, sodium bicarbonate, or trona for efficient dry scrubbing of SO2, HCI, HF, and other acid gases. Typical SO2 and HCI results show 90-98% removal.
Levels of mercury control can be achieved through injection of activated carbon of various formulations. Blended sorbents of hydrated lime and activated carbon can remove acid gasses, mercury and THC. Other mercury approaches are also compatible with the UltraCat.
VOC, Organic HAPS, and THC
The catalytic ceramic filters are able to eliminate a number of Volatile Organic Compounds (VOC). Many of these VOC are designated as HAPs (Hazardous Air Pollutants). Organic HAPs and THC are associated with many industrial processes. These can be removed by the embedded nano-catalyst to compliance levels while removing PM, NOx, and other pollutants at the same time. Examples and the cement and lime industries.
Organic HAPS as found in the total THC of cement emissions are broken down by the embedded catalyst. Effectiveness increases at temperatures above 400°F. Each of the seven O-HAPs designated by the PC NESHAP has different characteristics and the resulting destruction by the catalyst has been determined by lab studies corroborated by multiple pilot tests on diverse cement kilns. PM and O-HAPs (with NOx, SOx, and Hg if desired) are treated in a single system for Cement MACT compliance.