SCR Dual-Reactor Evaluation Unit

The XINYU HUACHUANG SCR Dual-Reactor Evaluation Unit is an advanced laboratory system engineered for precise selective catalytic reduction (SCR) testing. Featuring a dual-channel parallel design, it allows simultaneous evaluation of different catalyst batches under identical conditions. Equipped with intelligent PLC control and high-precision mass flow controllers, it accurately simulates industrial flue gas compositions, providing highly reproducible data for NOx conversion efficiency and ammonia slip analysis.

Working Principle

SCR Dual-Reactor Evaluation Unit operates by simulating actual industrial exhaust conditions. A simulated flue gas mixture (NO, Nh2, O2, N2, and H2O) is generated and precisely metered via mass flow controllers. The gas stream is then preheated and directed into two independent, parallel reactor channels. Inside the reactors, the SCR catalyst facilitates the reduction of NOx into harmless nitrogen (N2) and water (H2O). An advanced online analysis system (such as FTIR or chemiluminescence detectors) continuously monitors the gas composition at the inlet and outlet of each reactor, automatically calculating NOx conversion rates and ammonia escape rates in real-time.

Key Advantages

● High-Efficiency Parallel Testing: The dual-reactor design doubles testing throughput, allowing direct and intuitive comparison of different catalysts under identical parameters, saving time and costs.

● Precise Parameter Control: High-precision mass flow controllers and multi-zone heating systems ensure accurate control of temperature (±1℃), gas flow rates, and ammonia-to-nitrogen ratios.

● Comprehensive Performance Evaluation: Capable of testing critical metrics including NOx conversion efficiency, ammonia slip, N2O generation rate, and SO2/SO3 conversion.

● Intelligent Automation: PLC-PC integrated control enables automated data logging, historical curve generation, and unattended long-term operation.

● Robust & Safe Design: Reactors are constructed from high-temperature, corrosion-resistant materials (e.g., Quartz or SS316L), featuring multi-level safety interlocks for over-temperature and over-pressure protection.

Technical Specifications

Where It Is Used ?

● Power Generation: Performance evaluation of SCR catalysts for coal-fired, gas-fired, and biomass power plants.

● Automotive & Marine: Testing DeNOx catalysts for diesel engine exhaust, marine engine SCR systems, and non-road mobile machinery.

● Industrial Emissions: Catalyst screening for cement kilns, steel mills, waste incineration, and chemical processing plants.

● R&D & Academia: Fundamental kinetic research, catalyst formulation optimization, and poisoning/deactivation studies.

Usage Precautions

● Gas Safety: Always ensure gas cylinders are securely fastened and leak-tested before operation. Nh2 and NO are toxic gases; operate in a well-ventilated area or fume hood.

● Heating Sequence: Always purge the reactors with inert gas (N2) before heating. Never heat the system without gas flow to prevent catalyst damage or reactor overheating.

● Cooling Down: After testing, allow the system to cool down naturally with gas flowing. Do not force-cool with water or open the furnace while at high temperatures.

● Condensation Prevention: When testing with water vapor, ensure the sampling lines and exhaust pipes are heated/insulated to prevent condensation and corrosion.

Maintenance Guide

● Daily: Check gas cylinder pressures, verify MFC readings, and inspect exhaust gas treatment systems (e.g., scrubbers) to ensure safe emission.

● Weekly/Monthly: Clean or replace gas filters and moisture traps. Inspect reactor seals and tubing for any signs of corrosion or leaks.

● Quarterly: Calibrate mass flow controllers and temperature sensors to maintain testing accuracy. Check electrical connections in the PLC cabinet for tightness.

● Catalyst Handling: Carefully load and unload catalysts to avoid crushing or generating dust, which can alter bed pressure drop and affect testing accuracy.

After-Sales Service & Support

At XINYU HUACHUANG, we are committed to providing comprehensive and reliable after-sales support to ensure the continuous and efficient operation of your equipment. Our dedicated service team is always ready to assist you.

Comprehensive Warranty Coverage

We proudly offer a two-year warranty for our equipment. During this period, we provide free maintenance and repair services for any quality-related issues, excluding those caused by improper operation, unauthorized modifications, or force majeure. For equipment beyond the two-year warranty period, we continue to offer lifelong maintenance services, charging only the cost of replacement parts and labor.

Rapid Response Mechanism

We offer 7×24 hours professional engineering telephone support. Upon receiving a fault notification, our technical team will respond within 24 hours and provide a viable solution. If on-site service is required, our professional engineers will arrive at your facility within one week. In special circumstances where the equipment cannot be repaired, we will unconditionally replace it with a new unit or provide a substitute unit during the two-year warranty period, or take necessary measures to restore normal operation.

Frequently Asked Questions

Q1: What is the primary advantage of the dual-reactor design in this evaluation unit?

A: The dual-reactor configuration allows for simultaneous testing of two different catalysts or two different operating conditions under identical gas environments. This parallel testing eliminates variables, significantly accelerating the screening process and providing highly accurate comparative data for catalyst optimization and performance benchmarking.

Q2: Can this unit simulate complex real-world flue gas conditions, such as those containing sulfur dioxide and water vapor?

A: Yes, absolutely. The unit is equipped with precision mass flow controllers (MFCs) and specialized vaporization systems that can accurately introduce complex gas mixtures. It is specifically designed to evaluate catalyst anti-poisoning performance and long-term stability in harsh environments containing SO₂, H₂O, alkali metals, and dust.

Q3: How does the Industrial PLC + PC Software control system ensure the accuracy of the evaluation data?

A: The unit utilizes an advanced Industrial PLC + PC Software architecture to achieve fully automated control of heating, gas flow, and data logging. The PLC employs PID adaptive algorithms to maintain temperature fluctuations within ±1℃, while the PC software continuously records real-time inlet/outlet gas concentrations. This significantly reduces manual errors and ensures highly reproducible, reliable data for calculating NOx conversion efficiency and ammonia slip.

Q4: What types of SCR catalysts can be tested using this evaluation unit?

A: The unit is highly versatile and can accommodate various catalyst forms, including honeycomb, plate, and corrugated types, as well as powder or particle samples. The modular reactor design and customizable fixturing allow for quick changeovers, making it suitable for testing everything from laboratory-scale fresh catalysts to full-size industrial monoliths.

Q5: Is it possible to integrate online gas analysis instruments for real-time performance monitoring?

A: Yes. The SCR Dual-Reactor Evaluation Unit is designed with comprehensive data acquisition interfaces to seamlessly integrate with online analyzers such as FTIR (Fourier Transform Infrared Spectroscopy), CLD (Chemiluminescence Detectors), or Gas Chromatographs. This integration enables real-time, high-frequency monitoring of NOx, NH₃, and N₂O concentrations, instantly calculating conversion rates and selectivity to accelerate your R&D cycles.