Ultra-Low Temperature Catalyst: Unlocking Green Solutions for Industrial NOx Control

Introduction: The Urgent Need for Low-Temperature Denitrification

With global attention on sustainability and clean energy, reducing nitrogen oxides (NOx) emissions has become a key environmental priority. Traditional denitrification systems struggle to operate efficiently at low temperatures, especially in non-power industries. The emergence of ultra-low temperature catalysts presents a groundbreaking solution that allows effective NOx removal at 130–150°C, eliminating the need for expensive flue gas reheating.

What Is an Ultra-Low Temperature Catalyst?

An ultra-low temperature catalyst is a specially developed material that enables Selective Catalytic Reduction (SCR) of NOx at lower operating temperatures. Unlike conventional vanadium-titanium catalysts that require temperatures above 180°C, these new-generation catalysts can function efficiently in flue gas environments as low as 130°C.

Key Features:

• High dispersion of active components on porous carriers

• Enhanced adsorption of ammonia and nitrogen oxides

• Lower activation energy for denitrification reactions

• Customizable metal oxide systems to resist flue gas poisoning (e.g., sulfur, alkali metals)

Why Traditional SCR Systems Fail in Low-Temperature Scenarios

Industries such as waste incineration, biomass energy, steel sintering, and industrial kilns typically operate with low flue gas temperatures after desulfurization and dust removal. Standard catalysts underperform in these conditions, leading to increased energy consumption for gas reheating. For example:

• A 750t/d waste incinerator using traditional catalysts requires up to $8 million/year in heating costs.

• Steel sintering plants using preheating methods see additional emissions of up to 70,000 tons of CO2 annually.

Application Scenarios of Ultra-Low Temperature Catalysts

1. Waste Incineration

• Post-treatment flue gas temperature: 130–150°C

• Ultra-low temperature catalysts operate directly without reheating

• Reduces investment by 15% and eliminates heating costs

2. Biomass Boilers

• Highly variable fuel and low flue gas temperatures (130–150°C)

• Ideal for replacing SNCR systems and meeting stricter NOx limits (<50mg/Nm3)

• No need to alter original systems

3. Industrial Kilns

• Flue gas temperatures typically range from 120–180°C

• Enhances heat utilization and decreases carbon emissions

• Achieves <50mg/Nm3 NOx levels with minimal ammonia slip

4. Natural Gas Boilers

• Original emissions control methods (like low-NOx burners) reduce system efficiency

• Ultra-low temperature SCR units achieve <30mg/Nm3 NOx without energy loss

• Cuts annual fuel cost by millions for 50t boilers

Key Benefits for Industry and Environment

Reduced Energy Costs

• Operates without reheating: up to 50% energy savings

• Example: Steel sintering projects save 30–40% on yearly operational costs

Enhanced Environmental Performance

• Low-temperature operation reduces CO2 emissions

• Achieves high NOx removal rates (>90%)

• Minimizes ammonia slip and secondary pollution

Economic Efficiency

• Simplified process integration reduces capital investment

• Long catalyst life and low maintenance enhance ROI

Overcoming Technical Challenges

A major hurdle in low-temperature catalyst development is resistance to poisoning from sulfur and alkali metals. Research institutions and leading manufacturers have tackled this by:

• Optimizing catalyst compositions and carriers

• Improving mechanical strength and durability

• Validating long-term performance under industrial conditions

Case Study: Yuanchen Technology's Market Leadership

Yuanchen has achieved remarkable success in ultra-low temperature catalyst development:

• Ranked 3rd nationally in 2022 with 25,000m³ SCR catalyst production, worth 320 million CNY

• Holds 50% provincial and 20.2% national market share in medium-low temperature SCR catalysts for steel sintering

• Successful applications in hazardous waste incineration and coking industries

• New innovations in CO catalysts with layered coating design and composite materials

Future Outlook

The need for green, efficient NOx control will only grow. Ultra-low temperature catalysts are poised to:

• Expand to cement, chemical, and building materials industries

• Benefit from advances in nanomaterials and surface chemistry

• Play a key role in achieving carbon neutrality and emission reduction targets