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As stack emission regulations become more and more demanding, plant facilities will often seek the lowest possible emissions to meet or exceed the newest standards. There are two options currently available to lower NOx emissions: front-end burner technology and back-end selective catalytic reduction (SCR) technology. 

Nationwide Boiler’s CataStak™ SCR system was originally tested and utilized in our boiler rental fleet, and is now offered for both rent and for sale to lower NOx on many different types of fired equipment. 

What is a CataStak™ SCR?

Nationwide Boiler developed the CataStak™, a low-temperature SCR system capable of reducing post combustion NOx emissions by as much as 95%. The CataStak SCR system consists of a single-reactor housing with low temperature catalyst and an ammonia (aqueous or anhydrous) or urea (diesel exhaust fluid) injection skid. 

How Does it Work?

The CataStak SCR system is typically located between the flue gas exhaust and the economizer. As the flue gases exit the boiler, they are routed through the ammonia injection grid to the SCR housing with DeNOx catalyst. As the gases exit the housing, the NOx is released as nitrogen and water. 

One unique feature of our CataStak SCR system is that the catalyst that we supply facilitates the reaction of NOx and ammonia, allowing the reaction to occur at a lower temperature.

Why Choose a CataStak™ SCR System?

Three key advantages of the CataStak SCR system include easy field retrofit, low operating cost, and minimum operator intervention. When installing the SCR system, there is no need to change out burner controls or the fan, providing a simple installation and a major cost savings. Additional cost savings and increased efficiency are seen due to better turndown, lower O2, and reduced motor horsepower without FGR. Lastly, the CataStak can operate independently causing less boiler trips and less interference with plant operations.

With our CataStak SCR system, Nationwide Boiler can guarantee results as low as 2½ ppm NOx @ 3% O2, which is well below all current state implementation plan levels. Being able to achieve 2½ ppm NOx will give your plant peace of mind for any future changes to emissions regulations. The CataStak delivers exceptional performance, reliability, and compliance assurance. 

With over eighteen years of experience, a 100% success rate and over 120 installations, we have more experience and satisfied customers than any other competitor for boiler SCR systems. In addition to selling the system, Nationwide Boiler is an active user of the CataStak on our rental fleet for ultra low NOx boiler requirements.

The CataStak SCR system is available as an add-on for existing and new package boilers, gas-fired turbines, refinery heaters, and for other demanding combustion applications. Contact us today to learn how you can decrease your facility’s operating costs and lower your carbon footprint with a CataStak SCR system.

 

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What Is an Economizer?

Economizers are mechanical devices intended to reduce energy consumption or perform a useful function such as preheating a fluid. In basic terms, an economizer is a heat exchanger. The orientation of an economizer can be vertical, horizontal, or cylindrical depending on boiler size and space available, and it is fitted directly to the boiler near the flue gas outlet.

How does it Work?

In a boiler system, an economizer captures the heat of the flue gas and transfers it to the feed water. The process is simple. As the flue gas exits the boiler, it enters an economizer with finned tubes. The finned tubes absorb the heat and raises the temperature of the boiler feed water, lowering the needed energy input.

Why Add an Economizer?

Adding an economizer will increase boiler efficiency by 10-12%. In addition, the reduced amount of energy required for heating results in reduced fuel consumption and cost.

Nationwide Boiler’s EconoStak Economizers

A Nationwide Boiler EconoStak consists of the economizer and all of the associated piping and structural supports required for very efficient and safe operation. It is a fabricated assembly of finned tubing that uses hot stack gases to heat the boiler feed water. The EconoStak economizer reduces stack emissions and thermal pollution, as well as provides fuel cost savings. It can be can be utilized with one of Nationwide’s trailer-mounted rental boilers, or can be purchased with a new or reconditioned boiler.

 

 

 

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One of the leading causes of poor boiler performance is improper water treatment.  Improper water treatment, or not treating your boiler water at all, can cause irreversible boiler tube damage called scaling. To avoid scaling, boiler water should be circulated through a water softener before it is fed to the boiler. A water softener removes hard water minerals, like calcium and magnesium, which can cause scaling and damage in the boiler tubes. Acting as an insulator, scale deposits can prevent proper heat transfer, decrease boiler efficiency, and lead to costly downtime and even premature boiler failure. 

The Chemical Process – Ion Exchange

Hard water contains positively charged ions, like magnesium, calcium, and iron. An ion exchange in the water softener removes the positively charged ions from the water through the use of resin beads. The resin beads that are inside the resin tank are negatively charged by brine, which contains salt and potassium. As the water  goes through the resin tank, the magnesium, calcium, and iron are chemically attracted to the negative charge of the resin beads, sticking to the resin as the water runs through the tank. This process removes majority of the “hard” minerals from the water, creating “soft” water. 

The Cleaning Process – Regeneration

Regeneration cycles are required to clean the resin beads, allowing the system to continually remove hardness from the water supply. The regeneration process, which can take roughly one to two hours, consists of flushing out the solids, drawing brine from the brine tank, and recharging the resin beads. If your softener only has one resin tank, the boiler will be supplied with hard water during the regeneration process. In a system with two tanks, the standby resin tank will become operational during regeneration of the first tank to continue the flow of soft water to the boiler.

The Bottom Line – Soft Water Supply

It is important to supply your boiler with soft water at all times to avoid damage and costly repairs. Water softening, when combined with a reliable water treatment chemical program and blowdown schedule, can lead to many years of reliable boiler system performance.

Nationwide Boiler has installed duplex water softening systems in all of our mobile boiler rooms, mobile steam plants, and mobile feedwater systems to ensure optimal boiler performance 24/7. We also have larger skid-mounted, stand-alone water softeners available for rent or for purchase. For more information on products and services available, visit our website at www.nationwideboiler.com.

 

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Nationwide Boiler recently completed production of the world's first 1,000 hp mobile boiler room, designed at 290 psig for a larger range of operating pressures. We are proud of this collaborative effort between Nationwide Boiler and Superior Boiler Works, which came about in response to customer requests for a larger capacity and small footprint.

For an inside look at this unique piece of equipment, check out our latest video!

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