Monitoring ammonia slip from large-scale selective catalytic reduction (SCR) systems in combined heat and power generation applications with field effect gas sensors

Abstract

Abstract. Following tightened regulations, selective catalytic reduction (SCR) of nitrogen oxides (NOx) by ammonia (NH3) has over the last couple of decades found wider adoption as a means of reducing NOx emissions from e.g. power production and district heating plants. As in the SCR process NH3 injected into the flue gas reacts with and reduces NOx to nitrogen (N2) and water (H2O) on the surface of a specific catalyst, the NH3 injection has to be dynamically adjusted to match both instant and long-term variations in flue gas nitrogen oxide concentration in order to minimize NOx and NH3 emissions. One possibility of realizing such NH3 dosing control would be the real-time monitoring and feedback of downstream flue gas NOx and NH3 concentrations to the NH3 injection control unit. In this study the sensing characteristics and performance of SiC-based Metal Oxide Semiconductor Field Effect Transistor (MOSFET) sensors with a structurally tailored gas-sensitive gate contact of iridium (Ir) for in situ NH3 monitoring downstream from the SCR catalyst in a combined heat and power (CHP) plant have therefore been investigated and evaluated. The sensor's NH3 sensitivity and selectivity as well as the cross-sensitivity to common flue gas components – oxygen (O2), water vapour (H2O), nitric oxide (NO), nitrogen dioxide (NO2), carbon monoxide (CO), and a model hydrocarbon, ethene (C2H4) – were thereby investigated for relevant concentration ranges under controlled conditions in the laboratory. While, at the prescribed sensor operation temperature of 300 ∘C, the influence of H2O, CO, and C2H4 on the sensor's NH3 concentration reading could be regarded as practically insignificant, a moderate cross-sensitivity was observed between NH3 and NO2 and, to a lesser extent, between NH3 / NO and NH3 / O2. As the NOx concentration downstream from the SCR catalyst under normal SCR and power plant operation is expected to be considerably smaller than the NH3 concentration whenever any appreciable ammonia slip occurs, the observed NH3 / NOx cross-sensitivities may, however, be of less practical significance for ammonia monitoring in real flue gases downstream from the SCR catalyst. Furthermore, if required, the small influence of O2 concentration variations on the sensor reading may also be compensated for by utilizing the signal from a commercially available oxygen sensor. Judging from in situ measurements performed in a combined heat and power plant, the structurally tailored Ir gate field effect sensors also exhibit good NH3 sensitivity over the relevant 0–40 ppm range when directly exposed to real flue gases, offering an accuracy of ±3 ppm as well as low sensor signal drift, the latter most likely to further improve with regular zero-point calibration and thereby make the Ir gate MOSFET ammonia sensor a promising alternative for cost-efficient real-time ammonia slip monitoring or SCR system control in heat and/or power production plants.