Selective catalytic reduction process and off-line regeneration of deactivated catalyst of the process

1. A process for selective catalytic reduction of nitrogen oxides contained in a gas stream and off-line regeneration of nitrogen oxide removal catalyst, wherein the process comprises:

introducing a processed flue gas stream, containing nitrogen oxides and sulfur compounds, into a contacting zone defined by an SCR system that is integrated within a flue gas treating system, wherein the contacting zone contains an SCR catalyst, and contacting the processed flue gas stream with the SCR catalyst for a time sufficient to provide a deactivated SCR catalyst that is deactivated by sulfur compounds, and while contacting the processed flue gas stream with the SCR catalyst, yielding from the SCR system a denitrified flue gas stream for discharge into a stack;

discontinuing the introducing step to the SCR system having the deactivated SCR catalyst;

removing the deactivated SCR catalyst from the SCR system to provide removed SCR catalyst; and

regenerating off-line from the flue gas treating system the removed SCR catalyst to provide a regenerated SCR catalyst, wherein the regenerating step comprises passing at a flow rate a regeneration gas over the removed SCR catalyst under regeneration conditions to yield a regeneration effluent gas containing SOx and ammonia, recirculating at a circulation rate at least a portion of the regeneration effluent gas over the removed SCR catalyst, and passing a remaining portion of the regeneration effluent gas from the removed SCR catalyst.

2. The process as recited in claim 1 , comprising isolating of the SCR system by by-passing the processed flue gas stream around the SCR system as a by-pass stream and passing the by-pass stream to the stack before removing the deactivated SCR catalyst from the SCR system.

3. The process as recited in claim 2 , comprising:

discontinuing the step of re-introducing the processed flue gas stream into the contacting zone by isolating the SCR system having the spare SCR catalyst;

removing the spare SCR catalyst from the SCR system and replacing therewith the regenerated SCR catalyst; and

thereafter, re-introducing the processed flue gas stream into the contacting zone of the SCR system containing the regenerated SCR catalyst.

4. The process as recited in claim 3 , wherein the isolating of the SCR system having the spare SCR catalyst includes by-passing the processed flue gas stream around the SCR system as a second by-passed stream and passing the second by-pass stream to the stack before removing the spare SCR catalyst from the SCR system; and, wherein after replacing the spare SCR system with the regenerated SCR catalyst, discontinuing the by-passing step.

5. The process as recited in claim 1 , further comprising:

introducing heat energy into the at least a portion of the regeneration effluent gas to thereby control a regeneration temperature of the regeneration gas.

6. The process as recited in claim 5 , further comprising:

measuring the flow rate of the regeneration gas to provide a measured flow rate and comparing the measured flow rate against a desired flow rate to provide a differential flow rate; and

adjusting the flow rate in response to the differential flow rate.

7. The process as recited in claim 6 , further comprising:

measuring the circulation rate of at least a portion of the regeneration effluent gas to provide a measured circulation rate and comparing the measured circulation rate against a desired circulation rate to provide a differential circulation rate; and

adjusting the circulation rate in response to the differential circulation rate to maintain the recirculation of at least a portion of the regeneration effluent gas at the desired circulation rate.

8. The process as recited in claim 7 , further comprising:

discontinuing the passing of the regeneration gas the removed SCR catalyst after a sufficient time period to provide the regenerated catalyst.

9. The process as recited in claim 1 , further comprising:

introducing heat energy into the regeneration gas to thereby control a regeneration temperature of the regeneration gas.

10. The process as recited in claim 1 , comprising replacing the deactivated SCR catalyst with spare SCR catalyst, and thereafter re-introducing the processed flue gas stream into the contacting zone and contacting the processed flue gas stream with the spare SCR catalyst.

11. A process for selective catalytic reduction of nitrogen oxides contained in a gas stream and off-line regeneration of nitrogen oxide removal catalyst, wherein the process comprises:

providing within a flue gas treating system an inlet conduit configured to carry a processed flue gas stream, containing nitrogen oxides and sulfur compounds, from an upstream treating unit of the flue gas treating system to an SCR system and an outlet conduit configured to carry a denitrified flue gas stream from the SCR system of the flue gas treating system for discharge into a stack;

wherein the SCR system defines a contacting zone containing modules of SCR catalyst, and wherein the SCR system has an upstream inlet for receiving the processed flue gas stream and a downstream outlet for discharging from the contacting zone the denitrified flue gas stream, and wherein the modules of SCR catalyst are removable from the SCR system;

introducing the processed flue gas stream from the inlet conduit through the upstream inlet into the contacting zone and contacting the processed flue gas stream with the SCR catalyst of the modules of SCR catalyst for a time sufficient to provide a deactivated SCR catalyst that is deactivated by sulfur compounds, and while introducing the processed flue gas stream into the contacting zone, yielding from the contacting zone the denitrified flue gas stream through the downstream outlet for discharge into the outlet conduit;

discontinuing the step of introducing the processed flue gas stream into the contacting zone containing modules of deactivated SCR catalyst;

opening the SCR system and removing the modules of deactivated SCR catalyst from the contacting zone, replacing the removed modules of deactivated SCR catalyst with replacement modules of SCR catalyst, and thereafter closing the SCR system;

re-introducing the processed flue gas stream through the inlet conduit and into the contacting zone containing the replacement modules of SCR catalyst; and

regenerating off-line from the flue gas treating system the deactivated SCR catalyst of the modules of deactivated SCR catalyst to provide modules of regenerated SCR catalyst, wherein the regenerating step comprises passing a regeneration gas over the deactivated SCR catalyst under regeneration conditions to yield a regeneration effluent gas containing SOx and ammonia, and recirculating at least a portion of the regeneration effluent gas over the deactivated SCR catalyst.

12. The process as recited in claim 11 , wherein the inlet conduit further includes interposed inlet damper means for stopping and controlling flow of the processed flue gas stream, and wherein the outlet conduit further includes interposed outlet damper means for stopping and controlling flow of the denitrified flue gas stream, and wherein the isolating of the SCR system includes stopping the passing of the processed flue gas stream into the contacting zone, stopping the yielding from the contacting zone the denitrified flue gas stream, and by-passing the processed flue gas stream around the SCR system as a by-pass stream and passing the by-pass stream to the stack before removing the modules of deactivated SCR catalyst from the contacting zone; wherein after replacing the modules of deactivated SCR catalyst with the replacement modules of SCR catalyst, thereafter discontinuing the by-passing of the processed flue gas stream around the SCR system.

13. The process as recited in claim 12 , further comprising:

discontinuing the step of re-introducing the processed flue gas stream into the contacting zone by isolating the SCR system having the replacement modules of SCR catalyst;

removing the replacement modules of SCR catalyst from the SCR system and replacing therewith modules of regenerated SCR catalyst; and

thereafter, re-introducing the processed flue gas stream into the contacting zone of the SCR system containing the modules of regenerated SCR catalyst.

14. The process as recited in claim 13 , wherein the isolating of the SCR system having the replacement modules of SCR catalyst includes stopping the passing of the processed flue gas stream into the contacting zone, stopping the yielding from the contacting zone the denitrified flue gas stream, and by-passing the processed flue gas stream around the SCR system as a by-pass stream and passing the by-pass stream to the stack before removing the modules of replacement modules of SCR catalyst from the contacting zone; wherein after replacing the replacement modules of SCR catalyst with the modules of regenerated SCR catalyst, thereafter discontinuing the by-passing of the processed flue gas stream around the SCR system.

15. A process for selective catalytic reduction of nitrogen oxides, comprising:

introducing a processed flue gas stream, containing nitrogen oxides and sulfur compounds, into a contacting zone defined by an SCR system that is integrated within a flue gas treating system, wherein the contacting zone comprises an SCR catalyst configured to remove the nitrogen oxides contained in the processed flue gas stream and to generate a denitrified flue gas stream;

contacting the processed flue gas stream with the SCR catalyst for a time sufficient to provide a deactivated SCR catalyst; and

regenerating the deactivated SCR catalyst to provide a regenerated SCR catalyst, wherein the regenerating step comprises passing a regeneration gas over the deactivated SCR catalyst under regeneration conditions to yield a regeneration effluent gas containing SOx and ammonia, recirculating at least a portion of the regeneration effluent gas over the deactivated SCR catalyst, and passing a remaining portion of the regeneration effluent gas from the deactivated SCR catalyst.

16. The process as recited in claim 15 , wherein a temperature of the regeneration gas is between 220° C. and 500° C.

17. The process as recited in claim 15 , comprising measuring a flow rate of the regeneration gas to provide a measured flow rate, comparing the measured flow rate against a desired flow rate to provide a differential flow rate, and adjusting the flow rate in response to the differential flow rate.

18. The process as recited in claim 15 , comprising measuring a circulation rate of the portion of the regeneration effluent gas to provide a measured circulation rate, comparing the measured circulation rate against a desired circulation rate to provide a differential circulation rate, and adjusting the circulation rate in response to the differential circulation rate to maintain the recirculation of the portion of the regeneration effluent gas at the desired circulation rate.

19. The process as recited in claim 15 , wherein the deactivated SCR catalyst is regenerated off-line.

20. The process as recited in claim 15 , comprising discontinuing a flow of the processed flue gas into the contacting zone of the SCR system after the time sufficient to provide the deactivated SCR catalyst and before the regeneration step.