Modeling Deactivation of Catalysts for Selective Catalytic Reduction of NOx by KCl Aerosols

A detailed model for the deactivation of a V₂O₅–WO₃/TiO₂-based SCR monolith catalyst by potassium poisoning has been developed and validated. The model accounts for deposition of KCl aerosol particles present in the flue gas on the external catalyst surface, the reaction of the deposited particles with the catalyst at the surface of the monolith wall, the transport and accumulation of potassium, bound to Brønsted acid sites, throughout the catalyst wall, and the resulting loss in SCR activity. Using an experimentally measured KCl aerosol size distribution as input, the model can replicate the observed deactivation rate of a 3 wt % V₂O₅-7 wt % WO₃/TiO₂ monolith catalyst, exposed to a KCl aerosol at 350 °C for about 1000 h, as well as the resulting potassium-to-vanadium molar ratios in the catalyst wall. Simulations show that the particle deposition rate, as well as the deactivation rate, decreases if the particle size of the incoming aerosol is increased. The model provides, for the first time, a mechanistic framework for understanding and modeling SCR catalyst deactivation by KCl that may be applicable also for deactivation by other salts and at different operating conditions.