Numerical Study on the Staged SCR Catalyst for Marine Exhaust After-Treatment

This study numerically investigates the NO removal performance of a staged catalyst substrate employed in an industrial marine after-treatment system. The computational domain is based on the lab-scale experimental device used for measuring pressure drop, serving as a digital twin to accurately reproduce the staged catalyst configuration prior to its application in full-scale industrial reactors. Experiments were conducted to estimate the parameters for a porous model, employed for efficient computation of flow and reactive mass transfer inside the catalyst substrate without needing a complex computational mesh of the monolith structure. A reaction mechanism from the literature was modified and verified for marine SCR reactors. The three-dimensional numerical simulations in this study indicate that the NO removal in the staged catalyst substrate varies depending on the catalyst configuration, primarily due to differences in the upstream flow uniformity. This study demonstrates that relocating a single catalyst substrate to the downstream position improved conversion by 6.5 percentage points, while a two-stage catalyst configuration yielded a 15.5 percentage-point increase under identical exhaust conditions. In addition, the residence time exhibited significant variations depending on the catalyst arrangement and inlet velocity, highlighting it as a critical parameter governing NO reduction performance. The findings in the present study can serve as a reference for future analyses conducted under practical conditions in industrial-scale marine SCR systems.