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This list presents you with an opportunity to review additional Frequently Asked Questions and select those that you would like PCA, Inc. to contact you about.  We would like to serve you by answering them. All that is needed is to fill out the contact information below and then which questions are of interest.

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FAQs:

  • To see the commonly asked questions for Catalysts, click here.
  • To see the commonly asked questions for Enclosures and Silencers, click here.

                               Catalysts

1. I have both diesel and natural gas fired engines. Is there any difference in the air pollution control catalysts for these engines?
2.

What exactly do catalysts do to reduce pollution?

3.

Does the catalytic material get used up during use? How fast?

4.

What are the differences between 2-way VOC and 3-way NSCR catalysts and air pollution control catalysts?

5.

Don’t all catalyst manufacturers use the same chemical technology? Is there any difference in performance?

6.

How long should a catalyst last?

7.

How often should I wash a catalyst? Is there a limit to the number of washes before a catalyst needs to be replaced?

8.

Why is precoated catalyst material used by many companies inferior to the PCA product?

9.

Can I wash my own air pollution control catalysts?

10.

What are the problems created by improper washing?  What is the correct way?

11.

My catalyst catches a lot of soot. What can I do?

12.

Will a CO catalyst reduce NOx?

13.

What can I do if my lean burn engine will not meet CO permit levels?

14.

Can I have a damaged catalyst rewound? What are the tradeoffs to purchasing a new one instead?

15.

My catalyst disintegrated when the engine backfired. Is it dangerous to handle the pieces of foil laying all over the yard?

16.

What chemicals damage a catalyst? How do I know if they are present? Is the damage permanent?

17.

Why do different manufacturers make different shapes for the same purpose? Is there any difference between round, octagon, square or oval air pollution control catalysts?

18.

What can be done to prevent telescoping due to engine backfire?

19.

I notice that some of my elements develop gaps in the face of the catalyst? What can I do to prevent or cure this?

20.

Why are there partial gaps on one face of the catalyst and not the other? What can I do to prevent or cure this?

21.

What is the minimum, maximum exhaust gas temperature for an air pollution control catalysts?

22.

Can I estimate catalyst conditions by measuring the temperature of the exhaust gases before and after they enter the element? How long should I let the catalyst run before I take my measurements?

23.

What gasket material should I use? Is one style such as loose pack, flat, woven, single tadpole, double tadpole better than another?

24.

What is destruction efficiency?

25.

What is “Gas Hourly Space Velocity?” Why is it important? How do I calculate it? How much is too much or too little?

26.

Where do I find the information about the raw exhaust gas CO, NMHC and other components of the engine exhaust?

27.

Does the operating point (bhp) and rpm affect engine emission levels?

28.

How do I calculate the right size of catalyst?

29.

How do I convert actual cubic feet per minute to standard cubic feet per minute? Why is this important?

30.

Where do I find the amount of pollutants an engine creates?

31.

What can I do about special chemicals in the exhaust, such as formadehyde?

32.

Some manufacturers list one catalyst size for every engine. Is this OK?

33.

How does the “CPSI” or cells per square inch specification affect catalyst performance? Life? Aren’t more cpsi always better?

34.

What happens if I oversize or undersize a catalyst?

35.

Catalysts produce exhaust ‘backpressure.’ Is this a problem?

36.

I am putting an engine into storage. Does the catalyst require any special care?

37.

I am doing a major engine overhaul. Can I leave the catalyst in place?

38.

Some catalyst housings are made of stainless steel, others use carbon steel? Is there any performance difference in the two materials?

39.

The catalyst is stuck in the housing and I can’t pry it loose. What can I do?

40.

Can I run a catalyst without a fuel-air ratio controller?

41.

What does a fuel-air ratio controller do?

42.

What are the minimum/maximum oxygen limits in the exhaust gases so the catalyst will operate properly? Is any special setting best?

43.

I have two catalysts that seem to be the same size. One weighs a lot more than the other. What is going on here?

44.

I have a damaged catalyst. How do I dispose of it? Is it worth anything?

45.

I am told I don’t have enough catalyst to meet permitting requirements. Which is a better approach: use two catalysts in series or a larger one?

46.

Some manufacturers buy precoated honeycomb catalyst beds and wind this material into a catalytic element. What are the pro’s and con’s of this approach?

47.

My round catalyst has a 4” diameter metal plug in the middle. Other companies do not provide this plug. Why is the plug there? Do I need it?

48.

It looks like someone poked a hole in my catalyst with a screwdriver or something. Can I plug up this hole and use the element?

49.

Can catalysts be mounted horizontally or vertically? Will I encounter any problem when I mount one way or the other?

50.

Do catalysts have a direction for gas flow?

51.

Do turbine prime movers need catalysts? Please explain? Why do some solutions inject ammonia into the exhaust stream before the catalyst?

52.

My new catalyst just failed testing.  What can I do?

53.

Can I get a guarantee on the performance of the catalyst? Is there any fine print I need to read?

54.

The pre and post catalyst emissions read almost the same. What has happened?

55. I smell ammonia when I start up my natural gas engine.  When it warms up, the smell goes away?  What is happening?  What can be done to eliminate it?
56. Is there are gas velocity consideration when sizing catalysts?
57. Someone told me that ceramic monoliths can operate at higher temperatures than metal monoliths.  Is this true? 
58. Why do my catalysts only last a few months or burn up…  
59. Engine raw emissions unstable ----- fuel?, maint, no or maladjusted farc)
60. Can I rinse my elements with a hose? 
61. Is there a weight limit for catalysts?
62.  My round catalyst has a solid metal plug or plate in the middle. What is this for?
63. Why is your catalyst product better than others?  
64. WHAT IS YOUR QUESTION? Use the contact PCA tool to send an email.

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                              Enclosures and Silencers

1.

Do all ‘rated’ silencers provide the same performance? Aren’t all ‘industrial’, ‘critical’, ‘residential’ and ‘hospital grade units the same

2.

What is the maximum temperature where I can use a carbon steel housing? Why?

3.

What is “DIL”  Why is it important?

4.

What is the difference between dBA and dB?

5.

What is the difference in ‘sound pressure level’ and ‘sound power level’? Does it matter?

6.

What is self noise? How can I control it?

7.

What is Breakout noise? How can I control it?

8.

Should silencers be insulated to insure proper temperature for catalyst operation?

9.

What is the drain for?

10.

How tightly should I torque the catalyst retaining hardware?

11.

What is the function of an explosion relief valve? Where should I put it”?

12.

Are there some features that make some silencers / enclosures better than others?

13.

How should I specify a silencer?  What are the most common errors?

14.

Should I be concerned about backpressure?  How much should I allow?

15.

Is an angle/mitre/whistle cut exit stack better than a flat cut top?

16.

The paint on my unit burned off on the first day? What happened?

17.

Do I need an expansion joint next to the silencer or enclosure?

18.

Can the end flanges support the silencer or do I need to provide additional support?

19.

What are the relative benefits of the different mounting styles?

20.

What do the different ‘types’ such as Type 3 mean?

21.

What type of sensors should I use to measure temperature or pressure? Are there any mounting considerations?

22.

When I start up a new system, should I remove the catalyst for a while?  How long can I run without the catalyst

23.

Why should I care?

24.

WHAT IS YOUR QUESTION? Use the contact PCA tool to send an email.

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