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Simple Operation Specifically Engineered for Non-Utility Power Generation


ultra-5 diagramFuel Tech’s ULTRA-5® process is a patented approach that converts safe urea reagent to ammonia for use on small Selective Catalytic Reduction (SCR) systems for NO x emission control. Our ULTRA-5 technology offers a cost effective, simple solution for providing on–site ammonia generation of 0 – 5 lbs per hour from industrial grade aqueous urea for SCR applications of all types. From package boilers to combined heat and power (CHP) facilities, our urea based technology may be applied to new and retrofit SCR systems on all combustion processes.

Whether it is a new CHP plant to provide local energy or retrofit of a peaking turbine to reduce emissions, SCRs are a proven technology for NOx control. Many of these small SCR applications require 5 lbs per hour of ammonia or less and may be located indoors. Up until now, anhydrous ammonia in bottles or 19% aqueous ammonia systems has been used for the SCR reagent feed. The storage of ammonia in these confined spaces creates potential hazards from noxious fumes and fire hazards should leaks occur.

The urea employed in the ULTRA-5 process is a benign chemical that can be stored and utilized safely in place of ammonia reagent feed and storage systems.


ULTRA-5 installedThe ULTRA-5 process generates low pressure, dilute ammonia for SCR systems by thermally decomposing urea. The diluted ammonia is fed through the ammonia injection grid (AIG) to the SCR. Our process controls ammonia generation by metering aqueous urea into a decomposition chamber. The generation rate responds rapidly to SCR demand based on urea flow rate. In addition, upon shut down of urea flow, all ammonia is purged out of the system in less than seven seconds.



ULTRA-5 systems are simple, consisting of a blower or hot gas, electric heat source, decomposition chamber, and urea metering and process controls.



Problems with Other Urea Conversion Systems

Most urea-to-ammonia conversion systems on the market work by hydrolyzing urea. These processes often require higher priced specialty solutions, are complex and operate under high pressures and require significant steam consumption. These systems must shutdown for maintenance due to internal buildup or incorporate a volatile ammonia-laden “blowdown” system that requires disposal.

The ULTRA-5™ process thermally decomposes urea and does not involve hydrolysis. Since the ULTRA-5 process operates at temperatures in the range of 550 to 1,000°F, all of the outlet products are above the 450°F temperature where urea polymers typically start to form. This 400 to 450°F temperature zone appears to be in the range of normal operation of hydrolytic systems, which may contribute unwanted polymerized formaldehyde by-products and frequent maintenance outages.


The ULTRA-5 system is an economical and easy method to generate ammonia at low pressure.

Related Documents

ULTRA-5™ Brochure