# Dry Sorbent Injection

for SO

2 

# , SO

3 

# , Hg and HC l

# Dry Sorbent Injection

Our experience, technology and customer support set

UCC apart from other suppliers. UCC ensures optimum

plant performance through sophisticated predictive

modeling for the injection grid design, on-site testing

to validate sorbent type and injection rate, and proactive

lab testing and evaluation of the effects on existing ash

handling systems. UCC offers the expertise, confidence

and single point accountability our customers expect in

dry sorbent injection systems.

•	Performance-based turnkey solutions

•	Over 25,000 hours of DSI demonstration testing

•	VIPER TM mill technology delivers the highest

removal efficiency and greatest cost savings Utilities are actively evaluating various technologies and strategies to comply with EPA emissions

regulations. Removal efficiency, capital and operating cost, plant life, outage requirements,

scalability and impact on existing air pollution control (APC) equipment are typical considerations

and trade-offs. Many plants have determined that Dry Sorbent Injection (DSI) delivers a simple,

low cost solution to effective pollution control for their environmental fleet planning.

Since 2004, United Conveyor Corporation (UCC) has pioneered dry sorbent injection technology

which injects selected sorbents into the flue gas to control SO

2 , SO

3 , mercury and HCI. UCC leads

the industry in demonstration testing and is recognized as the technology leader that delivers

system performance and confidence to our customers. Our experience removes the guesswork

and we work closely with customers to deliver a reliable solution to each plant’s specification.



# UCC Advantage Many plants are looking for a single, comprehensive solution for the removal of

pollutants required by EPA MATS and CSAPR/CAIR regulations. Determining factors

include complex chemistry, fluid dynamics, sorbent selection, injection location and

interaction with existing APC equipment such as ACI systems, fuel additives and

fabric filter / ESP collection. UCC has extensive experience with simultaneous SO

2 ,

SO

3 , HCI and Hg removal to deliver comprehensive compliance strategies in a timely

and economical manner. 

# Multi-Pollutant Control Capability

UCC is committed to innovation and technology that deliver performance

advantages in our dry sorbent injection systems. Continuing efforts focus on

particle dispersion to improve removal efficiency, elimination of plugging

and system design practices that drive operational reliability.



## •	Splitters

The UCC design is optimized and tested for even sorbent distribution

and high removal efficiency while minimizing the risk of plugging.



## •	Injection Lances

The unique UCC design maximizes particle dispersion and eliminates

plugging with no impact on pressure drop.



## •	CFD Modeling

UCC specializes in Computational Fluid Dynamic (CFD) modeling of

plant duct flows to predict and enhance sorbent distribution in flue gas,

thereby maximizing performance and minimizing sorbent usage. 

# Innovation 

# •	Hydrated Lime

• T rona

•	Sodium Bicar b onate

• A ctivated C ar b on

• O t h er M ercury Sor b ent s

# On-Site Test and Demonstrations

UCC has conducted over 65 full-scale demonstration

tests and has over 25,000 hours of experience. This is

the most hands-on, practical experience in the industry

and provides clear differentiation in a crowded market.

UCC test experience includes a strong technical

understanding of SO

2 , SO

3 , HCI and Hg removal and

any multi-pollutant combination.

Our fleet of mobile test equipment incorporates the

latest injection and milling technology and is fully

automated to generate reliable, high quality data.

This unique capability provides the answers our

customers need to make critical compliance decisions. Full-scale, on-site demonstration testing is used to validate the plant’s compliance strategy

and optimize the overall performance of the DSI system. Utilities understand the need to

report compliance decisions to shareholders, and therefore require experienced planning,

execution and professional reporting of demonstration tests.

Every boiler unit is unique and emissions are influenced by coal type, combustion conditions,

ductwork, temperature and other APC equipment. During testing, modifications can be

made to the injection grid, sorbent combinations and injection rates to maximize emissions

removal. The ability to devise a meaningful, customized test plan and efficiently confirm

emissions compliance is heavily influenced by prior experience.



# When you need it done right,

you can count on UCC UCC process engineers are actively involved to ensure that demonstration testing goes smoothly and that the

results directly support emission control strategy decisions.

• C F D modeling (computational fluid dynamics) of the particle dispersion can be used to predict and enhance

performance and minimize sorbent usage prior to testing.

• T est matrices are developed that leverage UCC experience and data from previous tests. C onveying

requirements are determined using UCC proprietary pneumatic programs.

• A comprehensive test plan is submitted to the plant in advance and serves as the “playbook” for execution.

UCC demonstration equipment incorporates the latest injection

and milling technology and is installed and operated with minimal

disruption to the plant.

• T he industry’s most experienced field engineers are on-site for

supervision, operation and troubleshooting.

• D S I process engineers are on-site to provide real-time data

evaluation, consultation, and test plan adjustments as required

to achieve best results.

The DSI process engineer consolidates and evaluates all the raw

data from the COM S, CEM S, testing PL C and source testing.

• R emoval results are compared to a database of previous site

testing to confirm performance and improve results.

• A final test report is provided that summarizes the data and

reviews it against the test objectives.

• UCC personnel are a continuous resource during plant/fleet

emission control strategy evaluation and decision making. 

# Preparation and Logistics

Execution

Data Evaluation and Reporting



# 25,000 + 65 + • N um b er of D emonstrations



# • O ver 25,000 H ours

O f T estin g

# VIPER TM 

# Mill Technology

T he VI P ER TM M ill is proven, reliable technology developed specifically for dry sorbent

injection. T he patented VI P ER M ill operates in-line with the D S I system and delivers the

smallest particle size, highest throughput and greatest cost savings in the industry. The

result is 30-50% lower sorbent usage compared with as-delivered material.

• Designed for trona and sodium bicarbonate

• Capacity: 0.5

– 7 tons per hour

• Median particle size: 9-15 μm (trona), 15-19 μm (S B C)

• Reduced sorbent usage saves millions of dollars

VIPER Milled Trona VIPER Milled S B C Unmilled Trona Unmilled S B C 

# Trona Sodium B icarbonate

Particulate Size – Sodium B icarbonate Particulate Size – Trona 

# Skid Mounted Installation with Automated Cleaning



# The only mill developed

specifically for DSI systems ton s p er h our

o p eration 

# 7

24/7 T he VI P ER M ill is equipped with an automated cleaning system to eliminate

sorbent build-up. The 30-minute cleaning cycle ensures consistency in particle

size while balancing horsepower, temperature rise and sorbent

throughput. T he VI P ER M ill uses either a simple bypass system

or redundant skid for uninterrupted DSI operation.

T he VI P ER M ill ships on a fully pre-piped and pre-wired skid

for simple installation and lower installed cost.

# Economic Advantage

VI P ER M ill technology saves

utilities millions annually T he annual savings using VI P ER M illing technology typically results in a payback

period of less than one year. I ntegration of a single VI P ER M ill can reduce sorbent

costs by millions of dollars annually compared to other DSI systems.

In a typical SO

3 removal application, the

VI P ER M ill achieves aggressive ppm targets

while saving nearly $1 million per year

compared with unmilled trona. Dry sorbent injection is readily added to existing units and has a lower capital cost, yet

higher operating cost, compared with dry scrubbers. An economic analysis comparing

these solutions concludes that UCC ’s D S I system with VI P ER M ill technology has a lower

cash outlay and net present value beyond 15 years. Each plant has a unique footprint

in terms of size, life expectancy, efficiency target and financial position and should

consider all variables in their specific evaluation.

In a typical SO

2 removal application, the

VI P ER M ill can reduce sorbent usage by

30-50%. This delivers a $3.0 million

annual savings over unmilled trona for a

typical 500- M W P R B unit at a 60 percent

removal rate. 

# VIPER Mill –Smart Investment DSI vs. Dry Scrubber

Unmilled vs. UCC Milled Trona

Unit

(MW) SO

3 (ppm) SO

3 Reduction

(% Removal) Unmilled

(ton/hr) Fine Milled

(ton/hr) Annual

Savings*

700 25 90% 0.7 0.4 $ 425,736

700 35 90% 1.0 0.5 $ 709,560

700 50 90% 1.3 0.6 $ 922,428 

# SO 3 

# Economics

Eastern B ituminous Coal: Unmilled Trona vs. UCC Milled Trona

PR B : Unmilled Trona vs. UCC Milled Trona

Unit

(MW) Sulfur

lb/mmbtu SO

2 Reduction

(% Removal) Unmilled

(ton/hr) Fine Milled

(ton/hr) Annual

Savings*

50 1.6 60% 2.4 1.7 $ 993,384

100 1.6 60% 4.8 3.4 $1,986,768

150 1.6 60% 7.2 5.1 $2,980,152

Unit

(MW) Sulfur

lb/mmbtu SO

2 Reduction

(% Removal) Unmilled

(ton/hr) Fine Milled

(ton/hr) Annual

Savings*

100 0.8 60% 1.5 1.1 $ 638,604

250 0.8 60% 3.8 2.7 $1,617,797

500 0.8 60% 7.5 5.3 $3,193,020 

# SO 2 

# Economics

* Based on Trona at $180/ton Dry Sorbent

Injection Dry Scrubber

Efficiency Target 90% SO 2

90% HCl

90% Hg

removal with ESP and

milled trona/activated

carbon 90% SO 2

90% HCl

90% Hg

removal with ESP

Outage for Installation N one 1 month

Lead Time 12 months 2 years

System Costs

(includes installation) $25M $250M

Operating Cost

(w/ sorbent costs) $20M / yr. $6.6M / yr. 90% Removal

– 600MW Unit with ESP/PR B Coal Cumulative Cash Outlay (NPV)

Milled Trona Injection Rate vs. Outlet SO

3 Concentration

Hydrated Lime Injection DSI systems are suitable for retrofit into units with

SCRs and/or wet scrubbers for effective SO

3 control.

UCC has experience using hydrated lime and trona

injection for SO

3 removal and has achieved SO

3 emission limits well below 5 ppm. Where trona is

preferred, VI P ER M illing technology will reduce sorbent

usage by 50%. 

# SO 3 

# Removal with Cost Savings

# Service and After-Market Support

The UCC commitment to quality is backed by

thousands of hours of development, testing and

evaluation. United Conveyor Corporation has one

of the world’s most advanced research laboratories

and conveyor test loops to simulate ash and

reagent handling applications and validate design

parameters. Our knowledge and experience in

material behavior, product innovation and system

development for challenging applications is

unmatched in the industry. The addition of a DSI system introduces calcium or sodium-based by-products to the existing ash

handling system. These by-products can alter the material characteristics of the existing fly ash,

thereby affecting its flow properties and performance of existing hoppers and conveying pipes. In

SO

2 applications, the additional solids load could exceed the design capacity of your existing system.

As the global leader in ash handling, UCC offers a comprehensive evaluation of your plant’s

current ash removal capacity. We will analyze the ash by-product and recommend any system

changes to accommodate the increased load and altered material flow characteristics caused by

the sorbent injection. 

# Potential Impact to Existing Ash System



# UCC supports you for

the life of your system

UCC is committed to providing the highest level of service for as long

as you own your system. Our field service engineers are available worldwide

to assist with erection and start-up, operator training and maintenance.



## •	Replacement Parts

UCC offers the most readily available inventory of replacement parts to minimize

downtime and reduce operating costs. Thousands of replacement parts are in stock and

ready for next day shipment.



## •	Preventative Maintenance

This program is designed to keep your DSI system operating at peak efficiency, proactively

prioritizing maintenance resources and minimizing the risk of unexpected downtime.



## •	Pre-outage and Outage Assistance

UCC inspection and advance planning ensures that parts are on-site before work begins,

installed properly and tested, to deliver a smooth start-up. UCC project management, field service and process engineering

teams work hand-in-hand with customers to provide seamless

execution of specification development, test and demonstration,

design, erection and start-up, operation and maintenance training.

UCC maintains a group of dedicated DSI process and field service

engineers to work directly with customers during all phases of

work, including after-market support. 

# Project Implementation and

Knowledgeable ResourcesAs an industry innovator, we have long been at the forefront of ash

handling technology. We recognize the importance of providing customers

with the best equipment and latest technology that meet their demanding

requirements and plant needs.

With our own advanced testing and technology lab, we are able to maintain

control over the quality and delivery of our systems and equipment. The

result is superior and predictable performance for our customers.

Our dedicated team of engineers, sales, service and in-house designers

spans the globe covering six continents, assuring you that we can provide

exceptional service whenever needed. This is our commitment to you. 

## The UCC Commitment

unitedconveyor.com Global Operations in:

United States • Europe • China • India

Systems in over 60 Countries

UCC® is a registered trademark of United Conveyor Corporation. All enclosed content is provided for information only.

United Conveyor Corporation reserves right to change without notice any information contained within.

M13-02 ©2013 United Conveyor Corporation 

## UCC Material Handling Solutions

Fly Ash (Dilute, Medium and Dense Phase)

• V acuum Systems

• Pressure Systems

B ottom Ash (Wet and Dry)

• Hydraulic Systems

• Pneumatic Systems

• Mechanical Systems

• V ibratory Systems

Mill Rejects

• Hydraulic System

• Pneumatic Systems

Economizer Ash

• Hydraulic Systems

• Mechanical Systems

• Pneumatic Systems

Dry Sorbent Injection

• Predictive (CFD) Modeling

• On-Site Testing and Demonstration

• Pneumatic Systems

• Installation

Lime Handling

• Truck and Rail Unloading

• Pneumatic Systems

System Components

• Crushers

• Mixe r/ Unloaders

• Gate s / V alves

• Pipe/Fittings

• Filte r/ Separators

• Tank s/ V essels