Advanced Dry Sorbent Injection Systems for Reliable Acid Gas Control
Industrial facilities facing tightening MACT, NESHAP, and state-level air regulations need dependable, cost-efficient solutions for reducing SO₂, SO₃, HCl, HF, and other acid gases. IAC’s Dry Sorbent Injection (DSI) Systems deliver a proven pathway to compliance without the capital burden of large wet scrubbers or extensive process overhauls. As a vertically integrated EPC contractor and OEM, IAC engineers, fabricates, installs, and optimizes complete DSI systems tailored to the specific chemistry, gas flow, and performance requirements of each operation.
Our systems are built around full-scale, real-plant conditions—not theoretical lab models. With access to one of the industry’s largest mobile DSI testing fleets and deep expertise in baghouses, pneumatic conveying, sorbent handling, and automated controls, IAC ensures each installation meets its targeted removal efficiencies while maintaining uptime, fuel efficiency, and downstream equipment life.
Whether you’re addressing emission limits for a coal-fired boiler, biomass combustion, cement kiln, waste-to-energy facility, or process vent streams, IAC provides an end-to-end solution that integrates seamlessly with your plant’s existing APC equipment and operating strategy.
The Compliance and Operational Challenges Plants Must Solve
Facilities across power generation, cement, biomass, metals, and waste-to-energy operations face growing pressure to control acid gases and hazardous air pollutants without sacrificing reliability. Tightening MACT and NESHAP standards require measurable reductions in SO₂, SO₃, HCl, HF, and mercury, often pushing legacy scrubbers, ESPs, or underperforming APC systems beyond their limits.
At the same time, operators must maintain production targets, avoid derates, and manage fuel or feedstock variability—conditions that make conventional scrubbers or complex wet FGD systems difficult to justify. Many plants also face high retrofit costs, limited space for new equipment, and elevated maintenance demands from aging infrastructure.
Dry Sorbent Injection systems have become the preferred compliance path because they offer reliable removal efficiencies, fast installation timelines, and minimal disruption to existing baghouses, ductwork, and process flows. When engineered correctly, DSI provides the operational flexibility needed to stay within emission limits while supporting throughput, uptime, and long-term equipment life.
How IAC’s Dry Sorbent Injection Systems Deliver Proven Acid Gas Control
IAC’s Dry Sorbent Injection Systems provide a direct, reliable method for capturing acid gases before they reach downstream APC equipment. Each system is engineered to match the gas chemistry, temperature window, residence time, and mixing profile of your process stream—ensuring the highest possible removal efficiencies with the lowest practical operating cost.
Our DSI technology injects finely milled sorbents—such as hydrated lime, trona, sodium bicarbonate, or activated carbon—into the flue gas where they react with SO₂, SO₃, HCl, HF, and mercury. Reaction byproducts are then collected by the existing baghouse or particulate control device, allowing most plants to achieve compliance without major changes to their dust collection infrastructure.
Because IAC is both an OEM baghouse manufacturer and a full-service EPC contractor, our DSI systems are designed for seamless integration with your ductwork, conveying systems, pulse-jet baghouses, controls, and monitoring equipment. This holistic approach ensures balanced airflow, predictable pressure drop, and optimized performance across the entire emissions control system—not just the injection point.
Selecting the Right Sorbent for Your Process
The performance of any DSI system depends on choosing the correct sorbent chemistry for the process conditions, pollutant profile, and targeted removal efficiencies. IAC evaluates each plant’s flue gas temperature, flow rates, residence time, moisture content, and downstream APC configuration to ensure the selected sorbent delivers predictable, repeatable results.
Calcium-Based Sorbents (Hydrated Lime)
Sodium-Based Sorbents (Trona, Sodium Bicarbonate)
Activated Carbon Injection (ACI) for Mercury
DSI vs. Other Emissions Control Technologies
Choosing the right emissions control strategy requires balancing compliance needs, capital budgets, fuel variability, and operational impacts. Dry Sorbent Injection stands out because it delivers measurable acid gas and mercury reductions without the infrastructure, water consumption, or maintenance burden associated with larger wet scrubber or semi-dry FGD systems.
The table below outlines how DSI compares to the most common alternatives used in power generation, cement, biomass, metals, and waste-to-energy operations:
Technology Comparison Table
| Feature / Criteria | Dry Sorbent Injection (DSI) | Wet Scrubber | Semi-Dry Scrubber (SDA) |
| CAPEX Requirements | Low | High | Moderate |
| Water Usage | None | High | Moderate |
| Footprint | Compact / Skid-Based | Large | Large |
| Installation Time | Fast (Weeks) | Long (Months) | Moderate |
| Removal Efficiency (SO₂) | Moderate to High (50–90%) | High (>95%) | High (>90%) |
| Maintenance Needs | Low | High | Moderate |
| Ideal Use Cases | Retrofits, fast-track projects | New builds with space & budget | New builds or large-scale retrofits |
| O&M Costs | Low | High | Moderate |
| Integration with Existing Baghouses | Seamless | Requires upgrades | Requires integration planning |
Key Takeaways:
- Faster to Deploy: Ideal for tight compliance windows or emergency retrofits.
- Lower Risk: Less operational complexity and minimal water or chemical handling.
- Budget Friendly: Enables incremental investment compared to full FGD systems.
Modular Design: Scales with your plant’s capacity and emissions load.
Engineered System Design for Complete, Plant-Ready DSI Performance
Every Dry Sorbent Injection project begins with a detailed engineering evaluation to ensure the system performs reliably under real operating conditions. IAC designs DSI solutions as fully integrated process packages—matching sorbent characteristics, injection location, residence time, duct geometry, gas temperature, and downstream particulate control to deliver predictable removal efficiencies.
Our engineering teams model the flue gas stream using advanced CFD to define optimal lance placement, mixing behavior, and distribution patterns, minimizing sorbent waste and supporting uniform reaction across the duct cross-section. From there, we design the complete material handling and metering system, including storage silos, feed bins, blowers, injection lances, and controls that scale with your required turndown range.
Because each component is fabricated in our 500,000 sq. ft. manufacturing facility and installed by our EPC and field services teams, every DSI system is delivered as a cohesive, engineered solution—not a bolt-on package. This end-to-end approach ensures stable pressure drop across the baghouse, consistent emissions performance, and long-term operational reliability.
Full-Scale Demonstration Testing to Validate Performance Before Investment
Achieving reliable acid gas mitigation requires more than theoretical calculations—plants need proven data under real operating conditions. IAC maintains one of the industry’s largest fleets of mobile DSI and ACI demonstration rigs, allowing facilities to verify removal efficiencies, optimize sorbent selection, and establish accurate operating curves before committing to permanent equipment.
Our on-site testing programs measure SO₂, SO₃, HCl, HF, and mercury reduction across a full range of loads, temperatures, and fuel/feedstock conditions. By pairing continuous emissions monitoring with precise feed-rate controls, IAC validates true stoichiometric ratios, milling requirements, residence time impacts, and duct mixing behavior. This ensures the DSI system is engineered with the correct sorbent chemistry and particle size for predictable long-term performance.
Demonstration testing also identifies opportunities to reduce OPEX by lowering sorbent consumption, improving distribution patterns, or adjusting lance design and placement. With these data-backed insights, plant operators have full confidence that the final DSI system will meet compliance, maintain production, and support downstream baghouse performance without surprise costs.
Partner With IAC for Proven, Compliance-Ready DSI Solutions
Achieving consistent acid gas and mercury reduction requires more than equipment — it demands an engineered system built around your process, your emissions profile, and your operating realities. IAC delivers complete Dry Sorbent Injection solutions backed by full-scale testing, in-house fabrication, EPC integration, and decades of air pollution control expertise.
If you’re evaluating DSI for a new application, preparing for upcoming MACT or NESHAP requirements, or seeking a lower-CAPEX alternative to wet or semi-dry scrubbers, our engineering team is ready to help.
Request a consultation or technical review using the form below, and our specialists will outline the right approach for your facility.