DSI On-Site Demonstrations
United Conveyor Corporation is the industry leader and the first to provide customer on-site demonstration. UCC has over 25,000 hours of Dry Sorbent Injection (DSI) demonstration tests. Full-scale, on-site DSI demonstrations help utility customers address regulatory requirements for the reduction of SO2, SO3, mercury and acid gases.
UCC has the industry’s largest number of full-scale demonstration tests with 45 conducted to date. Recent demonstration tests have been primarily focused on simultaneous removal of SO2, HCl, and mercury to provide specific information to the plant for for compliance of Utility MACT and Cross State Air Pollutant Rule (CSAPR) requirements. Tests have been conducted on a number of large, PRB-fired units, as well as smaller, bituminous-fired units.
UCC test equipment incorporates the latest injection and milling technology to generate reliable, high quality data for customers to make critical compliance decisions.
UCC modular demonstration systems provide both flexibility and performance with minimal disruption to a plant during installation and testing. Prefabricated, mobile equipment enables rapid installation. If desired, demonstration equipment can be rented longer term or be upgraded to become the permanent system. The result is lower total installed cost and shorter lead-time.
Customized demonstration testing evaluates overall DSI performance on the system. UCC conducts baseline testing before the demonstration and during each injection run so the effects of sorbent injection on each pollutant can be accurately assessed. UCC testing includes source emission testing (stack testing). Emissions removal results can then be compared to a database of previous testing at other coal-fired power plants. UCC DSI demonstrations illustrate clear benefits.
UCC offers Computational Fluid Dynamic (CFD) modeling of plant duct flows to best predict and enhance performance of the DSI system. CFD modeling ensures optimum sorbent distribution in the flue gas to maximize performance and minimize sorbent usage.
The mobile on-site demonstration units are equipped with VIPER™ Mill units used on Trona and Sodium Bicarbonate tests. The VIPER milling technology demonstrates how the reducing the sorbent particle size increases the reactive surface area to improve the emission removal efficiency and sorbent utilization.
- Dry sorbent trona/sodium bicarbonate injection can remove over 90 percent SO2
- Co-benefits include enhanced ESP performance and removal of Hg, HCl, and NOx
- In-line milling (to 12 -15 micron) can provide 30 to 50% better trona utilization
- Demonstrate SO2, acid gas (HCl, HF), and Hg removal simultaneously
- Successful demonstrations for SO3 and HCl removal with Hydrated Lime
- DSI delivers effective emission control at a fraction of the capital cost of a scrubber
Are all DSI on-site tests customized[+]
Every test is customized with different combinations of standard equipment and processes. We have performed over 50 DSI tests and this experience enables us to provide the most effective approach to solving each plant’s unique emission control requirements. We don’t perform tests to prove concept—our experience allows us to make that determination before we test. Instead, we perform tests to provide real answers allowing strategic decision making at the plant and fleet level.
How long is the typical test?[+]
Our reference database allows us to compare results and generate the minimum test schedule to get the most bang for the buck. The most straightforward tests can be completed in one-week or less. The most complex tests looking at multi-pollution control can typically be completed in two to three weeks. In addition to this testing time, some plants choose to see the system run longer to observe operational impacts.
What equipment is provided for testing?[+]
We provide all equipment and material necessary to perform the testing. Our standard VIPER Mill trailer includes the mill, blower, air compressor, air cooler, feed system, PLC controls and miscellaneous hose/pipe, splitters, valves and lances. Our equipment is operated by our operators drawn from our staff of 19 trained field service engineers. A comprehensive Test Plan is created for every test and includes customized P&IDs, installation procedures, test protocols and a testing matrix.
What support is necessary from the plant?[+]
The plant provides installation and tear-down services. Every test is provided a comprehensive Test Plan that includes customized P&IDs, installation procedures and testing matrix. The assigned field service operators will be on-site during installation and tear-down to provide oversight. Sometimes the plant contracts directly with a third party source testing company but we have excellent relationships with multiple testing companies and can provide a turn-key test.
How much advance notice is necessary to perform a test?[+]
We recommend at least three months between award and the test start. This timeframe can be compressed but the more the timeframe shrinks the more likely it becomes that compromises will be necessary to complete the test.
Does UCC provide the sorbent for the tests?[+]
We recommend you contract directly with the sorbent supplier but we can purchase the sorbent if desired.