ACI/DSI Upgrades

ADA’s System Upgrade Packages


Update your system for improved safety and reliability, plus reduce operating costs. The ADA-ES, Inc. (ADA) upgrade service for Activated Carbon Injection (ACI) Systems and Dry Sorbent Injection (DSI) Systems incorporates the industry’s best expertise in mercury and acid gas control. Our service is customized to meet your specifications and tailored to your current system design. ADA’s experienced engineers will always be available when you need them. ADA is the industry leader in ACI, with more systems designed, installed and in operation than any other company in the US. We also offer sales and service of DSI systems for the coal-fired utility industry.

Improved Safety and Performance

Safety. Does your ACI system meet the National Fire Protection Agency (NFPA)’s latest requirements? If you’re even slightly uncertain that your equipment is up-to-date and meets current safety regulations, you could be playing a dangerous game.

Performance. Meeting state and federal compliance levels for mercury is challenging. ADA can help you assess whether you are using too much sorbent; if your system could be more reliable with updated features. We will review your operation forecast to help you identify periods with increased risks of non-compliance.

ADA can help. ADA® Health Check System Inspection provides a strategy review combined with expert analysis to ensure consistent and optimal compliance with state and federal mercury and fire safety rules. This is a value-added approach from world-class mercury control experts. We will help you answer critical questions:

  • Are my systems ready for MATS?
  • Are my systems NFPA compliant?
  • Do my systems incorporate state-of-the-art features to optimize performance and safety?
  • Can I reduce my costs or sorbent usage?
  • Does my plant have any unique operating concerns that impact compliance:
    • Coal variability? Plant cycling?
    • Seasonal operational changes?
  • Am I using the right/best sorbent?
  • Will halogen improve performance of ACI?
  • Am I spending my compliance dollars wisely?

We can review your equipment and overall compliance strategy and provide guidance on how you can best meet fire safety, mercury compliance and improve operating costs across a range of operating conditions.

Health Check and Upgrade Packages

ADA’s team of experts uses an interactive engineering process to review your equipment performance. We can optimize effectiveness and provide you with upgrades that not only increase reliability, but also reduce your operating costs and improve safety.

ADA’s Health Check Includes These System Reviews

  • Review and optimize air flow management to assure the system is correctly sized and adequately controlled
    • Reduce wear on conveying equipment by controlling particle velocity
    • Eliminate plugging by ensuring proper conveying air characteristics are maintained
  • Review distribution manifold design and optimize to reduce sorbent feed rates
  • Assist with increasing the turndown capability, fluidization, and sorbent handling capabilities to accommodate next-generation sorbent characteristics
  • Assure systems are NFPA 654, 68, and 69 design-rated for safe operation in environments where combustible dusts could be present

Performance Benefits of Upgrades

Increased System Safety: New ACI systems are typically designed to meet NFPA guidelines. Many of the early ACI systems do not meet this critical safety criteria.

Increase Equipment Reliability & Reduce Maintenance: by using our pneumatic conveying systems (designed specifically for each application), the life of your equipment increases greatly because the components are operating within their peak performance ranges.

Improve System Component Reliability: adding VFDs on the blowers provides air flow management to regulate conveying velocity, depending on the volume of material. This often reduces wear and plugging in the conveying system (due to increased air flow management), resulting in less maintenance and replacement time required, which increases the overall system availability.

Reduce Sorbent Consumption: by optimizing the injection grid design, sorbent is able to more efficiently treat the flue gas, and less overall sorbent is required.

ADA – Your Trusted Partner

ADA understands the many factors that affect mercury removal and we can help you determine the optimal control strategy for your plant and operations. We assess and recommend ways to improve performance, reliability and safety. Some of the key factors considered include:

  • Properties of the coal including halogen content, sulfur and mercury
  • Boiler operation, load profile, flue gas temperatures, etc.
  • Performance of emissions control equipment and operating practices
  • Relative costs and potential performance limitations of various control strategies

Our team has supported plants in evaluating mercury control options for more than 25 years, including conducting mercury control demonstrations at more than 100 plants.

We provide ACI systems serving more than 140 utility boilers, and have internationally recognized mercury control experts on staff. With our expertise on your side, it’s simple to save money and achieve your compliance goals.

Please also see our new briefing document: The Impacts of NFPA 652 on ACI System Design and Operation.

NFPA 652 is the starting point for processes handling particular solids and dusts.

Have a question about your ACI or DSI equipment? Contact us today to speak with one of our experts.

Need a recommended parts list for your ADA equipment? Let us know and we’ll provide one.

Email us today: Or call 720.598.3700 to speak to a member of our Customer Care Team