ADA - Powdered Activated Carbon Sorbents

The demand for activated carbon for mercury control is rising rapidly, as all new coal fired plants and utilities in the 19 states with mercury regulations are beginning to contract for term supplies. In addition, it is anticipated that the Environmental Protection Agency will create a new federal mercury emissions rule to replace the court remanded Clean Air Mercury Rule. Combined, these market drivers will create a very large demand for activated carbon and existing domestic production will need to be increased substantially to meet it.

As the leader in mercury control systems and testing knowledge, ADA is in a unique position to understand the interaction between carbon sorbents and mercury emissions. Using the experience gained in over 40 full-scale tests, ADA has applied this knowledge base to producing a cost efficient and highly effective sorbent for the near term market place.

Our new brominated carbon sorbent is called Power PAC Premium. The results of full scale testing for mercury control are shown below in the performance graph.

Other full scale test results will be available soon from other plants burning PRB coals with different air pollution control devices.

ADA-ES, via its subsidiary, Crowfoot Supply Company, LLC, completed construction of a green field facility to process activated carbon (AC) at the Port of Natchitoches in Natchitoches Parish, Louisiana in July 2009. (See photo link above in right margin: Natchitoches Facility) The facility is capable of processing 8,000 lbs/hour of powdered activated carbon, has a 40,000 sq. ft. warehouse for storage, plus includes a material processing center, as well as, loading and transfer capabilities for bulk bag, tanker trucks or rail cars. The Natchitoches port location can also accommodate load out onto barges for high volume delivery requirements via the inland waterways system. State-of-the-art air pollution control equipment has been installed to assure environmental compliance.

The demand for activated carbon in 2010 and beyond is expected to outpace domestic supply capacity. In order to meet this demand with a high quality domestically produced product, ADA has begun the process of building the largest powdered activated carbon manufacturing plant in the world. In 2008, ADA-ES formed a joint venture with Energy Capital Partners (ECP), a private equity company dedicated to investments in electrical utilities and power generation. The joint venture is called ADA Carbon Solutions and its main purpose is to build a carbon plant focused on the production of activated carbon (AC) for the mercury emissions control market for coal-fired power plants, cement kilns and other industrial boilers.

Construction of the new carbon plant began in September 2008 in Red River Parish, Lousiana. The first production line of this facility will be capable of producing 125 to 175 million pounds of AC per year and is expected to come on-line in June 2010. (See photo link above in right margin: ADA Carbon Solutions Plant). In addition, the air permit for the facility allows for a second production line, which, if constructed, would be capable of producing up to an additional 175 million pounds of AC per year.

ADA is planning now to be able to meet the growing demand for activated carbon, as more plants and industrial facilities will be required to use it for pollution control. Starting the long permitting process now, will enable new plants to be built much faster and assure they are ready to supply domestically produced carbon when needed for future demand.

ADA has two other sites under consideration for the new plants in North Dakota. Both are situated near active lignite mining operations for several reasons. Activated carbon produced from low rank coal like lignite, has produced the most effective mercury control carbons in numerous full scale tests. Also, citing our new plant near an active mining operation will enable the plant to have a ready source of feedstock coal, with a known quality and not risk having its supply subject to permitting delays from a new coal mine.

The plant has “state of the art” manufacturing equipment, designed specifically for producing carbon for the mercury control market. The initial production line has 4 multi-hearth furnaces and advanced pollution control equipment. Finished carbon will be stored in silos until shipment is made by bulk bag, tanker truck or railcar.

Two production lines are being permitted at each of the three sites. This will enable future demand to be filled quickly and enable each site to produce up to 250,000,000 pounds of carbon per year.

Long term supply contracts are already being negotiated with customers who also share the view that carbon supply will become scarce, as more and more utilities mercury emissions are regulated and controlled with activated carbon.