How It Works
1- Sorbent Preparation & Micronisation
Bulk sorbent (e.g. hydrated lime, sodium bicarbonate, trona or PAC) is delivered and stored in silos. It is fed into a classifier mill equipped with a rotating grinding disc and classifying wheel. Only particles meeting the target fineness (d90 ≈ 20 µm) pass through; coarser particles are recirculated. The resulting high‑surface‑area powder enhances reaction kinetics.
2- Pneumatic Conveyance & Injection
Finely ground powder is transported via screw feeders and blowers and injected into the hot flue gas stream. The dry process avoids liquid effluents and simplifies plant integration.
3- Reaction & Capture
Pollutants (SO₂, SO₃, HCl, HF) and mercury react with the alkaline powder, forming neutral salts that are captured in existing baghouses or ESPs. Rapid reaction ensures completion within the short residence time.
4- Particulate Collection & Clean Gas
Reaction by‑products and any unreacted powder are removed by high‑efficiency filters, producing clean exhaust gas. The dry process avoids wastewater management.
Applications
Cement
Building materials
Waste‑to‑energy
Power generation
Glass
Metals
Pulp and paper
Wood
Core System Components
To deliver best‑in‑class performance, our Dry Sorbent Injection system integrates several key components:
- Classifier mill (SORBAMILL) – a patented grinding mill with dual rotating impellers and an integrated classifying wheel. It micronises and sorts the reagent, recirculating coarser particles until they meet the target fineness. This ensures a narrow particle‑size distribution and high specific surface area.
- Milling and dosing skid – combines the classifier mill with a precise dosing system. The skid feeds micronised sorbent into the pneumatic conveying line, maintaining an optimised stoichiometric ratio and ensuring stable injection even under fluctuating loads.
- Pneumatic conveying system – transfers the finely ground powder to multiple injection lances. Careful design of pipework, blowers and flow controls maintains the powder in suspension and prevents plugging.
- Injection lances and reaction duct – deliver sorbent into the hot flue gas stream, creating uniform mixing and maximising contact with pollutants. The reaction duct provides sufficient residence time for neutralisation to occur before entering the particulate control device.
Key Benefits
Economical
Eliminates the scrubber tower, reducing capital cost and installation time. Precise stoichiometric control minimises sorbent consumption and operating cost.
Compact
Comprises silos, a milling‑and‑dosing skid and injection lances. The integrated grinding/classification and dosing skid fits easily into existing plants.
Simple & Reliable
Few moving parts, robust design and automated controls deliver high uptime. Dry Sorbent Injection safety ensures trouble‑free operation.
Highly Efficient
Achieves up to 75% SO₂ and over 99% HCl removal. With PAC addition, mercury removal exceeds 95%. Optimised IICS and particle size enable over 99.5% efficiency.
Intelligent Instant Control System
Exclusive adaptive control adjusts dosing in real time to maintain performance under variable conditions.
Why Choose AquipTec & MetalTek
This advanced Dry Sorbent Injection (DSI) solution is the result of a cooperative partnership between AquipTec (Australia) and MetalTek SRL (Italy). MetalTek excels in the design and manufacture of Regenerative Thermal Oxidiser (RTO) plants, leveraging over 25 years of experience in environmental process technology. The systems are certified as EN 1090‑2 (2018) and UNI EN ISO 3834‑2 (2006), ensuring the highest standards in fabrication and welding. AquipTec contributes local engineering, project delivery and 24/7 service across Australia and New Zealand, ensuring systems comply with regional standards and site‑specific requirements.
Together, we provide:
- Integrated Technology – Proven European/glob classifier mills and dosing systems combined with Australian control integration.
- Tailored Solutions – Systems optimised for fuel type, flue‑gas composition, temperature and emission limits.
- Local Support – On‑ground installation, commissioning, spare‑parts supply and responsive after‑sales service.
- Sustained Performance – Continuous technical collaboration ensures upgrades and lifecycle support.
- Vertically Integrated Manufacturing – The manufacturing process is vertically integrated, giving us full control from design to production. Skilled workers and trusted suppliers deliver consistent quality and allow rapid adaptation to customer needs.
Frequently Asked Questions (FAQ)
What exactly is Dry Sorbent Injection (DSI) and how does it improve industrial emissions control?
Dry Sorbent Injection (DSI) is a proven flue gas cleaning technology that injects finely milled dry alkaline sorbents — such as sodium bicarbonate, hydrated lime, Sorbalite, or trona — directly into hot flue gases. These sorbents chemically react with acid gases like SO₂, HCl and other contaminants, forming stable salts that are captured by downstream particulate controls (e.g., baghouses). This approach significantly lowers harmful emissions, helping facilities comply with stringent environmental regulations while avoiding the high capital costs of wet scrubber systems.
What are the advantages of a AquipTec & Metaltek-based DSI system compared to traditional emission control systems?
Lower capital and operating costs compared to wet scrubbers since no large towers or wastewater handling are required.
Compact and modular design that fits easily into existing plant layouts.
Precise sorbent dosing and adaptive control enable efficient pollutant neutralisation while optimising sorbent consumption.
High reliability and minimal maintenance thanks to rugged equipment design and automated controls.
Why choose a Metaltek-equipped DSI system via AQUIPTEC for my plant’s emission control needs?
AQUIPTEC’s Dry Sorbent Injection solution integrates Metaltek-designed classifier mills and dosing systems, delivering precise sorbent micronisation and controlled injection for optimum pollutant neutralisation. Metaltek is a specialist in industrial flue gas purification mills and dosing equipment with over 30 years of experience, offering custom dosing units for different reagent types and facility conditions. Their systems are robust, reliable, easy to integrate into existing plants, and can be tailored for varying flue gas compositions, flow rates and regulatory targets — ensuring efficient emission control and reduced operational costs.
How does the system adapt to changes in plant operations and regulatory requirements?
Modern Dry Sorbent Injection systems supplied by AQUIPTEC and Metaltek include advanced process controls and automatic dosing regulation that adjust sorbent feed rates based on real-time flue gas conditions. Metaltek dosing units are designed to integrate with control systems that modulate reagent delivery according to detected pollutant concentrations, ensuring consistent performance even under variable load conditions. Additionally, these systems can be configured with multiple injection points, customized capacities and optional monitoring features to meet evolving operational needs and tighter emissions standards