Activated Carbon Injection System

In industrial facilities such as power generation and waste incineration, combustion processes operating at high temperatures emit numerous toxic substances into the air. These emissions often include dioxins, furans, and mercury, which are harmful to both human health and the environment. If not properly treated, they can contribute to air pollution, respiratory issues, and long-term ecological damage.

One way industries overcome this issue is by using Powdered Activated Carbon (PAC)—a high-performance adsorbent with an extremely porous structure that allows it to trap and hold contaminants at the molecular level. When injected into the flue gas stream, PAC adsorbs toxic substances like dioxins and mercury, preventing them from being released into the air. The polluted carbon is then captured by downstream filters, such as baghouses, ensuring cleaner emissions and compliance with environmental regulations.

Beyond flue gas treatment, PAC is also widely used in water treatment processes. It plays a critical role in removing micropollutants—including pesticides, pharmaceuticals, and industrial chemicals—from wastewater. It is also a key material in drinking water purification, helping to eliminate taste, odor, and harmful trace substances.

By using activated carbon, industries and municipalities can address critical environmental challenges in both air and water quality. Its versatility and effectiveness make it an essential tool in efforts to provide cleaner, safer, and more sustainable environments for communities and ecosystems.

PAC is widely applied in sectors including chemical manufacturing, steel production, waste disposal, coal-fired power generation, and metal casting. In these environments, conventional baghouse filters are generally not sufficient to fully manage emissions due to the presence of gas-phase pollutants that bypass particle-only filtration systems.

PAC is injected into the flue gas line prior to the baghouse filters to increase emission control efficiency. Once introduced, this adsorbent binds with targeted contaminants in the gas flow. These PAC-bound compounds are then captured by the filter bags, significantly improving the system’s overall ability to limit harmful releases into the atmosphere.

This method not only supports regulatory compliance but also offers a flexible and scalable solution that can be adapted to various industrial processes and emission levels.
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Implementation of PAC in such industries poses several challenges, including:

• Storage of raw material with sacks, big bags, silos:

Ensuring safe, dust-free, and efficient storage of powdered activated carbon requires specialized infrastructure and equipment, which can take up significant plant space.

• Conveying the material to dosing systems:

Moving PAC from storage to the dosing system must be done carefully to prevent spillage, dust emissions, and material loss, requiring pneumatic or mechanical conveying systems.

• Accurate dosing into the desired process:

Precise and consistent dosing is critical for effective emission control. Inaccurate dosing can lead to reduced system efficiency, increased operational costs, or regulatory non-compliance.

These requirements can significantly increase system costs, primarily due to the need for substantial space within the facility. Additionally, inefficient handling methods may lead to longer operation times, higher labor demands, and increased energy consumption. All of these factos can impact overall operational efficiency and cost-effectiveness.

Polimak’s Activated Carbon Injection (ACI) system provides a long-term, high-performance solution for effective gas emission control across a wide range of industrial applications. Designed as a compact and integrated package, the system minimizes the need for extensive plant space. Its design ensures easy installation, and its user-friendly operation reduces the need for extensive training or complex setup.


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Polimak’s packaged system for Powdered Activated Carbon (PAC) handling is a fully integrated solution designed for efficient, safe, and dust-free material transfer—from bulk bag unloading to injection into the process line. This system is ideal for industrial applications where PAC is delivered in bulk bags and includes the following key components:


• Hoist System

• Big Bag Discharging Platform

• Storage Silo

• Weighing and Dosing Unit

• Pneumatic Conveying System for PAC injection

• Lime Dosing System (optional: to enhance functionality.)

Working Principle of the PAC Injection System

1. Bulk Bag Loading:

Powdered Activated Carbon (PAC) is delivered in FIBCs and placed onto the system’s carrier platform using a forklift or hoist.

2. Discharge to Hopper:

The outlet of the big bag connection is opened, allowing PAC to flow into the powder hopper.

3. Transfer to Storage Silo:

The PAC is discharged from the hopper into a sealed storage silo for intermediate holding.

4. Dosing System Activation:

A dosing unit located below the silo automatically discharges the PAC and feeds it into the pneumatic conveying pipeline.

5. Weighing and Feeding:

The PAC is metered using a weighing system and a precision feeder, ensuring it enters the pipeline at the desired feed rate.

6. Pneumatic Conveying:

A roots blower transports the PAC through the pipeline, injecting it into the process line, which is typically part of the dust collection system.

7. Flow Direction Control:

PAC injection can be configured to operate in the same or opposite direction of the airflow, depending on system requirements.

8. Automation and Control:

A PLC-controlled automation system regulates the precise amount of PAC injected into the process. The control panel manages material flow rate, capacity, speed, and timing for optimal performance.

Key Benefits of Activated Carbon Injection in Flue Gas Treatment

• Compact and packaged design

With a smart design crafted by Polimak engineers, the system ensures easy material handling, safe storage, and accurate dosing of activated carbon.

• Short delivery times

Modular engineering allows for faster c, keeping implementation timelines on track.

• Easy installation

Plug-and-play components reduce the need for complex setup and specialized labor.

• Quick commissioning

ystem startup is fast and efficient, reducing interruptions and ensuring a seamless transition to full operation.

• Space-saving footprint

Smartly engineered to deliver full functionality in a minimal footprint.

• Lower investment and operating costs

Efficient design reduces capital expenditure as well as recurring costs for energy, labor, and maintenance.

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These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
Installed below silos or hoppers, these valves are used for maintenance operations of equipment such as rotary valves, screw feeders, etc., that are positioned below the butterfly valve.
These valves are typically actuated by pneumatic actuators and are used to automatically open and close the product flow to discharge material to downstream equipment.
In this design, the butterfly valve is sandwiched between two flanges. Rubber sealing at both faces of the valve provides a tight seal between the flanges and the wafer butterfly valve.
One side of the valve has a bolted flange connection, while the other side features a built-in short pipe designed for fixing a flexible sleeve.
These valves have bolted flange connections on both sides, making them suitable for installation on silos, hoppers, screw feeders, and similar applications.
Bulk tanker trucks or open trucks can be filled with powdered materials delivered within FIBC bags. These systems generally consist of bulk bag discharging station, mechanical or pneumatic conveyor and loading bellow. Big bag discharge station transfers the bulk solid from big bag to conveying system. Conveying system transfers it to truck loading area. And loading bellow is used to fill tanker truck without any dust emission. Since truck loading operations are done within limited time, high capacity big bag discharge systems and bulk material conveying systems are used. For short distances, screw conveyors are preferred to transfer material from big bag discharge station to truck loading chute. For long conveying distances, pneumatic conveying systems provide better service. There may exist a storage hopper or silo above bulk truck loading bellow to compensate material flow between inlet and outlet. Bulk bag discharge and truck filling systems have automatic control system that monitors product level in truck and operates all equipment accordingly. Optional weighing system can be added to measure the amount of material that is filled to truck.
Big bag discharge systems can deliver dry bulk solids in powder and granular form to weighing and batching systems. The loading hopper of the weighing system should remain full during dosing and batching. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the dosing speed and conveying distance, mechanical conveying systems or pneumatic loading systems may be used. Dust collectors can be employed to prevent dust emissions during hopper loading, especially for materials with high dust content.
Dry bulk packaging systems are used to fill powdered or granular materials into bags, drums, jars, sacks, etc. Bulk materials delivered in big bags must be transferred to packaging machines without interruption. The loading hopper of the packaging system should remain full during the filling and packaging process. Big bag discharge systems can monitor the product level in the loading hopper and maintain a constant level automatically. Depending on the packaging speed, mechanical conveying systems or pneumatic loading systems can be selected. Dust collectors can be used to prevent dust emissions during hopper loading, especially for materials with high dust content.
Mixer automation systems are used to mix dry bulk solids according to specific recipes. Raw materials delivered in FIBC bags can be transferred to mixing units through a combination of conveying equipment and bulk bag discharge systems. Depending on the type of application, pneumatic conveying or mechanical feeding systems can be used to fill mixers. Big bag discharge stations can be manufactured with built-in dosing systems. The amount of raw material to be loaded into the mixer is automatically controlled with the help of a weighing and dosing system. Dust collectors can be used to prevent dust emissions during the mixer filling process.
Bulk material stored in big bags can be automatically filled into small bags. Big bag discharge systems come with optional built-in bag filling units. For low filling capacities, these units are installed below the big bag discharge hopper, providing a practical and cost-effective solution. Both big bag discharging and bag filling operations can be handled by a single, compact system. For higher bag filling needs, bag filling machines are installed near the bulk bag discharge stations. Pneumatic conveying systems or mechanical conveyors can be used to transfer bulk material from the FIBC bag discharge station to the bag or sack filling system.
Mechanical conveyors can be used for silo loading from big bag discharge stations. Screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to big bag discharge stations to fill silos. The selection of conveying equipment directly depends on the conveying distance, height, transferred material, and capacity. Bucket elevators are preferred for high silos, while screw feeders are preferred for shorter silos and short distances. The big bag discharge system can be installed on top of the silo for faster filling. In this case, rotary valves or butterfly valves are better choices as they provide simple flow control. Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air content in the silo escapes to the atmosphere and carries some dust along with it. Vacuum fans and jet filters in dust collectors prevent dust emissions into the environment. The collected dust is sent back to the silo, thus preventing product loss.
Pneumatic conveying systems installed after bulk bag discharge units transfer bulk material through conveying pipelines to fill silos. This configuration is useful in applications where high transfer rates and long conveying distances are needed. In production lines where raw materials are stored in warehouses far from storage silos, bulk bag discharge stations can be installed close to the warehouses, and pneumatic conveying systems are used to fill silos from long distances. This design reduces the need for forklifts and cranes for bulk material transfer on the production site and increases overall efficiency.

Pneumatic conveying systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Pneumatic conveying systems installed after bag dump units transfer bulk material through pipelines to fill silos. This configuration is ideal for applications requiring high transfer rates and long conveying distances. In production lines where raw materials are stored in warehouses far from storage silos, bag dump stations can be installed close to warehouses, allowing pneumatic conveying systems to transport materials over long distances. This design reduces the excessive use of forklifts and cranes for bulk material transfer within the production site, improving overall efficiency.

Pneumatic transfer systems used for silo loading utilize blower pumps or compressors. Motor power, pipeline diameter, and equipment selection depend on factors such as the type of bulk material, transfer distance, silo height, and transfer capacity. Level sensors, jet filters, and other equipment are installed on storage silos to ensure the proper operation of the silo filling system.
Mechanical conveyors can be used for silo loading from bag dump stations. In this configuration, screw feeders, bucket elevators, rotary valves, or chain conveyors are connected to bag dump stations to fill silos. The selection of conveying equipment depends on factors such as conveying distance, height, material properties, and capacity. Bucket elevators are preferred for high silos, while screw feeders are ideal for shorter silos and short distances. Bag dump systems can be installed on top of the silo for faster filling. In such cases, rotary valves or butterfly valves are better choices as they provide simple flow control.

Dust collection systems may be required depending on the dust content of the bulk solid. During silo loading, air inside the silo escapes to the atmosphere, carrying dust particles with it. Dust collectors equipped with a vacuum fan and jet filter capture airborne dust. The collected dust is returned to the silo, preventing product loss and ensuring a cleaner environment.
The inlet skirt is an optional feature designed to extend the lifespan of the flexible connector sleeve. Its upper portion is attached to the outlet port of the upstream equipment and extends down into the bin activator’s inlet port. The primary function of the inlet skirt is to serve as a protective shield, safeguarding the flexible connector seal from wear and damage.
A vibratory motor is externally mounted to the bin activator. When powered, the motor generates vibrations that facilitate a steady flow of dry bulk materials within the system. Depending on the application requirements, one or two vibratory motors can be installed externally.
To accommodate a bin activator, the cone of a silo must be shorter than usual, resulting in a wider outlet. A flange supplied with the bin activator is separately welded to the silo’s outlet, slightly above the opening, at the production site. Once installed, the vibrating bin discharger is securely bolted to the flange, ensuring a stable and reliable connection.
Special spring suspension links and an engineered polymer seal work together to create a flexible connection between a vibrating bin discharger and the equipment positioned above it.

The proper design and installation of the polyurethane seal prevent it from slipping off and ensure a secure seal, eliminating the risk of dry bulk material leakage. Additionally, the seal offers high stress resistance and long-term durability, withstanding stresses caused by motor vibrations, pressure conditions, and other operational factors.

Externally installed spring suspensions provide full resilience to the vibrations of the cone head. They ensure that the generated vibrations affect only the cone itself rather than the upstream equipment structure.
An internally tapered, conical-shaped baffle plate is positioned at the center of the bin activator’s diameter. The baffle is rigidly attached to the equipment body using structural steel components. It facilitates bulk material flow from upstream equipment by directly inducing vibrations into the material.

A secondary deflector plate reduces the weight of the bulk material in the lower portion of the bin activator by acting as a wedge beneath the material, directing it around the areas adjacent to the cone’s surface.

Polimak baffle plates are available in various configurations, including convex and cone plates, and in different angles (15°, 30°, 45°, or even 60°) depending on the flow characteristics of the handled bulk material and the specific application requirements.