Industrial Accessories Company 4800 Lamar Ave

Mission, Kansas 66202

DSI TECHNOLOGY

PP031 01-07-13 R3

IAC PRODUCTS - SYSTEMS - SERVICES

PRODUCTS: APC – BAGHOUSES; HEAT EXCHANGERS

BULK MATERIAL HANDLING

SYSTEMS: DRY FGD & ACID GAS CONTROL

HAP CONTROL MERCURY; ARSENIC

BIOMASS PROCESING & HANDLING

SERVICES: Hg & ACID GAS DEMONSTRATION TESTING

OEM PARTS & COMPONENTS

RETROFIT & BAGHOUSE CONVERSIONS

MECHANICAL INSTALLATION

STRUCTURAL STEEL FABRICATION

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IAC CONSTRUCTION COMPANY

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UTILITY MACT REQUIREMENT

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TOXICS RULE EMISSION LIMITS

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MACT STANDARDS FOR BIOMASS

Major Source Boiler MACT

Subcategory Pollutant Proposed Rule Heat Input Emission Limit

Final Rule Heat Input Emission Limit

Existing – Biomass

Stoker/other

PM 0.02 lbs/MMBtu 0.039 lbs/MMBtu

HCl 0.006 lbs/MMBtu 0.035 lbs/MMBtu

Hg 9.00E-07 4.60E-06

CO 560 ppm @ 3% O2 490 ppm @ 3% O2

New – Biomass Stoker

PM 0.008 lbs/MMBtu 0.0011 lbs/MMBtu

HCl 0.004 lbs/MMBtu 0.0022 lbs/MMBtu

Hg 2.00E-07 3.50E-06

CO 560 ppm @ 3% O2 160 ppm @ 3% O2

Area Source Boiler MACT

Subcategory Pollutant Proposed

RuleEmission Limit Final Rule Emission

Limit

New Biomass fired boilers

≥ 30 MMBtu/hr

PM 0.03 lbs/MMBtu 0.03 lbs/MMBtu

CO 100 ppm 7% O2 Management Practice

New Biomass fired

boilers≥ 10 MMBtu/hr and < 30 MMbtu/hr

PM 0.03 lbs/MMBtu 0.07 lbs/MMBtu

CO 100 ppm 7% O2 Management Practice

Boilers Burning less than 15% biomass

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DESIGN VARIABLES FOR DRY SORBENT INJECTION

Flue Gas Design Flow Max / Normal / Low Turndown Considerations & Requirements

Sorbent Characteristics Particle Size Milling (Reactivity increases w/surface area)

Porosity Increase reactivity

Injection Location Flue Gas Temp. Temperature is critical for increased reactivity

Mixing Sorbent & Flue Gas Mixing (turndown required)

Residence Time Increased time allows for better improved reaction

Type of Particulate Collector Baghouse / ESP Required NSR

Computational Fluid Dynamics (CFD) Mixing CFD to determine injection locations

Injection Lance Design Open or w/Nozzles Mixing & Flue Gas turndown required

Sorbent Feed Rate Controls Fixed Feed Rate CEM control not practical (Hg)

Adjustable Feed Rate CEM controls Feed Rate (SOx)

Demonstration Testing Full Scale Testing Verification and Validation of Design

DRY SORBENT INJECTION

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DRY SORBENT INJECTION

DRY SORBENT INJECTION TEST PLAN Test Objective Acid Gas Mitigation % Removal vs Sorbent use. Establish Relationship.

Emission Controls Required - Today & Future.

Establish Co-Benefit Relationship - Nox; Hg Reductions.

Sorbent(s) to be used One or Multiple Trona; Sodium Bicarbonate; Calcium Hydroxide; etc.

PAC Several Vendors; Brominated; Enhanced PAC

Sorbent Particle Size Milling Requirements (*1)

CFD Requirement Injection Location Evaluate Duct Layout and Design with lance configuration.

Injection Location A/H Inlet High Temperature Zone ~700 F

A/H Outlet Low Temperature Zone ~300 F

Real Time Test Data Analysis CEM's Data Sox; Hg; Flue Gas Flow, Temperature, Oxygen Content

Ontario Hydro Test Will require 24 Hrs turnaround

Test Equipment Design Sorbent Silo / Bin Weigh Scales for real time feed rate data

Convey Air Supply Designed for Lances Flow and Pressure Requirements

Lances

Quantity & Design based on Injection Location and Mixing

Requirements

Results Interpretation Sorbent Consumption With existing APC Equipment

Projection with alternate Particulate Collector

Impact to Particulate

Collector Changes to be implemented (if any).

Impact to installed Boiler

Train

Evaluate impacts to SCR; Ash Characteristics & Disposal

Impacts (if any).

(*1) General Guideline: SO3 Control Milling may (not) be required due to low consumption.

SO2 Control

For removal rates >50%, Milling may reduce sorbent

utilization.

PERMANENT SYSTEM DESIGN

BASIS

Demonstrate & Validate Confirm Capital and Operating Costs

Sorbent Selection Evaluate Available Sorbents

Install Permanent System Design flexibility for today's need and future requirements

CALCIUM SORBENT REACTIONS

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• Ca(OH)2 + SO2 CaSO3 + H2O

• Ca(OH)2 + SO3 CaSO4 + H2O

• Ca(OH)2 + 2HCL CaCl2 + 2H2O

• Ca(OH)2 + 2HF CaF2 + 2H2O

CaSO3, CaSO4 , CaCl2 and CaF2 are collected in fly ash.

Na2SO4, NaCl, NaF and NaNO3 are collected in fly ash.

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SODIUM BICARBONATE / TRONA REACTIONS

• 2NaHCO3 Na2CO3 + H2O + CO2

• 2(Na2CO3 .NaHCO3.2 H2O) 3Na2CO3 + 5H2O + CO2

• Na2CO3 + SO2 + 1/2O2 Na2SO4 + CO2

• Na2CO3 + SO3 Na2SO4 + CO2

• Na2CO3 + 2HCl 2NaCl + H2O + CO2

• Na2CO3 + 2HF 2NaF + H2O + CO2

• Na2CO3 + NOx NaNO3 + CO2

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CALCIUM HYDROXIDE (Ca(OH)2

POLLUTANTS

NSR

1.0 1.5 2.0 2.5 3.0

SO2 1.16 1.74 2.32 2.90 3.48

SO3 0.93 1.40 1.86 2.33 2.79

HCL 1.01 1.52 2.02 2.53 3.03

HF 1.85 2.78 3.70 4.63 5.55

CALCIUM SORBENT REQUIRED (LBS/LBS)

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SODIUM SORBENT REQUIRED (LBS/LBS)

Trona / SOLVAir Select 200

POLLUTANTS

NSR

1.0 1.5 2.0

SO2 2.41 3.62 4.82

SO3 1.93 2.90 3.86

HCL 2.11 3.17 4.22

HF 3.86 5.79 7.72

SODIUM BICARBONATE

POLLUTANTS

NSR

1.0 1.5 2.0

SO2 2.63 3.95 5.26

SO3 2.10 3.15 4.20

HCL 2.30 3.45 4.60

HF 4.20 6.30 8.40

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SOLVAir(R) Select 200 Trona w/Baghouse)

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SOLVAY TEST REPORT (W/BAGHOUSE)

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0

10

20

30

40

50

60

70

80

90

100

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

NSR

SO

2 R

em

ov

al R

ate

(%

)

Trona 2006 Trona 2007 SBC

Comparison of SO2 Removal Rates with Trona and Sodium Bicarbonate (SBC) w/ESP

• The 2006 data was obtained during a test using a temporary set up. • The 2007 data was generated from a permanent installation • Unmilled trona Select 200: d90 = 140 µm, d50 = 30 µm

STURTEVANT MILL DESIGN SPECIFICATION

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Product Size Distribution = d50 10 – 15 um

Capacity 6 tph (with 100bhp/125hp Model 6HD)

Product outlet temperature <110dF

Blow through or gravity feed possible – 500 to 1000 cfm to cool

Feed Particles to be < ½” to protect against clogging

Mill can be cleaned via auto-wash or manually. When water wash is used, it must be off-line and must be dry before it is brought back on line.

STURTEVANT BLOW THRU MILL DESIGN

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TYPICAL TRONA SILO & INJECTION DESIGN

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IAC DSI LANCE TIP DESIGN

LANCE TIP DESIGNS

1. Bayonet Tip for even dispersion.

2. Flat end at staggered depths.

3. Flared end for co-current flow.

4. Dispersion “V” tip end.

Note:

1. Lance tip design is based on duct layout and arrangement

2. Lance diameter based on flow rates and quantity of lances utilized.

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SO3 / SULFURIC ACID CONTROL OPTIONS

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SO3 / SULFURIC ACID CONTROL OPTIONS

Fuel Additive

Dolomite

Magnesite

Furnace Injection

Micronized Lime

Aqueous Slurry Magnesium Hydroxide

Alkali Injection in to SCR Outlet / AH Inlet

Magnesium Oxide Powder

Trona / Sodium Bicarbonate

Slurry of Sodium Bisulfite/Sulfite (SBS)

Slurry of Caustic Soda (NaOH)

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SO3 / SULFURIC ACID CONTROL OPTIONS

Alkali Injection in at AH Outlet

Ammonia Injection (Anhydrous or Aqueous)

Hydrated Lime with or without Humidification

Wet ESP downstream of Limestone WFGD

With SO2 Control Options

Semi-Dry FGD

Alkaline (Caustic Soda; Magnesium Hydroxide) WFGD

Note:

1. Combination of SO3 Sorbents can be employed.

2. Multiple Sorbents can provide multi pollutant mitigation (SO3; Hg; HCL; Dioxin; etc.)

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MULTI-POLLUTANT MITIGATOPN WITH MULTI-SORBENT INJECTION

Fuel & Furnace Additive – SO2; SO3 Reduction

Dolomite

Magnesite

Micronized Lime

Aqueous Slurry Magnesium Hydroxide

Alkali Injection @ Air Heater Inlet/Outlet – HCL; SO2; SO3

Magnesium Oxide (or Hydroxide) Powder

Trona / Sodium Bicarbonate

Hydrated Lime

PC Fired Boiler

Salable Ash

Desired

ESP

Activated

Carbon

Fabric Filter

Fabric Filter

SCR / SNCR De-NOx

SO2

Scrubber

SCR Converts Hg to oxidized form

Oxidizes Elemental Hg and Adsorbs

Absorbs Oxidized Hg

PAC INJECTION FOR MERCURY REMOVAL

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CFD MODELLING FOR LANCE LOCATION

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IAC “SUPER SACK TEST RIG” WITH SCALES

Super-Sack Test Rig w/Screw Feeder & Weigh Scales

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IAC “SUPER SACK TEST RIG” WITH SCALES

Super-Sack Test Rig w/Screw Feeder & Weigh Scales

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MERCURY TESTING 132 MW PLANT / AIR HEATER OUTLET

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MERCURY TESTING 315 MW PLANT / AIR HEATER OUTLET

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DSI: SBC; LIME; TRONA SILO

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CONTROLLED INJECTION RATE WITH FEED BIN ON SCALES

MULTIPLE INJECTION LANCES FOR EVEN DISTRIBUTION

956 Cu.Ft. SILO W/BIN VENT

DSI – DEMONSTRATION TESTING (12,000 PPH)

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PD BLOWER IN ENCLOSURE – 800 ICFM CONVEY AIR

HEAT EXCHANGER

SILO ON SCALES

PIN MILL IN ENCLOSURE; RATED CAPACITY: 6 STPH

DSI – DEMONSTRATION TESTING

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HOPPER DISCHARGE:

• Manual Slide Gate Valve

• Rotary Valve w/VFD

• Blow Thru Adapter

CONTROL PANEL

• Control Logix PLC

• Touch Screen Controls

DSI – DEMONSTRATION TESTING (36,000) PPH

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Three DSI Bins with 3 Blowers

Bins on Scales for Varied Feed Rates

PD Blower in Sound Enclosure

One 6-Ton/Hr Pin Mill per Silo

Pin Mill in Sound/Weather Enclosure

DSI –TESTING EQUIPMENT

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PD Blower in Enclosure

Pin Mill w/Contriols in Enclosure

Bin Discharge with Live Bottom & Feeder

DSI –TESTING EQUIPMENT

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IAC- MULTI MIX SORBENT (IN DEVELOPMENT) – SOx & Hg MITIGATION

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PERFORMANCE OF IAC- MULTI MIX MERCURY REDUCTION

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DRY SORBENT INJECTION TEST PLAN Test Objective Acid Gas Mitigation % Removal vs Sorbent use. Establish Relationship.

Emission Controls Required - Today & Future.

Establish Co-Benefit Relationship - Nox; Hg Reductions.

Sorbent(s) to be used One or Multiple Trona; Sodium Bicarbonate; Calcium Hydroxide; etc.

PAC Several Vendors; Brominated; Enhanced PAC

Sorbent Particle Size Milling Requirements (*1)

CFD Requirement Injection Location Evaluate Duct Layout and Design with lance configuration.

Injection Location A/H Inlet High Temperature Zone ~700 F

A/H Outlet Low Temperature Zone ~300 F

Real Time Test Data Analysis CEM's Data Sox; Hg; Flue Gas Flow, Temperature, Oxygen Content

Ontario Hydro Test Will require 24 Hrs turnaround

Test Equipment Design Sorbent Silo / Bin Weigh Scales for real time feed rate data

Convey Air Supply Designed for Lances Flow and Pressure Requirements

Lances Quantity & Design based on Injection Location and Mixing Requirements

Results Interpretation Sorbent Consumption With existing APC Equipment

Projection with alternate Particulate Collector

Impact to Particulate Collector Changes to be implemented (if any).

Impact to installed Boiler

Train Evaluate impacts to SCR; Ash Characteristics & Disposal Impacts (if any).

(*1) General Guideline: SO3 Control Milling may (not) be required due to low consumption.

SO2 Control For removal rates >50%, Milling may reduce sorbent utilization.

PERMANENT SYSTEM DESIGN BASIS

Demonstrate & Validate Confirm Capital and Operating Costs

Sorbent Selection Evaluate Available Sorbents

Install Permanent System Design flexibility for today's need and future requirements

BENEFITS OF “RELIABLE DEMONSTRATION” TESTING

IAC “M” Intermediate Pressure Pulse Jet Baghouse 12 x 318TB-BHTP-500

Electric Arc Furnace Baghouse 1,200,000 ACFM @ 250 F

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IAC “M” Intermediate Pressure Pulse Jet Baghouse 12 x 318TB-BHTP-500

Penthouse Access: Top Doors; Headers & Valves; & Outlet Damper

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ASME 14in Headers with 3in Pulse Valves 25 Rows; 20 Bags per Row; Bag: 6” Dia x 26’-6” Long

IAC “M” Intermediate Pressure Pulse Jet Baghouse 6 x 234TB-BHTP-288

Coal Fired Boiler Baghouse 220,000 ACFM @ 420 F

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SUCTION CONVEYING FROM HOPPER TO STORAGE AND LOAD-OUT SILO

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Pneumatic Conveying from Flap Valve(s) at Hopper Discharge Receiver Filter at top of Silo

Articulating Arm w/Telescoping Load-Out Chute for Rail Car/Truck Loading

PEBBLE LIME ADDITION FOR ARSENIC MITIGATION

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SILO WITH SCALE CONTROL FOR LIMESTONE ADDITION ON COAL BELT

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IAC Representative DSI Installations

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Plant Unit MW Pollutant DSI Location Sorbent Date

Carbo Ceramics Line 4 N/A SO2/HCL/HF FF Inlet Trona Dec-12

AEC, Thomas Hill Unit 3 670 Hg AH Inlet AS-022 Nov-12

Sierra Pacific, Valmy Unit 1 250 SO2 AH Inlet SBC Sep-12

OMU; Elmer Station Unit 1 215 SO3 AH Inlet & Outlet Hydrated Lime Aug-12

Sierra Pacific, Valmy Unit 1 250 SO3 AH Inlet & Outlet Trona; SBC & Hydrated

Lime Jul-12

Santee Cooper, Winyah Generating Station

Unit 4 300 Hg Economizer Outlet; AH Inlet & Outlet;

ESP Inlet AS-022; & Hydrated Lime Jul-12

GRE, Stanton Station Unit 1 188 SO2 AH Inlet Trona May-12

OG&E; Sooner Station Unit 1 550 SO2 AH Inlet Trona; SBC Nov-11

U.S.Steel - Minntac Taconite Kiln N/A Hg Preheat & Waste Gas ID Fan Inlet

PAC Oct-11

Constellation Energy Crane 2 200 HCL AH Inlet & Outlet Trona; Hydrated Lime Sep-11

Constellation Energy Wagner 2 130 HCL AH Inlet & Outlet Trona; Hydrated Lime Aug-11

Constellation Energy Wagner 3 325 HCL AH Inlet & Outlet Trona; SBC Aug-11

OG&E; Sooner Station Unit 1 550 SO2 AH Inlet Trona; SBC Jul-11

GRE, Stanton Station Unit 1 188 SO2 AH Inlet Trona; SBC Jul-11

Luminant, Sandow Station Unit 4 550 SO3 AH Inlet MgO May-10

IAC Representative DSI Installations

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Plant Unit MW Pollutant DSI Location Sorbent Date

Constellation Energy Wagner 2 130 Hg & SO2 AH Inlet & Outlet PAC; Trona Apr-09

Constellation Energy Wagner 3 325 Hg & SO2 AH Inlet & Outlet PAC; Trona; SBC Apr-09

Temple Inland N/A Steam SO3 N/A Trona Feb-09

GRU; Deerhaven Gen. Sta. Unit 2 238 As Coal Belt Feed Pebble Lime Nov-08

Heron Lake Bio Energy, LLC Ethanol Plant Steam SO2 AH Inlet Trona Nov-08

Constellation Energy Wagner 3 325 HCL AH Inlet & Outlet PAC; Trona; SBC Apr-08

Constellation Energy Crane 1 200 HCL AH Inlet & Outlet PAC Apr-08

Lincolnway Energy Ethanol Plant Steam SO2 Boiler Outlet Trona Apr-08

Red Trail Energy, LLC Ethanol Plant Steam SO2 Boiler Outlet SBC Jun-07

Constellation Energy Wagner 2 130 Hg AH Outlet PAC May-07

Constellation Energy Wagner 3 325 Hg AH Outlet PAC; Trona; SBC May-07

Constellation Energy Crane 1 200 Hg AH Outlet PAC May-07

Corning Glass Furnace N/A HCL & HF Cooler Outlet Hydrated Lime Nov-04

Wabash Alloys Dickson, TN N/A HCL Baghouse Inlet Enviroblend Jul-01

Wabash Alloys Cleveland, OH N/A HCL Baghouse Inlet Enviroblend Jul-01

Wabash Alloys Tipton, IN N/A HCL Baghouse Inlet Enviroblend Jul-01

Wabash Alloys Wabash, IN N/A HCL Baghouse Inlet Enviroblend Jul-01

Excel Energy; Red Wing Sta. Unit 2 N/A SO2 Boiler Injection Limestone May-00

Excel Energy; Red Wing Sta. Unit 1 N/A SO2 Boiler Injection Limestone May-99

IAC Intermediate “M-Pulse” Baghouse Installations

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•Lincolnway Energy- Nevada, IA Coal Fired Boiler 220,000 ACFM 400F •Corn Products- LP Goldfield, IA Coal Fired Boiler 220,000 ACFM 400F •Red Trail- Richardton, ND Coal Fired Boiler 220,000 ACFM 400F •Heron Lake Bio Energy, MN Coal Fired Boiler 220,000 ACFM 400F •Caterpillar- Mapleton, IL Foundry Melt Shop 240,000 ACFM 250F •Nucor Steel-Blytheville, AR LMF and Meltshop 200,000 ACFM 250F •Drake Cement, Drake, AZ Raw Mill / Kiln 206,000 ACFM 482F •Drake Cement, Drake, AZ Clinker Cooler 98.100 ACFM 392F •Nucor Steel, Decatur, AL Electric Arc Furnace 1,200,000 ACFM 250F

•Dalmia Cement Ltd. Cement Mill 443,200 ACFM 194F •Krupp Polysius India Ltd. Kiln / Raw Mill 80,046 ACFM 464F •Birla / Satna Cement ESP Conversion 40,023 ACFM 203F •Birla / Satna Cement ESP Conversion 22,366 ACFM 203F

IAC Intermediate “M-Pulse” Installations in India

IAC Representative Hi-Pulse Baghouse Installations

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•Ashgrove Cement- Springfield, MO Lime Kiln 30,000 ACFM 400F •Cemex- Louisville, KY Clinker Hot Tank 25,000 ACFM 400F •IAT Incineration- Richmond, WA Medical/Bio-Waste 5,000 ACFM 500F •Continental Carbon- Ponca City, OK Carbon Black Reactor 20,000 ACFM 500F •PPG- Lake Charles, LA Glass Furnace 35,000 ACFM 480F •Phila Electric- Eddystone, PA Magnesium Oxide 225,000 ACFM 450F •Carbo Ceramics- Toomsboro, GA Lime Kiln 87,000 ACFM 450F •Ashgrove Cement- Portland, OR Lime Kiln 20,000 ACFM 425F •BMH/James Hardie- Nashville, AR Gypsum Dryer 120,000 ACFM 400F •BMH/Ga Pacific- Gypsum Dryer 80,000 ACFM 400F •Reynolds Metals- Anode Bake Fce 141,000 ACFM 450F •Intalco Aluminium- Ferndale, WA Anode Bake Fce 168,000 ACFM 450F •Cemex- Fairborn,OH Alkali By-Pass 65,000 ACFM 500F •Clow Corp- Oskaloosa, IA Electric Arc Furnace 2x27,500 ACFM 250F •Drake Cement, AZ Coal Mill 20,598 ACFM 194 F •Vienna Correctional Inst. Coal Fired Boiler 2x25,000 ACFM 450 F •Carbo Ceramics- Toomsboro, GA Lime Kiln#1 80,000 ACFM 425 F •Carbo Ceramics- Toomsboro, GA Lime Kiln#2 80,000 ACFM 425 F •Carbo Ceramics-Toomsboro, GA Lime Kiln#3 80,000 ACFM 425 F •Victaulic Foundry, Easton, Pa Induction Furnaces 80,000 ACFM 250 F •Victaulic Foundry, Chihuahua, MX Induction Furnaces 86,000 ACFM 250F

Contact Information Corporate Address: 4800 Lamar Avenue

Mission, Kansas 66202

Corp Tel: (913) 384.5511 E-Mail: iaccorp@iac-intl.com

Sales Tel: (800) 334.7431

Corp Fax: (913) 384.6577

Knoxville Address: Pramodh Nijhawan

318 Saint Andrews Drive

Knoxville, TN. 37934

Tel: (865) 675-7867 E-Mail: pnijhawan@iac-intl.com

Cell: (865) 300-3401

Fax: (865) 675-7582 Web: www.iac-intl.com

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