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Coal-fired power plants use different controls for two different pollutants: sulfur dioxide (SO₂), a gas formed when coal sulfur burns, and particulate matter, including fly ash carried in exhaust. Fuel choices and flue-gas desulfurization (FGD) reduce sulfur emissions; electrostatic precipitators (ESPs) and fabric filters collect particles. In many systems these controls work in sequence, and the captured material must still be managed as a residual.

Why SO₂ and particulate matter need different controls

Burning coal releases sulfur in the fuel as sulfur oxides, including SO₂, into the flue gas. The same combustion process also creates fly ash, some of which travels with that gas as particles. A scrubber or sorbent system targets SO₂ and other acid gases; an ESP or baghouse captures particles. Dry sulfur-control systems produce reaction solids that are collected by a downstream particulate device, so the systems can be linked without doing the same job.

How coal plants reduce sulfur dioxide

Lower the sulfur entering the boiler

Operators can select lower-sulfur coal, blend fuels, or switch fuels where the boiler and plant configuration allow. These measures reduce the sulfur available to form SO₂, rather than removing it after combustion. A change between coal ranks may require costly equipment modifications, and fuel switching is constrained by the plant’s design and fuel characteristics. The U.S. EPA describes fuel blending and switching as options for reducing acid-gas emissions in its Progress Report – Emission Controls and Monitoring.

Capture sulfur during combustion in some boilers

In a fluidized-bed boiler, limestone can be injected into the furnace to react with sulfur compounds as the fuel burns. This is a combustion-stage option, not a control that every coal boiler can use; applicability depends on boiler design and operating context. EPA discusses it among options under the Acid Rain Program and Cross-State Air Pollution Rule.

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Remove SO₂ from flue gas with FGD

Flue-gas desulfurization (FGD), commonly called scrubbing, is the principal post-combustion SO₂ control at coal-fired generating units. In wet FGD, exhaust contacts an alkaline liquid slurry, often lime- or limestone-based. SO₂ reacts with the reagent and is transferred into a liquid and residual stream. Reagent selection and plant design affect system size, cost, and performance.

EPA’s 2011 technical analysis describes modern wet scrubber technology as capable of 96% SO₂ removal. That is a technology capability, not a guaranteed result at every plant; actual performance depends on the installed system and operating conditions. EPA’s 2011 analysis is available in its Regulatory Impact Analysis for the Final Mercury and Air Toxics Standards.

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Use dry FGD or dry sorbent injection

Dry FGD brings the flue gas into contact with a sorbent without saturating the gas as in a wet scrubber. Its reaction products are solids, which are captured with fly ash by a downstream particulate collector. EPA’s 2011 technical analysis says modern lime-based dry FGD paired with a downstream fabric filter can remove at least 93% of SO₂. This figure also describes a technology capability, not a universal unit-level outcome.

Dry sorbent injection (DSI) feeds alkaline powder into the exhaust after combustion so it can react with acid gases. The resulting solids must then be collected. EPA says DSI is most efficient with a baghouse downstream; an ESP can also be used, though it may require more reagent to remove a similar amount of acid gas. The capture device and the sorbent process therefore need to be considered together.

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How plants remove particulate emissions

Electrostatic precipitators

An ESP uses electrical energy to charge particles in the gas stream and attract them to oppositely charged collection plates. In a dry ESP, mechanical rappers dislodge accumulated material from the plates; a wet ESP washes particles from its collection surfaces. EPA explains the mechanism and operating indicators in its Monitoring by Control Technique – Electrostatic Precipitators.

EPA reports that ESP collection efficiency can exceed 99%, but this is not a guarantee for every installation. Particle resistivity, flue-gas conditions, equipment design, and operation influence performance. Its monitoring guidance lists outlet particulate concentration and opacity alongside secondary corona power, voltage, current, spark rate, inlet temperature, gas flow, rapper operation, and active electrical fields as indicators operators can track.

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Fabric filters, or baghouses

A baghouse passes particle-laden gas through porous fabric bags. Dust builds up on the bags as a filter cake, which is periodically removed so the filters can continue operating. EPA’s 2011 analysis says fabric filters and ESPs can each remove more than 99% of PM2.5 mass in appropriate systems. EPA’s 1999 report describes typical baghouse efficiencies above 99%. These are technology-level descriptions, not a promise of a particular plant’s emissions; configuration and operating conditions matter.

Cyclones and mechanical pre-collectors

Cyclones and other mechanical collectors can separate larger particles before the gas reaches a higher-efficiency device. They should not be treated as a substitute for an ESP or baghouse when fine particles are the concern: EPA’s 1999 report notes that their collection efficiency falls well below 90% for the smallest particles. The report, Wastes from the Combustion of Fossil Fuels, also discusses collection systems and their residuals.

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What the controls capture—and what remains

Controls transfer pollutants out of the exhaust; they do not make the captured material cease to exist. Wet FGD produces a liquid and wet residual stream, while dry FGD and DSI leave solids that can be collected with ash. EPA’s 1999 report says wet systems produce more waste than dry systems. The form and amount of residuals affect handling and disposal requirements, so waste management is part of choosing and operating a control system.

How to compare control options at a plant

Control option Primary target and location Key consideration
Lower-sulfur coal, blending, or fuel switching Reduces sulfur entering the boiler, before combustion Fuel availability, coal chemistry, and boiler compatibility; some fuel changes require costly modifications.
Limestone injection in a fluidized-bed boiler Reacts with sulfur compounds in the furnace Applicable to suitable fluidized-bed boiler configurations, not all coal plants.
Wet FGD scrubber Captures SO₂ from flue gas using alkaline slurry Uses a liquid process and produces wet residuals; reagent and design affect performance and cost.
Dry FGD or DSI Reacts with SO₂ or other acid gases; solids are captured downstream Requires a particulate collector; DSI is most efficient with a baghouse, according to EPA.
ESP Collects particles from flue gas using electrical charge Performance depends in part on particle resistivity and gas conditions; electrical and mechanical operation require monitoring.
Fabric filter (baghouse) Collects particles as gas passes through filter bags Filter condition and cleaning are operational considerations; it can also collect dry sulfur-control products.
Cyclone or mechanical collector Pre-collects larger particles Not equivalent to an ESP or baghouse for fine-particle capture.

There is no universally best combination. Fuel chemistry, ash loading and resistivity, gas flow, existing equipment, retrofit space, reagent and energy needs, maintenance, local requirements, and residual handling all influence the choice. EPA notes that ESPs can be less flexible than fabric filters for fuel switching in some circumstances. Published removal figures describe technology capabilities under specified configurations; a plant’s measured results require unit-specific emissions data.

What EPA’s U.S. figures show about deployment and monitoring

In a report updated November 21, 2024, using data through 2023, EPA reported that FGD was installed at 75.2% of U.S. coal-fired units and at units generating 83.6% of U.S. coal-fired electricity measured in megawatt-hours. These are U.S. figures for 2023, not a current global deployment estimate. EPA calls FGD the principal means of controlling SO₂ at coal-fired electricity generating units. See the agency’s Progress Report – Emission Controls and Monitoring.

The same EPA report says 99% of SO₂ emissions from reporting units under the Cross-State Air Pollution Rule (CSAPR) were measured by continuous emissions monitoring systems (CEMS) in 2023, and that all coal-fired units in that reporting set monitored SO₂ using CEMS. The denominator is the reporting CSAPR units, not every U.S. plant. CEMS provide emissions measurements; equipment indicators such as ESP opacity, electrical readings, gas temperature, and flow can help operators identify control problems but are not substitutes for measured emissions.

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