Article Photos

McDONALD

S olar, wind, hydroelectric and other forms of ''green'' energy sources get most of the publicity when alternative energy is discussed.

But a family-owned McDonald company steeped in the Mahoning Valley's steel industry believes it has space-age technology to help make coal a cleaner source of power than it is now - and create local jobs in the process.

Already known for making pollution control equipment for coal-fired power plants, along with equipment for the coal mining and other heavy industries, Steel & Alloy Utility Products Inc. executives say they can build a system that will virtually eliminate the gas that creates acid rain.

''We felt we'd reached our peak,'' company Vice President Nick Gallo said of the company's existing system that cleans as much as 60 percent of gases produced by burning coal in power plants. ''We believed there had to be something better.''

The Gallos say they found it through their partner, Phoenix System International in Pine Brook, N.J., which has licensed the technology from the National Aeronautics and Space Administration. The space agency 10 to 15 years ago developed the method of removing emissions from the fuel stream when preparing the space shuttle.

The result of NASA's system left only fertilizer as the byproduct, which it used to enrich its orange groves, said Nat Gallo, father of Nick and Nathan and son of Thomas Gallo Sr., who founded Steel & Alloys in the 1940s.

Working with South Carolina Electric & Gas, the partners built a small pilot power plant in South Carolina to further develop the process, which the Gallos said is unique because it occurs after burning coal and so doesn't interfere with the burn.

The tests showed the process, called low temperature multipollutant control system, can remove 99.95 percent of sulfur dioxide, which creates acid rain, 98.25 percent of nitrous oxide and 95.15 percent of mercury.

The byproduct is material that can be used for fertilizer, which the customer could sell to help recoup its investment, they said. If a fertilizer buyer can't be found, the waste can be diluted with water and simply washed down the drain.

The Gallos said the process allows the addition of equipment to remove carbon dioxide, which is widely blamed for global warming because it traps the sun's heat and keeps it from escaping into space.

Instead of the common practice of storing the gas, the Gallos said their process allows the gas to be used in producing biodiesel or jet fuel, something they said already is being done using algae.

Besides being more efficient, the Gallos say their system offers 10 to 15 percent lower capital costs, 3 to 8 percent lower operating cost and uses less water than current technology.

In addition, tougher pollution requirements are scheduled to take effect over the next decade, requiring coal-using companies to drastically reduce emissions.

The Gallos say they're seeking financing to build a larger power plant capable of producing about 100 megawatts, a project they said would require roughly $100 million.

They said they're working with the offices of Gov. Ted Strickland and U.S. Rep. Timothy Ryan, D-Niles, to secure half of the cost and allow them to start building the equipment. The other half would come from the buyer.

If the Gallos find financing, they said their company has the expertise to make the large storage tanks, pumps, spray nozzles and other parts to build the system. The equipment would be shipped to a customer's site to be assembled.

Potential uses besides power production include garbage incineration, steelmaking and shipyards, they said.

Steel & Alloy, which has a few of its normal 60-worker staff idled due to the business downturn, could add 60 workers if the project takes shape on a small scale, the Gallos said.

''We're chomping to get started,'' Nathan Gallo said.

lringler@tribtoday.com