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Abstract Modified magnetospheres (MAG) as a regenerable adsorbent offer a promising alternative to conventional activated carbon injection (ACI) for mercury removal from flue gas. However, large-scale application faces challenges in achieving uniform flue gas dispersion and in high-value recovery of desorbed mercury vapor from spent MAG rich in mercury. In this study, a dual strategy combining swirl injection and value-added HgSe recovery was developed. The swirl injection model was validated at a 315 MW coal-fired power plant, reducing mercury in flue gas to 0.035 μg/m 3, with swirl pressure identified as a key factor. An in situ selenium-based recovery agent (I–Se/SiO 2 ) selectively stabilized desorbed Hg 0, and DFT calculations indicated that it had significantly higher selectivity toward Hg 0 than HgCl 2 under flue gas conditions. Continuous field operation achieved 100% mercury recovery as pure HgSe (99.97%) with superior optical properties. Economic analysis showed that system investment and operating costs were only 32% and 19% of those for ACI, with a payback period under one year. This work establishes a new paradigm integrating end-of-pipe mercury abatement with resource recovery in coal-fired power plants.
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