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This study presents a comprehensive evaluation of sorbent injection to mitigate sodium emissions in a 250 MW_e cyclone-fired boiler using lignite coal. Using historical boiler operational data, a computational fluid dynamics (CFD) model was validated and simulations were subsequently conducted to identify optimum sorbent injection locations for maximizing dispersion within the boiler cross-section and limiting sorbent temperatures to avoid deactivation. Data from the literature were used to guide sorbent injection rates and target sorbent particle sizes. Subsequent field demonstrations with the injection of a commercially available sorbent achieved a 60–80% reduction in the gas phase sodium, which was visually corroborated by reduced deposition on heat exchanger probes placed inside the boiler as well as by data on ash composition as a function of size. Furthermore, a diffusion-kinetic model, incorporating alkali vapor (NaOH) capture and subsequent sorbent deactivation, was developed and integrated into the CFD simulations as a post-processing tool and tested against the field demonstration data. Additional bench-scale testing was conducted with a range of sorbents as part of tool development for selecting from locally available sorbent sources. These bench-scale tests indicated a definite shift in the aerosol particle size distribution (PSD) toward a coarser range and depletion in the ultra-fine sizes, confirming the capture of vapor phase sodium species by the sorbents. Notably, in these tests, the sorbents remained effective even when they became molten, suggesting the potential for more convenient and cost-effective injection strategies. Full article