Recent advances in flue gas desulfurization gypsum processes and applications - A review

An assessment of inorganic components in condensable particulate matter as a function of surface aggregation, spatial suspension state and particle size

Experimental studies assessed the removal efficiency and fine-size distribution of CPM coupled with compositional analysis across air pollution control device systems (APCDs) at an ultra-low emission (ULE) power plant. The findings indicated total CPM emissions were reduced to a minimum of 0.418 mg/m3 at the Wet Electrostatic Precipitator (WESP). The Wet Flue Gas Desulfurization (WFGD) showed the highest removal efficiency (98%) across all particle sizes, notably in the ultra-micron range. Selective Catalytic Reduction (SCR) demonstrated a mere 34% overall efficiency, with a negative removal rate in the ultra-fine particle range. The WESP effectively removed CPM only in sub-micron and ultra-micron sizes, but significantly increased water-soluble ions formation in ultra-fine spatially suspended CPM (CPMspa), leading to overall negative efficiency. Thus, the removal efficiency of the ultra-fine particle range was most affected among the three particle size ranges when the flue gas went through the APCDs. Major metal elements and water-soluble ions were more readily removed by APCDs due to their surface aggregation, while the removal of trace elements like Hg and Se was limited. Reducing SO42-/NH4+ formation in SCR, and optimizing WESP spray system operations based on flue gas components are essential steps in controlling CPM concentration in ULE power plants.

Synthesis and utilization of polyol-modified high specific surface area Ca(OH)2: an investigation

Calcium hydroxide (Ca(OH)2) finds widespread use in the petrochemical industry, particularly in flue gas desulfurization applications. However, its conventional usage is limited by its inherently low specific surface area, hampering its efficiency. To address this limitation, this study aims to develop a simple and industrially scalable preparation process for Ca(OH)2 with a high specific surface area, thereby enhancing its effectiveness in various applications. This study aimed to develop a preparation process for making Ca(OH)2 with a high specific surface area, suitable for industry and easy to make. Ca(OH)2 with a specific surface area of 41.555 m2/g was successfully synthesized by incorporating polyols during lime digestion. The prepared high specific surface area Ca(OH)2 is more than five times the specific surface area of ordinary Ca(OH)2. Incorporation of polyols within the lime digestion process induces a reduction in both Ca(OH)2 grain size and particle dimensions, concurrently amplifying the specific surface area and optimizing mass transfer efficiency. Specifically, the desulfurization breakthrough time for Ca(OH)2 subject to a 15% triethanolamine modification was notably extended to 879 s, surpassing the desulfurization breakthrough time of unaltered Ca(OH)2 by more than tenfold. Moreover, the modified Ca(OH)2 exhibited remarkable efficacy in neutralizing acidic wastewater. A new approach for the preparation of high-performance Ca(OH)2 is proposed in this study, which could facilitate the industrial production of Ca(OH)2 with high specific surface area.

Application of the Industrial Byproduct Gypsum in Building Materials: A Review

The industrial byproduct gypsum is a general term for byproducts discharged from industrial production with calcium sulfate as the main ingredient. Due to the high number of impurities and production volume, the industrial byproduct gypsum is underutilized, leading to serious environmental problems. At present, only desulfurization gypsum and phosphogypsum have been partially utilized in cementitious materials, cement retarders, etc., while the prospects for the utilization of other byproduct gypsums remain worrying. This paper mainly focuses on the sources and physicochemical properties of various types of gypsum byproducts and summarizes the application scenarios of various gypsums in construction materials. Finally, some suggestions are proposed to solve the problem of the industrial byproduct gypsum. This review is informative for solving the environmental problems caused by gypsum accumulation.

A green method to clean copper slag and rapidly recover copper resources via reduction-sulfurizing smelting and super-gravity separation at low temperature

Massive copper slag containing heavy metals is produced in copper making and 0.5 - 8.0 wt% Cu is lost into it, deserving to be recovered. In this study, the waste coke and gypsum were employed to clean the copper slag, the lost copper was reduction-sulfurized and enriched to the matte droplets. However, the free-settling of matte droplets under normal gravity needed a higher temperature of 1350 ℃. On this basis, the matte droplets were efficiently separated from the cleaned slag via super-gravity at a low temperature of 1200 ℃ within 3 min, the recovery ratio of Cu was up to 99.56%, and the grade of Cu in the matte phase and cleaned slag was 85.84 wt% and 0.08 wt%, respectively. Moreover, the migration, distribution and leaching behavior of heavy metal elements (Pb, Zn, Ni, etc.,) were performed and analyzed, and the treatment and utilization of volatilized vapors and tailings were also discussed. This study proposed a green method to clean the copper slag and simultaneously recover copper resources via reduction-sulfurizing smelting and super-gravity separation at a low temperature, providing scientific guidance and application prospects for the synergistic treatment of hot copper slag with waste coke and gypsum.

Study on activation of fluorogypsum by sodium sulfate and sodium nitrite

Given the issues related to poor hydration activity, long setting time and low early strength of industrial by-product fluorogypsum (FG), the composite modifiers (Na2SO4 and NaNO2) were utilized to enhance its reactivity. The investigation of the mechanism involved the utilization of contemporary analytical methods, including X-ray diffraction (XRD), 1H low-field nuclear magnetic resonance (NMR), and Scanning electron microscope and Energy Dispersive Spectrometer (SEM-EDS). The results demonstrated that the incorporation of modifiers significantly enhanced both the hydration rate and activity of fluorogypsum. The optimum concentration of the composite modifier was found to be 1.5 wt% Na2SO4 and 0.5 wt% NaNO2. The addition of modifiers (1.5 wt% Na2SO4 and 0.5 wt% NaNO2) significantly shortens the setting time of FG paste, reducing it by approximately 500 min compared to the control sample. After 28 days of curing, the flexural strength and compressive strength of the fluorogypsum sample containing modifiers (1.5 wt% Na2SO4 and 0.5 wt% NaNO2) increased by 55.5 % (reaching 4.2 MPa) and 31.5 % (reaching 37.6 MPa), respectively. The modifiers facilitate the transformation from anhydrite (CaSO4, AH) to dihydrate gypsum (CaSO4·2H2O, DH). Both NaNO2 and Na2SO4 alter the growth rates of different crystal axes during DH crystal growth, transforming them into prismatic and needle-shaped DH. The prismatic and needle-shaped DH crystals were arranged in layers, resulting in a compact structure with low hole content and few pores, which led to increased density of the hardened paste and higher strength. The current study provides evidence that the inclusion of composite modifiers greatly improves the activity of FG, making it more efficient in the field of building materials.

Application of Calcium Sulfate Whiskers to Cement-Based Materials: A Review

In recent years, significant attention has been paid to the use of calcium sulfate whiskers (CSWs) to enhance the performance of cement-based materials (CBM). This technology has attracted widespread interest from researchers because it enhances the performance and sustainability of CBM by modifying the crystal structure of calcium sulfate. This article summarizes the fundamental properties and preparation methods of calcium sulfate whisker materials as well as their applications in cement, potential advantages and disadvantages, and practical applications and prospects. The introduction of CSWs has been demonstrated to enhance the strength, durability, and crack resistance of CBM while also addressing concerns related to permeability and shrinkage. The application of this technology is expected to improve the quality and lifespan of buildings, reduce maintenance costs, and positively impact the environment. The use of CSWs in CBM represents a promising material innovation that offers lasting and sustainable advancement in the construction industry.

Advancements and sustainable strategies for the treatment and management of wastewaters from metallurgical industries: an overview

Metallurgy is pivotal for societal progress, yet it yields wastewater laden with hazardous compounds. Adhering to stringent environmental mandates, the scientific and industrial sectors are actively researching resilient treatment and disposal solutions for metallurgical effluents. The primary origins of organic pollutants within the metallurgical sector include processes such as coke quenching, steel rolling, solvent extraction, and electroplating. This article provides a detailed analysis of strategies for treating steel industry waste in wastewater treatment. Recent advancements in membrane technologies, adsorption, and various other processes for removing hazardous pollutants from steel industrial wastewater are comprehensively reviewed. The literature review reveals that advanced oxidation processes (AOPs) demonstrate superior effectiveness in eliminating persistent contaminants. However, the major challenges to their industrial-scale implementation are their cost and scalability. Additionally, it was discovered that employing a series of biological reactors instead of single-step biological processes enhances command over microbial communities and operating variables, thus boosting the efficacy of the treatment mechanism (e.g., achieving a chemical oxygen demand (COD) elimination rate of over 90%). This review seeks to conduct an in-depth examination of the current state of treating metallurgical wastewater, with a particular emphasis on strategies for pollutant removal. These pollutants exhibit distinct features influenced by the technologies and workflows unique to their respective processes, including factors such as their composition, physicochemical properties, and concentrations. Therefore, it is of utmost importance for customized treatment and disposal approaches, which are the central focus of this review. In this context, we will explore these methods, highlighting their advantages and characteristics.

Characterization of flue gas desulphurized (FGD) gypsum of a coal-fired plant and its relevant risk of associated potential toxic elements in sodic soil reclamation

Thermal Power Plant generates FGD gypsum as by-product during coal combustion. This study evaluates the characterization (spectroscopic and elemental), potentially toxic elements (PTEs) distribution, and environmental risk assessment of FGD gypsum for safe and sustainable use in agriculture. The XRD and SEM analysis confirmed the dominance of crystalline CaSO4·2H2O in FGD gypsum. The order of concentrations of PTEs in FGD gypsum was Fe > Al > Mn > Zn > Ni > Co. The residual fraction was the dominant pool, sharing 80-90% of the total PTEs. The heavy metals (HMs) were below the toxic range in the leachates. The Co, Ni, Al, Fe Mn, Zn had low (< 10%) risk assessment code and the ecotoxicity was in the range of 0.0-7.46%. The contamination factor was also low (0.0-0.16) at the normal recommended doses of FGD gypsum application for sodicity reclamation. The enrichment factor was in the order of Al < Mn < Co < Zn < Ni. Mn [enrichment factor (Ef) 1.2-2.0] and Co (Ef 1.7-2.8) showed negligible enrichment of metals, whereas Ni (Ef 4.3-5.2) and Zn (Ef 4.5-5.6) reported moderate accumulation in soil. The application of FGD gypsum @ 10 t ha-1 for sodicity reclamation will develop a geo-accumulation index below the critical values indicating its safe and sustainable use to achieve land degradation neutrality (LDN) and UN's Sustainable Development Goals.

Interactions between flue gas desulfurization gypsum and biochar on water infiltration characteristics and physicochemical properties of saline-alkaline soil

The application of flue gas desulfurization gypsum (FGDG) improves the soil structure, reduces soil pH, and accelerates soil salt leaching. Biochar amendment to soil can affect the soil infiltration rate, increase soil porosity, decrease soil bulk density, and enhance the water retention capacity. This study investigated the interactive effect of FGDG and biochar on water infiltration characteristics and physicochemical properties as well as determined the optimal amendment rate as a saline-alkaline soil conditioner. Seven experimental schemes were designed, and the newly reclaimed cultivated soil from Pingtan Comprehensive Experimental Zone in Fujian Province, China, was used in an indoor soil column experiment to simulate soil infiltration. Five models were employed to describe the infiltration process. The power function was used to represent the dynamic process of the wetting front. The conclusions of this study are as follows: (1) there was a reduction in the infiltration capacity of saline-alkaline soil (sandy soil) in each treatment, and the application of FGDG alone had the highest inhibition effect compared to the control (CK). The Kostiakov model provides the best fit for the experimental data of soil cumulative infiltration. (2) All treatments increased the total porosity and water content of saline-alkali soil, with the combined application of FGDG and biochar found to be more effective. (3) The application of FGDG alone or in combination with biochar decreased the pH and increased the electrical conductivity of the saline-alkali soil significantly, with the combined application having the most significant effect. In contrast, soil amended with biochar alone had minimal effect on the pH and EC of the soil. (4) The best improvement ratio was achieved with the F1B2 combination (75 g/kg FGDG + 30 g/kg biochar).

Effectiveness of flue gas desulfurization gypsum in reducing phosphorus solubility in poultry litter when applied as an in-house amendment

Phosphorus (P) runoff from agricultural lands receiving poultry litter (PL) poses a major environmental challenge. Application of flue-gas-desulfurization (FGD)-gypsum produced from coal power plants in agricultural lands has shown promise to reduce P losses. However, no information is available about the effectiveness of FGD-gypsum addition in reducing P solubility when applied as an in-house amendment. Hence, the objectives of this study were to understand a) effectiveness of FGD-gypsum as a litter amendment in reducing P loss risk; and b) how FGD-gypsum amendment in PL alters the distribution of P forms. Broiler chickens were raised for five flocks in seven individual litter treatments replicated four times in a randomized complete block design. Based on the FGD-gypsum addition, the PL treatments were broadly classified as FGD-gypsum treated and untreated. Toxic metal concentrations were analyzed in FGD-gypsum as well as the treatments. Sequential water extractions were performed to understand P solubility. Litter P fractionation was performed to identify bioavailable P (Water-P), labile P (NaHCO3-P), aluminum/iron chemisorbed P (NaOH-P), and mineral occluded P (HCl-P). Results indicated significantly higher soluble P in all untreated than in all FGD-gypsum treated litters in the initial water extraction. The FGD-gypsum treated litters reduced soluble P by 58 to 67% in the 1st water extraction compared to untreated litters. Fractionation study revealed lower proportion of Water-P and higher proportion of NaHCO3-P and HCl-P in all FGD-gypsum treated than in untreated litters. This study suggests reuse of FGD-gypsum in broiler houses can help reduce P mobility without any toxic metals concerns.

Investigating the Corrosive Influence of Chloride Ions on Slag Recovery Machine Shells in Power Plants

An effective strategy for achieving cost-effective and environmentally friendly desulfurization wastewater in coal-fired power plants involves the incorporation of desulfurization wastewater into the slag water system. The objective of this study was to analyze the corrosion behavior of Q235-A slag-picker shell material upon the introduction of FGD wastewater into the slag water system. The dynamic weight loss method, electrochemical testing method and microscopic phase characterization were employed to investigate the impact of varying chloride ion concentrations (ranging from 1000 mg/L to 30,000 mg/L) of flue gas desulfurization wastewater (FGD wastewater) on the corrosion of Q235-A slag-picker shell material. The test results indicate that as the concentration of chloride ions increases, the corrosion rate increases from 1.1487 mm/a to 1.5590 mm/a when the concentration is less than 10,000 mg/L. However, when the concentration exceeds 10,000 mg/L, the corrosion rate decreases from 1.559 mm/a to 1.0393 mm/a. The corrosion rate is above 1 mm/a at all concentrations. As the Cl- concentration, the quality of the corrosion product film initially increases and then decreases. The primary components of the corrosion product are α- FeOOH, γ-FeOOH, β-FeOOH, Fe3O4 and γ-Fe2O3.

Heavy metal pollution risk of desulfurized steel slag as a soil amendment in cycling use of solid wastes

The by-product of wet flue gas desulfurization, desulfurized steel slag (DS), had chemical characteristics like natural gypsum that can be used to improve saline-sodic soil. However, contamination risk of heavy metals for cycling utilization of DS in agriculture was concerned mostly. Both pot and field experiments were conducted for evaluating the potential pollution risk of DS as the amendment of saline-sodic soil. Results showed that application of DS decreased the contents of Cd, Cu, Zn, and Pb, while significantly increasing chromium (Cr) content in DS-amended soils. The field experiment demonstrated that the migration of heavy metals (Cd, Zn, Cu, and Pb) in the soil profile was negligible. The application of DS at the dosage of 22.5-225 tons/ha significantly increased the Cr content in alfalfa (Medicago sativa L.) but lower than the national standard for feed in China (GB 13078-2017). DS altered the chemical fraction of heavy metals (Zn, Cu, and Pb), transferred exchangeable, reducible into oxidizable and residual forms in DS-amended soil. Application of DS combined with fulvic acid (FA) could effectively reduce the movement of heavy metals in soil and the accumulation of Cr in alfalfa. Based on our results, DS was a safe and feasible material for agricultural use and presented relatively little pollution risk of heavy metals. However, the results also showed that DS to a certain extent had a potential environmental risk of Cr if larger dosages of DS were used.

Resource utilization of high-concentration SO2 for sulfur production over La-Ce-Ox composite oxide catalyst

Sulfur dioxide is one of the main causes of air pollution such as acid rain and photochemical smog, and its pollution control and resource utilization have become important research directions. La₂O₃ was incorporated into CeO₂ to enhance the surface basicity of La-Ce-O_x catalyst and increase the concentration of chemisorbed oxygen, thereby promoting the improvement of catalytic performance of SO₂ reduction by CO. Results have showed that the incorporation of La₂O₃ would not only increase the concentration of chemisorbed oxygen and hydroxyl on the catalyst surface, but also increase the basicity of the catalyst, thereby facilitating the adsorption of SO₂ on the catalyst surface. The 12%La-Ce-O_x was the optimal catalyst, and its SO₂ conversion at 350-400 ℃ reached close to 100%, and the sulfur yield at this temperature range was higher than 93%. Finally, according to the in situ infrared diffuse reflectance spectrum, it was found that the main reaction intermediates of 12%La-Ce-O_x in the catalytic reduction of SO₂ were weakly adsorbed sulfate, SO₃^2-, non-coordinating CO₃^2-, monodentate carbonate, and CO, so the catalytic reaction followed the L-H and E-R mechanisms simultaneously.

Garbage-classification policy changes characteristics of municipal-solid-waste fly ash in China

Policy is a powerful tool determining solid-waste treatment and disposal. In 2019, China carried out the "garbage-classification policy" in 46 cities. So-called dry garbage is then separated from municipal solid waste and treated alone by incineration. This work investigated the influence of the policy on contents and leaching characterizations of municipal solid waste incineration fly ash. Median value of Cl was significantly increased from 17.43 wt% to 28.63 wt%. Median content of CaO maintained a similar value (51.21 wt% and 47.27 wt%). Ten year ago, CaClOH was not generally observed in fly ash. However, this phase was widely detected nowadays. Median value of heavy-metal (Zn, Pb, Cu, Cd, Cr, and Ni) was decreased from 9007.69 mg/kg to 7652.72 mg/kg. Thus, the policy also positively affected hazardous-waste collection. Heavy-metal leaching concentrations were decreased and chemical speciation became more stable because CaClOH supplied more alkalinity and binding ability for heavy metals. Therefore, fly-ash treatment technologies and their running parameters should be regulated to adapt above new characterizations after the garbage-classification policy.

Identification of mercury species in coal combustion by-products from power plants using thermal desorption-atomic fluorescence spectrometry on-line coupling system

Along with the environmental protection policies becoming strict in China, the air pollution control devices (especially selective catalytic reduction (SCR)) are widely equipped in coal-fired power plants. The installation and run of these devices will inevitably affect mercury (Hg) species distribution in coal fired by-products such like fly ash (FA) and gypsum. In this work, a new on-line coupling system based on atomic fluorescence spectrometry (AFS) with a home-made chromatographic workstation was successfully developed to identify Hg species through thermal programmed desorption (TPD). The influences of matrix, furnace temperature, and carrier gas flow on analytical performance were investigated and the parameters were optimized. The FA and gypsum samples from coal-fired power plants equipped with SCR were collected and the mercury species were analyzed by the developed coupling system. HgCl₂ and HgO were the main species in FA, while Hg₂Cl₂ and HgO were the main species in gypsum. All of Hg species in the studied FA and gypsum samples were released below 400 °C. A sequential extraction procedure was applied to further verify the operational Hg species including mobile and non-mobile fractions in FA and gypsum samples. This study demonstrated that AFS coupled with TPD procedure was an effective method to analyze Hg species in coal combustion by-products from power plants.

Mercury sources, contaminations, mercury cycle, detection and treatment techniques: A review

Mercury is considered a toxic pollutant harmful to our human health and the environment. Mercury is highly persistent, volatile and bioaccumulated and enters into the food chain, destroying our ecosystem. The levels of mercury in the water bodies as well as in the atmosphere are affected by anthropogenic and natural activities. In this review, the mercury species as well as the mercury contamination towards water, soil and air are discussed in detail. In addition to that, the sources of mercury and the mercury cycle in the aquatic system are also discussed. The determination of mercury with various methods such as with modified electrodes and nanomaterials was elaborated in brief. The treatment in the removal of mercury such as adsorption, electrooxidation and photocatalysis were explained with recent ideologies and among them, adsorption was considered one of the efficient techniques in terms of cost and mercury removal.

Zero-liquid discharge technologies for desulfurization wastewater: A review

Zero-Liquid Discharge (ZLD) has received a lot of attention due to water scarcity and pollution. This article reviews the treatment of desulfurization wastewater in pretreatment, concentration and solidification with the trend of zero-liquid discharge in China. We summarize the advantages, disadvantages, performance, benefits and other characteristics of different ZLD technologies. Membrane-based technology is an effective means of recycling wastewater in ZLD systems. Therefore, we focus on the application of bipolar membrane electrodialysis (BMED) in desulfurization wastewater and high-salt wastewater treatment, discussing its limitations and solutions. In addition, several Chinese ZLD cases and economic analysis are introduced. It is believed that ZLD will become a new trend in desulfurization wastewater treatment in the future. Therefore, exploring new materials and technologies with low cost and high efficiency is the focus of future work.

Membrane Separation Used as Treatment of Alkaline Wastewater from a Maritime Scrubber Unit

Since 1 January 2020, the sulfur content allowed in exhaust gas plume generated by marine vessels decreased to 0.5% m/m. To be compliant, a hybrid scrubber was installed on-board, working in closed loop and generating a high volume of alkaline wastewater. The alkaline water suspension was treated by a silicon carbide multitubular membrane to remove pollutants, and to allow the water discharge into the natural environment. In this paper, membrane filtration behavior was analyzed for the maritime scrubber wastewater. A range of operating parameters were obtained for several feedwater quality-respecting industrial constraints. The objective was an improvement of (I) the water recovery rate, (II) the filtration duration, and (III) the permeate quality. Thus, in high-fouling water, a low permeate flow (60 L h^-1 m^-2) with frequent backflushing (every 20 min) was used to maintain membrane performance over time. In terms of water quality, the suspended solids and heavy metals were retained at more than 99% and 90%, respectively. Other seawater discharge criteria in terms of suspended solids concentration, pH, and polyaromatic hydrocarbons were validated. The recommended operating conditions from laboratory study at semi-industrial scale were then implemented on a vessel in real navigation conditions with results in agreement with expectations.

Numerical Simulation of Multi-Nozzle Droplet Evaporation Characteristics for Desulfurization Wastewater

Spraying flue gas desulfurization wastewater into flue ducts is an emerging technology that is receiving extensive attention in thermal power plants. In order to study the evaporative performance of wastewater-atomizing droplets under variable working conditions, a combined Euler–Lagrange model was developed to demonstrate the thermal behavior of FGD wastewater spray evaporation in flue gas. The effects of several control factors under various operating conditions were numerically determined and validated against experimental data. Due to the complicated parameters and various other conditions, a least-square support vector machine (LSSVM) model relying on numerical results was used to anticipate the evaporation rate of the droplets. We prove that the LSSVM model has high prediction accuracy for the evaporation rate at different cross-sections of flue under a different operating situation. The conclusion is that for the sake of improving the quality of evaporation, the spacing between two adjacent nozzles should be increased while increasing the flow rate. However, using a higher flue gas temperature, higher initial temperature and smaller diameter of droplets can shorten the time and distance of complete evaporation. In summary, this research analysis can be used effectively to determine the design of the FGD wastewater flue gas evaporative process in thermal power plants.

Recycling of Industrial Waste Gypsum Using Mineral Carbonation

Direct mineral carbonation (MC) is used to mitigate carbon dioxide (CO2) emissions. This method has the great advantages of reducing the amount of industrial residues and creating valuable materials by incorporating CO2. Waste gypsum, industrial waste including flue gas desulfurization (FGD) gypsum (25.27–53.40 wt% of CaO), and phosphogypsum (30.50–39.06 wt% of CaO) can be used for direct MC (conversion rate up to 96%). Mineral carbonation converts waste gypsum into calcium carbonate (CaCO3), which can be recycled during desulfurization. Furthermore, ammonium sulfate ((NH4)2SO4), which is used as a fertilizer, can be prepared as a by-product when the carbonation reaction is performed using ammonia (NH3) as a base. In this study, recent progress in the carbonation kinetics and preparation of CaCO3 using FGD gypsum and phosphogypsum with NH3 was investigated. Temperature, CO2 partial pressure, CO2 flow rate, and NH3 concentration were reviewed as factors affecting carbonation kinetics and efficiency. The factors influencing the polymorphs of the prepared CaCO3 were also reviewed and summarized. A state-of-the-art bench-scale plant study was also proposed. In addition, economic feasibility was investigated based on a bench-scale study to analyze the future applicability of this technology.

Preparation of CSHW with Flue Gas Desulfurization Gypsum

Calcium sulfate hemihydrate whiskers (CSHW), a multi-functional and high value-added building material, were prepared with flue gas desulfurization (FGD) gypsum by hydrothermal method, which could be a reasonable disposal of FGD gypsum. In order to obtain CSHW of a high aspect ratio, a series of manufacturing parameters such as reaction temperature, stirring speed, material-water ratio, and reaction time were investigated. The effect of stabilizing treatment and glycerol concentration on CSHW morphology were also studied by environmental scanning electron microscopy (ESEM) and statistical analysis. The results showed that the optimum preparing conditions of reaction temperature, stirring speed, water-material ratio, and reaction time were 160 °C, 200~300 rpm, 11:1 and 1 h, respectively. Furthermore, stabilizing treatment with octodecyl betaine was necessary for the preparation of CSHW. The final prepared whiskers had smooth surface, uniform morphology, a diameter of 260 nm, and a corresponding aspect ratio of 208.2. Moreover, the addition of glycerol reduced the activity of water, contributing to a lower reaction temperature and much smaller diameter.

Pilot-scale study on seeded precipitation assisted nanofiltration for flue-gas desulfurization wastewater softening

In order to reduce the cost of chemical softening, the seeded precipitation assisted nanofiltration (NF) process was introduced into zero liquid discharge (ZLD) of flue-gas desulfurization (FGD) wastewater treatment. A pilot-scale system was developed and run for 168 h in a coal-fired power plant. The system mainly consists of lime softening, ambient temperature crystallizer (ATC) and NF, in which the raw water treatment capacity was 1 m³/h. The results indicated that the system operated stably, the softening cost was 13.30 RMB/m³, and the electricity cost was 3.39 RMB/m³ for the FGD wastewater in this pilot system. High quality gypsum was got from the ATC unit, of which the purity was 95.8%. Through this system, the hardness removal rate was higher than 98.9% and the water recovery rate reached 96%. In addition, the pressure and permeate flux kept stable in the ultrafiltration (UF) unit and NF unit, indicating no scaling occurred in the two units during 168 h test. Thus, a feasible and cost-effective process was provided by using the seeded precipitation assisted NF to deal with the FGD wastewater.

Indirect aqueous carbonation of CaSO4·2H2O with aspartic acid as a recyclable additive

Calcium leaching using additives is the most critical step in the indirect aqueous carbonation process of CaSO₄·2H₂O. However, recovery of the soluble additives from the sulfate-rich carbonation filtrate limits the large-scale industrial implementation of current carbonation technologies. To address this issue, we employed aspartic acid (Asp) as a leaching additive. The dissolution capability of CaSO₄·2H₂O in aqueous ammonia was found to improve significantly owing to the complexation effect between Asp and the Ca²⁺ ions. The maximum amount of dissolved CaSO₄·2H₂O was determined according to the competitive relationship between the complexing effect and the inhibitory effect of free ammonia molecules on the dissociation of CaSO₄·2H₂O, and the solution pH influences such competition. The precipitation of CaCO₃ was examined by monitoring the variations in the pH and conductivity of the carbonation reaction system. As a result, the shift in the Asp dissociation equilibrium extended the induction period, and the growth period was divided into three stages according to the relative difference between the consumption and formation rates of CO₃²⁻. Moreover, it was determined that the carbonation products consisted of stable spherical vaterite particles. The recovery of Asp was also demonstrated at its isoelectric point, with a recovery efficiency of >80% being achieved, and recycling experiments confirmed the stability of the recycled Asp. Finally, the amount of dissolved CaSO₄·2H₂O and the total carbonation efficiency during cycling were determined as 16.3 ± 0.4 g L⁻¹ and 46.5 ± 1.9%, respectively.

Aspartic acid was employed as a recyclable additive during the indirect aqueous carbonation of CaSO₄·2H₂O. The multiple roles of aspartic acid were found to be Ca²⁺ leaching agent, CO₂ absorbent, and CaCO₃ polymorph regulator.

Influence of Calcined Flue Gas Desulfurization Gypsum and Calcium Aluminate on the Strength and AFt Evolution of Fly Ash Blended Concrete under Steam Curing

In order to improve the early strength of fly ash blended cement concrete under steam curing conditions, fly ash was partly substituted by calcined flue gas desulfurization (FGD) gypsum and active calcium aluminate. The effect of the composition and curing condition on the workability, mechanical property, and volume stability was systematically evaluated. The variety of hydration products and the evolution was determined by XRD to explore the formation kinetic of ettringite. Results show that the addition of calcined FGD gypsum and active calcium aluminate is able to improve the early compressive strength but using more FGD gypsum and a high sulfur aluminum ratio leads to a reduction in compressive strength from 28 to 90 days due to the increment of ettringite and crystallization of dihydrate gypsum. Both the free expansion ratio and limited expansion exhibited a continuous increasement with time, especially in the first 14 days of testing. Cracks were not observed on the surface of samples immersed in water for a year. The improvement of strength and shrinkage resistance is mainly due to the formation of ettringite generated before 14 days and the precipitation was highly limited from 14 to 28 days. Moreover, the characteristic peak of gypsum appeared after 28 days, indicating the conversion of partial of calcined FGD gypsum. The work presented here provides a new solution for improving the early strength of fly ash concrete without reducing the later strength and consuming extra energy.

Intracluster Sulphur Dioxide Oxidation by Sodium Chlorite Anions: A Mass Spectrometric Study

The reactivity of [NaL·ClO₂]⁻ cluster anions (L = ClO_x⁻; x = 0–3) with sulphur dioxide has been investigated in the gas phase by ion–molecule reaction experiments (IMR) performed in an in-house modified Ion Trap mass spectrometer (IT-MS). The kinetic analysis revealed that SO₂ is efficiently oxidised by oxygen-atom (OAT), oxygen-ion (OIT) and double oxygen transfer (DOT) reactions. The main difference from the previously investigated free reactive ClO₂⁻ is the occurrence of intracluster OIT and DOT processes, which are mediated by the different ligands of the chlorite anion. This gas-phase study highlights the importance of studying the intrinsic properties of simple reacting species, with the aim of elucidating the elementary steps of complex processes occurring in solution, such as the oxidation of sulphur dioxide.

Band application of flue gas desulfurization gypsum improves sodic soil amelioration

Blending flue gas desulfurization (FGD) gypsum with surface sodic soil is a universally recognized method for the rapid amelioration of sodic soils; however, little information is available on whether other application methods (band application) will reclaim sodic soil. Three FGD gypsum application methods (single-band, dual-band and blend applications) and a control treatment (non-FGD gypsum) were carried out using sodic soil in soil bins to investigate the effects of the application method on the wetting front, major cations in the leachate during the process of water infiltration and soluble and exchangeable cations in the soil profile after infiltration. The results showed that the wetting fronts in the band treatments were denser in the horizontal direction than in the vertical direction, but the blend and control treatments only had vertical migration. The main channel of the stream in the band treatment was concentrated below the application site of FGD gypsum. The orders of desalting capacity were blend treatment, dual-band treatment and single-band treatment for the same volume of outlet water. There was no water outflow in the control treatment even after 115 days of leaching. The dual-band treatment significantly decreased the soil sodicity of the 0-40 cm soil profile, while the single-band treatment only effectively reclaimed (horizontally) half of the soil. In the blend treatment, the exchangeable sodium percentages were 21.3 % and 34.7 % at depths of 30-35 cm and 35-40 cm, respectively, and were close to zero at a depth of 0-30 cm. Compared with blend treatment, band application could be a better way to reclaim sodic soil with FGD gypsum due to its advantages of long-term and efficient amelioration with low consumption.

Physical, Chemical and Geotechnical Characterization of Wet Flue Gas Desulfurization Gypsum and Its Potential Application as Building Materials

In South Africa, coal represents the primary source of energy used for electricity generation. Coal power plants use the wet flue gas desulfurization (WFGD) process to remove sulfur dioxide (SO2) from their flue gas. However, this technology produces a large amount of synthetic gypsum, resulting in waste disposal and environmental pollution. This study investigated the physical, chemical and geotechnical properties of WFGD gypsum and its potential application to develop cement-free bricks. WFGD gypsum was collected from a coal power plant in South Africa. It was found that the principal oxides of WFGD gypsum were sulfur trioxide (SO3) and calcium oxide (CaO), which represented more than 90% of the total weight. Calcium sulfate (CaSO4) and calcium di aluminate (CA2) were the predominant minerals in the raw material. The density of the WFGD gypsum was 2.43 g/cm3. The maximum dry density and optimum moisture content values were 1425 kg/m3 and 18.5%, respectively. WFGD gypsum had a liquid limit of 51% but did not display any plasticity characteristics. The optimum curing temperature of gypsum bricks was 40 °C. WFGD gypsum-based bricks exhibited compressive strength of up to 2.3 MPa and a density of about 28% less than that of typical clay bricks. Additionally, there was no significant decrease in compressive strength after seven wet/dry cycles. These results show that WFGD gypsum could be used to produce lightweight building materials with low strength requirements.

Gaseous mercury re-emission from wet flue gas desulfurization wastewater aeration basins: A review

Wet flue gas desulfurization (WFGD) simultaneously removes Hg and SO₂ from coal-fired power plant flue gas streams. Hg⁰ re-emission occurs when the dissolved Hg(II) is converted to a volatile form (i.e., Hg⁰) that can be subsequently emitted into the ambient air from WFGD wastewater aeration basins. Others have shown that Hg⁰ re-emission depends on pH, temperature, ligands (Cl, Br, I, F, SO₃^2-, SO₄^2-, NO₃^-, SCN^-, and ClO^-), O₂, minerals (Se and As), and metals (Fe and Cu) in WFGD wastewater. Still others have shown Hg⁰ re-emission restriction via inhibitor addition (adsorbents and precipitators). This is the first review that summarizes the complex and inconsistently reported Hg⁰ re-emission mechanisms, updates misconceptions related to Hg(II) complexation and reduction, and reviews applications of inhibitors that convert aqueous Hg(II) into stable solid forms to prevent gaseous Hg⁰ formation and release.

Zinc and cadmium adsorption from wastewater using hydroxyapatite synthesized from flue gas desulfurization waste

The purpose of this work is to produce an alternative cost-effective adsorbent to remove zinc and cadmium from wastewater using hydroxyapatite (HAP) synthesized with hydrothermal method from FGD (Flue gas desulfurization) waste generated by two different coal power plants. The effects of FGD type (Cayırhan and Orhaneli) and molar ratio (H₃PO₄/CaSO₄) (0.6-4.79) on HAP synthesis were investigated. Afterwards, effects of the adsorbent dose (1-2 g/L), heavy metal concentration (30, 40, 50 mg/L) and contact time (1, 2, 3, 4 h) on zinc and cadmium adsorption yield from synthetic wastewater using produced HAP were examined. FGD waste and synthesized FGD-HAP were characterized by X-Ray Diffraction (XRD), Fourier Transformed Infrared Spectroscopy (FT-IR), Scanning Electron Microscope (SEM) and Brunauer-Emmett-Teller (BET) instruments. The zinc and cadmium concentration was studied by Inductively coupled plasma atomic emission spectroscopy (ICP-AES). Maximum zinc adsorption capacity of the Cayırhan FGD-HAP was 49.97 and 49.99 mg/L, Orhaneli FGD-HAP was 49.96 and 49.99 mg/L, for 1 g/L and 2 g/L adsorbent dose, respectively, for 50 mg/L heavy metal concentration and 4 h contact time. Maximum cadmium adsorption capacity of the Cayırhan FGD-HAP was 39.98 and 39.99 mg/L, Orhaneli FGD-HAP was 40 and 39.99 mg/L, for 1 g/L and 2 g/L adsorbent dose, respectively, for 40 mg/L heavy metal concentration and 4 h contact time. Adsorption yields were calculated between 98.53% and 100%. The adsorption data were well explained by a second-order kinetic model, and the Freundlich isotherm model fits the equilibrium data. The adsorption results demonstrated that FGD's waste is an effective source to synthesize HAP, which is used as an adsorbent for zinc and cadmium removal from wastewater due to high adsorption capacity.

Removal of SO2 from smelting flue gas by using copper tailings with MnSO4: factors optimization by response surface methodology

The abatement of SO₂ and the utilization of copper tailings are identified as two attention-attracting environmental issues in the copper smelter. In this study, to improve the flue gas desulfurization performance and the utilization of copper tailings, SO₂ removal from smelting flue gas by using copper tailings combined with MnSO₄·H₂O was investigated. The effects of operation variables, including inlet SO₂ concentration, absorption temperature, slurry concentration, and MnSO₄·H₂O amount, on the flue gas desulfurization performance were studied based on the response surface method. It was found that the effect of operation variables on SO₂ removal follows the descending order: the inlet SO₂ concentration, MnSO₄·H₂O concentration, absorbent temperature, and solid-liquid ratio. The interaction between the inlet SO₂ concentration and MnSO₄·H₂O concentration is an important factor for breakthrough sulfur capacity. Elevated temperature and high initial SO₂ concentration inhibited the efficient removal of SO₂. Moreover, a proposed equation exhibits good consistency in the prediction for the breakthrough sulfur dioxide capacity. Therefore, the results can provide a reliable reference and basis for industrial application for flue gas desulfurization with copper tailings.

Enhanced SO2 Absorption Capacity of Sodium Citrate Using Sodium Humate

A novel method of improving the SO2 absorption performance of sodium citrate (Ci-Na) using sodium humate (HA–Na) as an additive was put forward. The influence of different Ci-Na concentration, inlet SO2 concentration and gas flow rate on desulfurization performance were studied. The synergistic mechanism of SO2 absorption by HA–Na and Ci-Na was also analyzed. The consequence shows that the efficiency of SO2 absorption by Ci-Na is above 90% and the desulfurization time added with the Ci-Na concentration rising from 0.01 to 0.1 mol/L. Both the desulfurization efficiency and time may increase with the adding of HA–Na quality in Ci-Na solution. Due to adding HA–Na, the desulfurization efficiency of Ci-Na increased from 90% to 99% and the desulfurization time increased from 40 to 55 min. Under the optimum conditions, the desulfurization time of Ci-Na can exceed 70 min because of adding HA–Na, which is nearly doubled. The growth of inlet SO2 concentration has little effect on the desulfurization efficiency. The SO2 adsorption efficiency decreases with the increase of inlet flow gas. The presence of O2 improves the SO2 removal efficiency and prolongs the desulfurization time. Therefore, HA–Na plays a key role during SO2 absorption and can dramatically enhance the SO2 adsorption performance of Ci-Na solution.

Quantitative research on heavy metal removal of flue gas desulfurization-derived wastewater sludge by electrokinetic treatment

Flue gas desulfurization-derived wastewater sludge (FGD-WWS) has been produced increasingly in China and India etc., and its content of heavy metals (HMs) including Cd, Cr, Cu, Hg, Ni and Zn seriously exceeds the limits allowed. Developing the suitable disposal of FGD-WWS is therefore significantly important and necessary. The novel process of electrokinetic treatment combined with chemical pretreatment of HMs in FGD-WWS were proposed here to improve the removal efficiency. Results indicate that the effects of different pretreatment agents (citric acid (CA), ammonia, tetrasodium of N, N-bis (carboxymethyl) glutamic acid (GLDA), and rhamnolipid) on the ET of HMs were different. To investigate the mechanism of combined process, the transformation potential (TP), exchange potential (EP) and removal potential (RP) were calculated. Correlation analysis shows the correlation between TP and RP was higher than that between EP and RP, indicating that the removal efficiency is mainly affected by the fraction transformation of HMs. Electric field, pH and pretreatment agents are main factors causing fraction transformation and affecting TP. Focusing on fraction transformation is an efficient way to improve further the removal efficiency. The work is promisingly valuable for developing the technology of treating FGD-WWS.

Possibility of using alternative fuels in Polish power plants in the context of mercury emissions

The progressive decarbonisation of industry is leading to a reduction in coal consumption and the substitution for coal with other types of fuels, including waste-derived alternative fuels. These fuels are characterised by high variation in the content of highly toxic mercury. Co-combustion with coal can cause significant emissions, exceeding mercury emission limits. Various alternative fuels (refuse-derived fuel (RDF), waste paper, textiles, plastics, film, tires and their char, and sewage sludge) were examined for mercury content. The mercury content in analysed alternative fuels ranged from 0.4 to 92.0 µg Hg/MJ, with an average of 17.7 µg Hg/MJ. The fuels with the highest mercury content were RDFs (2.0-79.3 µg Hg/MJ) and sewage sludge (42.3-92.0 µg Hg/MJ). An acceptable amount of RDF added to hard coal which would remain within the emission limits was estimated to be 9-24% of the chemical energy in the blend. For sewage sludge, this amount was estimated to be 5-13%. For brown coal, with a much higher mercury content than hard coal, co-combustion with alternative fuels has a positive effect on reducing mercury emissions. It is possible to meet the mercury emission limits with a 95% contribution of the chemical energy coming from RDF. The blending of various types of waste supported by mild pyrolysis of high-mercury waste allows alternative fuels with relatively low mercury content to be produced. Such fuels may contribute a reduction in mercury emissions from coal-fired power plants in Poland.

Synthesis and Characterization of Zeolites Produced from Low-Quality Coal Fly Ash and Wet Flue Gas Desulphurization Wastewater

This study investigated a low-energy-consuming procedure for the synthesis of zeolite materials from coal fly ash (CFA). Materials containing zeolite phases, namely Na–X, Na–P1, and zeolite A, were produced from F–class fly ash, using NaOH dissolved in distilled water or in wastewater obtained from the wet flue gas desulphurization process, under atmospheric pressure at a temperature below 70 °C. The influence of temperature, exposure time, and alkaline solution concentration on the synthesized materials was tested. In addition, chemical, mineralogical, and textural properties of the obtained materials were determined by X-ray diffraction (XRD), X-ray fluorescence (XRF), scanning electron microscopy (SEM), and cation exchange capacity (CEC). Cd(II), Ni(II), NH₄⁺ cation, and Se(VI) anion sorption experiments were conducted to compare the sorption properties of the produced synthetic zeolites with those of the commercially available ones. Zeolitization resulted in an increase of CEC (up to 30 meq/100 g) compared to raw CFA and enhanced the ability of the material to adsorb the chosen ions. The obtained synthetic zeolites showed comparable or greater sorption properties than natural clinoptilolite and synthetic Na–P1. They were also capable of simultaneously removing cationic and anionic compounds. The structural, morphological, and textural properties of the final product indicated that it could potentially be used as an adsorbent for various types of environmental pollutants.

Effect of Flue Gas Desulfurization Gypsum on the Properties of Calcium Sulfoaluminate Cement Blended with Ground Granulated Blast Furnace Slag

This work aims to investigate the effect of additional flue gas desulfurization gypsum (FGDG) on the properties of calcium sulfoaluminate cement (CSAC) blended with ground granulated blast furnace slag (GGBFS). The hydration rate, setting time, mechanical strength, pore structure and hydration products of the CSAC-GGBFS mixture containing FGDG were investigated systematically. The results show that the addition of FGDG promotes the hydration of the CSAC-GGBFS mixture and improves its mechanical strength; however, the FGDG content should not exceed 6%.

Thermal and Economic Analysis of Multi-Effect Concentration System by Utilizing Waste Heat of Flue Gas for Magnesium Desulfurization Wastewater

Compared with limestone-based wet flue gas desulfurization (WFGD), magnesia-based WFGD has many advantages, but it is not popular in China, due to the lack of good wastewater treatment schemes. This paper proposes the wastewater treatment scheme of selling magnesium sulfate concentrate, and makes thermal and economic analysis for different concentration systems in the scheme. Comparisons of different concentration systems for 300 MW power plant were made to determine which system is the best. The results show that the parallel-feed benchmark system is better than the forward-feed benchmark system, and the parallel-feed optimization system with the 7-process is better than other parallel-feed optimization systems. Analyses of the parallel-feed optimization system with 7-process were made in 300, 600, and 1000 MW power plants. The results show that the annual profit of concentration system for a 300, 600, and 1000 MW power plant is about 2.58 million, 5.35 million, and 7.89 million Chinese Yuan (CNY), respectively. In different concentration systems of the scheme for selling magnesium sulfate concentrate, the parallel-feed optimization system with the 7-process has the best performance. The scheme can make a good profit in 300, 600, and 1000 MW power plants, and it is very helpful for promoting magnesia-based WFGD in China.

Mercury-bearing wastes: Sources, policies and treatment technologies for mercury recovery and safe disposal

Due to the lenient environmental policies in developing economies, mercury-containing wastes are partly produced as a result of the employment of mercury in manufacturing and consumer products. Worldwide, the presence of mercury as an impurity in several industrial processes leads to significant amounts of contaminated waste. The Minamata Convention on Mercury dictates that mercury-containing wastes should be handled in an environmentally sound way according to the Basel Convention Technical Guidelines. Nevertheless, the management policies differ a great deal from one country to another because only a few deploy or can afford to deploy the required technology and facilities. In general, elemental mercury and mercury-bearing wastes should be stabilized and solidified before they are disposed of or permanently stored in specially engineered landfills and facilities, respectively. Prior to physicochemical treatment and depending on mercury's concentration, the contaminated waste may be thermally or chemically processed to reduce mercury's content to an acceptable level. The suitability of the treated waste for final disposal is then assessed by the application of standard leaching tests whose capacity to evaluate its long-term behavior is rather questionable. This review critically discusses the main methods employed for the recovery of mercury and the treatment of contaminated waste by analyzing representative examples from the industry. Furthermore, it gives a complete overview of all relevant issues by presenting the sources of mercury-bearing wastes, explaining the problems associated with the operation of conventional discharging facilities and providing an insight of the disposal policies adopted in selected geographical regions.

Separating Sulfur from Fuel Gas Desulfurization Gypsum with an Oxalic Acid Solution

The separation of sulfur from the wet limestone fuel gas desulfurization (FGD) gypsum using oxalic acid solution was studied. Optimal separation conditions and a separation mechanism of sulfur were investigated. The obtained results indicate that the sulfur in FGD gypsum can be separated efficiently by oxalic acid solution. When separating under the optimal experimental conditions of 0.3 mol/L oxalic acid solution, 30 °C, and a 5/150 g/mL solid to liquid ratio for 8 min, the separation rate reached 97.0 wt %. Besides, the Avrami equation is more suitable for the kinetic analysis of the sulfur separation reaction than the unreacted shrinking core model. When the reaction temperature is less than or equal to 20 °C, the mechanism of the sulfur separation process is chemical-reaction-controlled; otherwise, it is diffusion-controlled. The activation energy E _a of the sulfur separation reaction is 34.84 kJ/mol. During the separation process, the pH of the solution gradually decreased due to the conversion of oxalic acid to sulfuric acid, so the liquid obtained after the sulfur separation of FGD gypsum can be recycled as industrial sulfuric acid. Nearly 1 mol of sulfuric acid can be obtained for every mole of oxalic acid consumption.