Effect of integration of mechanical ball milling and flue gas desulfurization gypsum on dealkalization of bauxite residue

The synergistic impact of mechanical ball milling and flue gas desulfurization(FGD)gypsum on the dealkalization of bauxite residue was investigated through integrated analyses of solution chemistry,mineralogy,and microtopography.The results showed a significant decrease in Na_(2)O content(>30 wt.%)of FGD gypsum-treated bauxite residue after 30 min of mechanical ball milling.Mechanical ball milling resulted in differentiation of the elemental distribution,modification of the minerals in crystalline structure,and promotion in the dissolution of alkaline minerals,thus enhancing the acid neutralization capacity of bauxite residue.5 wt.%FGD gypsum combined with 30 min mechanical ball milling was optimal for the dealkalization of bauxite residue.

Transformation of Flue-Gas-Desulfurization Gypsum to α-Hemihydrated Gypsum in Salt Solution at Atmospheric Pressure

Direct phase transformation of flue gas desulfurization gypsum in hot salt solution at atmospheric pres-sure was investigated.The effects of temperature,salt species,salt concentration,solids content,pH and modifier were examined.The crystals obtained under different conditions and solubility of calcium sulfate in contact with solid gypsum were also determined.α-Calcium sulfate hemihydrate crystals of stubby columnar shape and regular pentahedral sides were obtained under the following conditions：salt concentration 20%-30%,operation tempera-ture 95-100 °C,solids mass content in the slurry 10%-30% and neutral pH.Thermodynamic analysis revealed that phase transformation of calcium sulfate dihydrate to α-calcium sulfate hemihydrate occurs because of the difference in solubilities between the two solid gypsum phases in this system.

Calcium sulfate whisker prepared by flue gas desulfurization gypsum:A physical–chemical coupling production process

In this paper,the solid waste desulfurization gypsum produced by coal-fired power plants was used as a raw material to prepare calcium sulfate whiskers with high application prospects.Calcium sulfate whiskers with uniform morphology and high aspect ratio can be prepared by hydrothermal method in sulfuric acid solution.A new process of desulfurization gypsum activated by high-energy grinding to reduce the reaction temperature and sulfuric acid concentration was developed.Through the comparison of product morphology,the best grinding time was determined to be 3.5 h.The mechanism of desulfurization gypsum through physical–chemical coupling to reduce energy consumption was clarified.The activation of desulfurization gypsum by grinding and the acidic environment provided by the sulfuric acid solution made the calcium sulfate solution reached rapid saturation and accelerated the nucleation rate.By calculating the conversion and crystallization rate of calcium sulfate whiskers,it was found that there were obvious"autocatalytic"kinetic characteristics during the crystallization process.

Promotion of conversion activity of flue gas desulfurization gypsum into α-hemihydrate gypsum by calcination-hydration treatment

The massive accumulation of flue gas desulfurization(FGD)gypsum produced in the wet limestone-gypsum flue gas desulfurization process not only encroaches on lands but also causes serious environmental pollution.The preparation ofα-hemihydrate gypsum(α-HH)is an important way to achieve high-value utilization of FGD gypsum.Although the glycerol-water solution approach can be used to produceα-HH from FGD gypsum under mild conditions,the transition is kinetically unfavorable in the mixed solution.Here,an easy pretreatment was used to activate FGD gypsum by calcination and hydration to readily complete the transition.The pretreatment deteriorated the crystallinity of FGD gypsum and caused it to form small irregular flaky crystals,which dramatically increased the specific surface area.Additionally,most of the organics adsorbed onto FGD gypsum surfaces were removed after pretreatment.The poor crystallinity,increased specific surface area,and elimination of organics adsorbed onto crystal surfaces effectively improved the conversion activity of FGD gypsum,thereby promoting dihydrate gypsum(DH)dissolution andα-HH nucleation.Overall,the phase transition of FGD gypsum toα-HH is facilitated.

Ternary System of Fe-based Ionic Liquid,Ethanol and Water for Wet Flue Gas Desulfurization

Fe-based ionic liquid （Fe-IL） was synthesized by mixing FeCl3·6H2O and 1-butyl-3-methylimidazolium chloride [Bmim]C1 in this paper. The phase diagram of a ternary Fe-IL, ethanol and water system was investigated to construct a ternary desulfurization solution for wet flue gas desulfurization. The effects of flow rate and concentration of SO2, reaction temperature, pH and Fe-IL fraction in aqueous desulfurization solution on the desulfiariza- tion efficiency were investigated. The results shows that the best composition of ternary desulfurization solution of Fe-IL, ethanol and water is 1 ： 1.5 ： 3 by volume ratio, and pH should be controlled at 2.0. Under such conditions, a desulfurization rate greater than 90% could be obtained. The product of sulfuric acid had inhibition effect on the wet desulfurization process. With applying this new ternary desulfurization solution, not only the catalyst Fe-IL can be recycled and reused, but also the product sulfuric acid can be separated directly from the ternary desulfurization system.

Influence of Thermally Treated Flue Gas Desulfurization(FGD) Gypsum on Performance of the Slag Powder Concrete

The feasibility of flue gas desulphurization （FGD） as concrete admixture was studied. A combined concrete admixture of the thermally-treated FGD gypsum and slag powder was explored. The FGD gypsum was roasted at 200℃ for 60 min and then mixed with the slag powder to form FGD gypsum-slag powder combined admixture in which the SO3 content was 3.5wt%. Cement was partially and equivalently replaced by slag powder alone or FGD gypsum-slag powder, at concentration of 25wt%, 40wt%, and 50wt%, respectively. The setting times, hydration products, total porosity and pore size distributions of the paste were determined. The compressive strength and drying shrinkage of cement mortar and concrete were also tested. The experimental results show that, in the presence of FGD gypsum, the setting times are much slower than those of pastes in the absence of FGD gypsum. The combination of FGD gypsum and slag powder provides synergistic benefits above that of slag powder alone. The addition of FGD gypsum provides benefit by promoting ettringite formation and forms a compact microstructure, increasing the compressive strength and reduces the drying shrinkage of cement mortar and concrete.

Wet flue gas desulfurization performance of 330 MW coal-fired power unit based on computational fluid dynamics region identification of flow pattern and transfer process

Wet Flue Gas Desulfurization(WFGD)unit based upon spray scrubber has beenwidely employed to control SO_(2) emissions from flue gas in coal-fired power plant.To clarify the dependence of desulfurization performance on inter-phase transfer behaviors with non-ideal contacting patterns of flue gas and slurry droplets,three regions in spray scrubber are distinguished in terms of gas-slurry flow structures using CFD method in the Eulerian-Lagrangian framework.A comprehensive model is established by involving the transfer process between two phases and chemical reactions in aqueous phase,which is validatedwith the measured data froma WFGD scrubber of 330 MW coal-fired power unit.Numerical results show that the overall uniformity degree of flue gas in whole scrubber is largely determined by the force-balanced droplets in the middle part of scrubber,which is dominated by counter-current mode.Both momentum transfer behavior and SO_(2) chemical absorption process present the synchronicity with the evolution of gas-slurry flow pattern,whilst the heat transfer together with H_(2)O evaporation has little effect on overall absorption process.Three regions are firstly defined as Gas Inlet Region(GIR),Dominant Absorption Region(DAR)and Slurry Dispersed Region(SDR)from the bottom to top of scrubber.SO_(2) is mainly scrubbed in DAR,which provides much more intensive interaction between two phases compared to GIR or SDR.A better understanding of the desulfurization process is obtained from the fundamental relationship between transport phenomena and chemical reactions based upon the complicated hydrodynamics of gas-slurry two-phase flow,which should be useful for designing and optimizing the scrubber in coal-fired power unit.

Fluoride Ion Adsorption Effect and Adsorption Mechanism of Self-Supported Adsorbent Materials Based on Desulfurization Gypsum-Aluminate Cement

The adsorption method has the advantages of low cost,high efficiency,and environmental friendliness in treating fluorinated wastewater,and the adsorbent material is the key.This study combines the inherent anion-exchange adsorption properties of layered double hydroxides(LDHs).Self-supported porous adsorbent materials loaded with AFm and AFt were prepared from a composite cementitious system consisting of calcium aluminate cement(CAC)and flue gas desulfurization gypsum(FGDG)by chemical foaming technique.The mineral composition of the adsorbent material was characterized by X-ray diffraction(XRD)and Scanning electron microscopy(SEM).Through the static adsorption experiment,the adsorption effect of the mineral composition of the adsorbent on fluoride ions was deeply analyzed,and the adsorption mechanism was revealed.XRD and SEM showed that the main hydration phases of the composite cementitious system consisting of CAC and FGDG are AFm,AFt,AH_(3),and CaSO_(4)·2H_(2)O.FGDG accelerates the hydration process of CAC and inhibits the transformation of AFt to AFm.The AFt content increased,and the AFm content decreased or even disappeared as the amount of FGDG increased.Static adsorption experiment results showed that AFm and AFt in adsorbent materials could significantly enhance the adsorption of fluoride ions.The adsorption of F^(−)in aqueous solution by PAG tends more towards monolayer adsorption with a theoretical maximum capacity of 108.70 mg/g and is similar to the measured value of 112.77 mg/g.

Evaluation of flue gas desulfurization gypsum as a low-cost precipitant for phosphorus removal from anaerobic digestion effluent filtrate

Land application of anaerobic digestion(AD)effluent as a fertilizer is desirable for nutrient recycling,but often supplies excess phosphorus(P),which contributes to surface water eutrophication.Reducing the P content in AD effluent filtrate using calcium(Ca)treatment prior to land application is a potential strategy for improving effluent disposal and meeting the discharge standard.This study took flue gas desulphurization(FGD)gypsum,a by-product of coal-fired power plants,as a low-cost Ca source,and combined with traditional phosphorus removal agents to achieve high phosphorus removal efficiency with less chemical cost.As the results showed,FGD gypsum dosages of 20 mmol/L Ca(3.44 g/L)and 40 mmol/L Ca(6.89 g/L)removed up to 97.1%of soluble P(initially 102.8 mg/L)within 60-90 minutes.Combining FGD gypsum treatment with traditional chemical treatments using calcium hydroxide[Ca(OH)2]or ferric chloride(FeCl3)could achieve>99%P removal with reduced chemical costs.This study demonstrated that FGD gypsum is an efficient calcium-based precipitant for phosphorus removal,offering a cost-effective and sustainable approach to enhance wastewater treatment practices and meet discharge standards in wastewater management.

Dynamic optimization oriented modeling and nonlinear model predictive control of the wet limestone FGD system

Nonlinear model predictive control(NMPC)scheme is an effective method of multi-objective optimization control in complex industrial systems.In this paper,a NMPC scheme for the wet limestone flue gas desulphurization(WFGD)system is proposed which provides a more flexible framework of optimal control and decision-making compared with PID scheme.At first,a mathematical model of the FGD process is deduced which is suitable for NMPC structure.To equipoise the model’s accuracy and conciseness,the wet limestone FGD system is separated into several modules.Based on the conservation laws,a model with reasonable simplification is developed to describe dynamics of different modules for the purpose of controller design.Then,by addressing economic objectives directly into the NMPC scheme,the NMPC controller can minimize economic cost and track the set-point simultaneously.The accuracy of model is validated by the field data of a 1000 MW thermal power plant in Henan Province,China.The simulation results show that the NMPC strategy improves the economic performance and ensures the emission requirement at the same time.In the meantime,the control scheme satisfies the multiobjective control requirements under complex operation conditions(e.g.,boiler load fluctuation and set point variation).The mathematical model and NMPC structure provides the basic work for the future development of advanced optimized control algorithms in the wet limestone FGD systems.

Use of flue gas desulfurization gypsum to reduce dissolved phosphorus in runoff and leachate from two agricultural soils

Controlling dissolved phosphorus(DP)loss from high P soil to avoid water eutrophication is a worldwide high priority.A greenhouse study was conducted in which flue gas desulfurization gypsum(FGDG)was applied by using different application methods and rates to two agricultural soils.Phosphorus fertilizer was incorporated into the soils at 2.95 g kg^(-1)to simulate soil with high P levels.The FGDG was then applied at amounts of 0,1.5,and 15 g kg^(-1)soil on either the soil surface or mixed throughout the soil samples to simulate no-tillage and tillage,respectively.Ryegrass was planted after treatment application.The study showed that FGDG reduced runoff DP loss by 33%and leachate DP loss 38%in silt loam soil,and runoff DP loss 46%and leachate DP loss 14%in clay loam soil,at the treatment of 15 g kg^(-1)FGDG.Mixing applied method(tillage)provided strong interaction with higher FGDG.To overall effect,the mixing-applied method performed better in controlling DP loss from silt loam soil,while surface-applied(no tillage)showed its advantage in controlling DP loss from clay loam soil.In practice it is necessary to optimize FGDG concentrations,application methods,and DP sources(runoff or leachate)to get maximized benefits of FGDG application.The FGDG application had no negative effects on the soil and ryegrass.

Removal of SO_2 from flue gas using Bayer red mud:Influence factors and mechanism

The absorbent composing of Bayer red mud and water was prepared and applied to removing SO2 from flue gas.Effects of the ratio of liquid to solid(L/S),the absorption temperature,the inlet SO2 concentration,the O2 concentration,SO4^2-and other different components of Bayer red mud on desulfurization were conducted.The mechanism of flue gas desulfurization was also established.The results indicated that L/S was the prominent factor,followed by the inlet SO2 concentration and the temperature was the least among them.The optimum condition was as follows:L/S,the temperature and the SO2 concentration were 20:1,25℃and 1000 mg/m^3,respectively,under the gas flow of 1.5 L/min.The desulfurization efficiency was not significantly influenced when O2 concentration was above 7%.The accumulation of SO4^2-inhibited the desulfurization efficiency.The alkali absorption and metal ions liquid catalytic oxidation were involved in the process,which accounted for 98.61%.

Investigation on the relationship between the fine particle emission and crystallization characteristics of gypsum during wet flue gas desulfurization process

The relationship between the fine particles emitted after desulfurization and gypsum crystals in the desulfurization slurry was investigated,and the crystallization characteristics varying with the operation parameters and compositions of the desulfurization slurry were discussed.The results showed that the fine particles generated during the desulfurization process were closely related to the crystal characteristics in the desulfurization slurry by comparison of their morphology and elements. With the higher proportion of fine crystals in the desulfurization slurry,the number concentration of fine particles after desulfurization was increased and their particle sizes were smaller,indicating that the optimization of gypsum crystallization was beneficial for the reduction of the fine particle emission. The lower p H value and an optimal temperature of the desulfurization slurry were beneficial to restrain the generation of fine crystals in the desulfurization slurry. In addition,the higher concentrations of the Fe3＋ions and the F- ions in the desulfurization slurry both promoted the generation of fine crystals with corresponding change of the morphology and the effect of the Fe3＋ ions was more obvious.With the application of the desulfurization synergist additive,it was beneficial for the inhibition of fine crystals while the thinner crystals were generated.

Model Free Adaptive Predictive Control of Desulfurization Slurry pH Based on CPS Framework

In order to improve the slurry pH control accuracy of the absorption tower in the wet flue gas desulfurization process,a model free adaptive predictive control algorithm for the desulfurization slurry pH which is based on a cyber physical systems framework is proposed.First,aiming to address system characteristics of non-linearity and pure hysteresis in slurry pH change process,a model free adaptive predictive control algorithm based on compact form dynamic linearization is proposed by combining model free adaptive control algorithm with model predictive control algorithm.Then,by integrating information resources with the physical resources in the absorption tower slurry pH control process,an absorption tower slurry pH optimization control system based on cyber physical systems is constructed.It is turned out that the model free adaptive predictive control algorithm under the framework of the cyber physical systems can effectively realize the high-precision tracking control of the slurry pH of the absorption tower,and it has strong robustness.

Effect of wet flue gas desulfurization(WFGD) on fine particle(PM_(2.5)) emission from coal-fired boilers

In this study, the characteristics of fine particles before and after wet flue gas desulfurization(WFGD) in three coal-fired heating boilers in northern China were investigated by using a dilution-based emission sampling experimental system. The influences of the WFGD process on the mass and number concentrations as well as the chemical composition of fine particles were analyzed. The removal efficiency of desulfurization processes on particulate matter mass was 30.06%–56.25% for the three study units. The WFGD had a great influence on the size distributions of particle mass concentration and number concentration. A significant increase in the number and mass concentration of particles in the size range of 0.094–0.946 μm was observed. The watersoluble ion content accounted for a very large proportion of PM_(2.5) mass, and its proportion in PM_(2.5) increased from 28.39%–41.08% to 48.96%–61.21% after the WFGD process for the three units. The desulfurizing process also drastically increased the proportion of cation component(Ca^(2+) for unit A, Mg^(2+) for unit B, and Na+for unit C) and the proportion of SO_4^(2-) in PM_(2.5), and it increased the CE/AE values of PM_(2.5) from 0.82–0.98 to 0.93–1.27 for the three study units.

Transformation and removal of ammonium sulfate aerosols and ammonia slip from selective catalytic reduction in wet flue gas desulfurization system

Selective catalytic reduction(SCR) denitration may increase the emission of NH4+and NH3.The removal and transformation characteristics of ammonium sulfate aerosols and ammonia slip during the wet flue gas desulfurization(WFGD) process, as well as the effect of desulfurization parameters, were investigated in an experimental system equipped with a simulated SCR flue gas generation system and a limestone-based WFGD system.The results indicate that the ammonium sulfate aerosols and ammonia slip in the flue gas from SCR can be partly removed by slurry scrubbing, while the entrainment and evaporation of desulfurization slurry with accumulated NH4+will generate new ammoniumcontaining particles and gaseous ammonia.The ammonium-containing particles formed by desulfurization are not only derived from the entrainment of slurry droplets, but also from the re-condensation of gaseous ammonia generated by slurry evaporation.Therefore,even if the concentration of NH4+in the desulfurization slurry is quite low, a high level of NH4+was still contained in the fine particles at the outlet of the scrubber.When the accumulated NH4+in the desulfurization slurry was high enough, the WFGD system promoted the conversion of NH3 to NH4+and increased the additional emission of primary NH4+aerosols.With the decline of the liquid/gas ratio and flue gas temperature, the removal efficiency of ammonia sulfate aerosols increased, and the NH4+emitted from entrainment and evaporation of the desulfurization slurry decreased.In addition, the volatile ammonia concentration after the WFGD system was reduced with the decrease of the NH4+concentration and p H values of the slurry.

Preparation of calcium ferrite by flue gas desulfurization gypsum

At present,the continuous accumulation of the flue gas desulfurization(FGD)gypsum in steel plants leads to the serious environmental issues and resource waste.To achieve green and sustainable development for the steel industry,it is significant to improve the usage of by-product gypsum.Employing the sintering FGD gypsum,ferric oxide,and graphite carbon as raw materials,the effects of the carbon content,reaction time,and molar ratio of CaO to Fe_(2)O_(3)on the desulfurization rate of gypsum were studied based on the orthogonal experiment.The results show that the order of the three influencing factors on the desulfurization rate of FGD gypsum is:molar ratio of CaO to Fe_(2)O_(3)>reaction time>carbon content.Under the optimal conditions of 20 wt.%carbon content,4 h reaction time,and 1:1 molar ratio of CaO to Fe_(2)O_(3),the desulfurization rate of desulfurization gypsum is 95.79%,and 97.57 wt.%of calcium ferrite appears in the solid product,which can be used as sintering additive to increase the economic benefits of enterprises and realize the green ecological development mode of internal generation and internal digestion of solid waste in iron and steel enterprises.

基于RSM的工业副产品改性硫铝酸钙水泥性能分析

为研究工业副产品烟气脱硫石膏(FGDG)、粉煤灰(FA)和石灰石(LS)对硫铝酸盐水泥(SAC)熟料无侧限抗压强度(UCS)和pH的影响规律,采用FGDG,FA和LS改性SAC熟料,并在7 d和28 d龄期进行UCS和pH测试.采用响应面方法(RSM),建立UCS和pH的回归模型,分析各因素交互对其影响.研究结果表明:UCS和pH均受到FGDG,FA和LS单因素和各因素交互作用影响.FGDG和LS,LS和FA的交互作用对浆体7 d和28 d的UCS影响显著,LS和FA,FGDG和FA的交互作用对浆体pH 7 d影响显著,但对浆体pH 28 d影响并不显著.利用RSM-BBD多目标优化法进行优化各工业副产品,建立的回归模型具有较高的可信度和精确度,得到改性硫铝酸钙水泥满足高UCS低pH时各工业副产品的合适添加比,其试验值和预测值误差较小.

Influence of crystal-transforming agent on the performance and mechanism ofα-high-strength gypsum prepared from FGD gypsum

This paper investigates the impact of flue gas desulfurization(FGD)gypsum's crystal modifier on the characteristics and microcosmic mechanism ofα-high strength gypsum.The results demonstrate that all three crystal modifiers can convert FGD gypsum toα-high-strength gypsum.Citric acid(CA)has the most significant influence onα-high-strength gypsum,and the preparedα-high-strength gypsum is short columnar,with an aspect ratio in the range of 1-3,and has a faster setting time,a larger specific surface area,and a smaller standard consistency,higher compressive strength,greater surface hardness,and smaller crystal particle size.The initial setting time of theα-high-strength gypsum manufactured with CA crystal modifier was decreased by 36%compared to the blank sample,the final setting time was lowered by 37.5%,and the water consumption of the standard consistency was reduced by 8%.The maximum strength is 32 MPa after 2 h,the absolute dry compressive strength is up to 38 MPa,and the surface hardness is improved by 24.43%.

电石渣替代石灰石用于火电厂脱硫的优势分析

电石渣是富含Ca(OH)_(2)的工业固体废弃物,替代石灰石进行火电厂脱硫具有经济、环境、社会、生态多重效益。从脱硫原理、影响因素等方面对比电石渣炉内脱硫技术和炉外烟气脱硫技术,并指出电石渣与石灰石相比所具备的优势,同时分析电石渣用于电厂脱硫存在的问题以及解决的方案,为电石渣合理替代石灰石用于火电厂脱硫提出参考性建议和未来发展的方向。