Preparation of calcium silicate absorbent from iron blast furnace slag

Calcium silicate hydrate (CSH) solids were prepared from hydrated lime and iron blast furnace slag in an aqueous agitated slurry at 92 degrees C. While it was hoped a minimal lime/slag ratio could be used to create near-amorphous CSH, the surface area of the product improved by increasing the lime/slag weight ratio to 2. The addition of gypsum to the lime/slag system dramatically improved the formation of surface area, creating solids with 139 m2/g after 30 hr of reaction when only a minimal amount of lime was present. The SO2 reactivity of solids prepared with gypsum greatly exceeded that of hydrated lime, achieving greater than 70-80% conversion of the alkalinity after 1 hr of reaction with SO2. The use of CaCl2 as an additive to the lime/slag system, in lieu of gypsum, also produced high-surface-area solids, 115 m2/g after 21 hr of reaction. However, the SO2 reactivity of these sorbents was relatively low given the high surface area. This emphasized that the correlation between surface area and SO2 reactivity was highly dependent on the solid phase, which was subsequently dependent on slurry composition.     

A Simple Model for SO2 Removal in the Duct Injection Process

Abstract

In the In-Duct Injection Process, a lime slurry is sprayed into the flue gas between the air preheater and solids collection equipment, and about 30-60 percent removal of SO₂ is achieved. A simple model of this process has been developed based on heat and mass transfer theories, and this model was fitted to the data obtained at proof-of-concept test units. Data taken with separate injection of dry lime and water were also modeled, but the SO₂ removal was less than for slurry injection, probably because of incomplete capture of lime particles by the water droplets.     

Preparation of Calcium Silicate Reagent from Fly Ash and Lime in a Flow Reactor

Abstract

The batch reaction between fly ash and hydrated lime in water to produce high surface area calcium silicates for flue gas desulfurization has been examined extensively. This paper examines the reaction in a flow reactor using two low-calcium fly ashes and introducing gypsum, calcium sulf ite hemihydrate, and calcium chloride as additives to the reaction. The flow system is compared to the batch reaction at similar operating conditions and a segregated flow model is used to approximate flow reactor behavior.

Experiments with calcium chloride and gypsum additives were modeled fairly well by the segregated flow approximation at residence times less than 12 hours. The flow reactor produced low surface area material at longer residence times when gypsum was present. Because the changing solution chemistry affected the batch reaction rate the fly ash and hydrated lime system without gypsum or calcium chloride could not be approximated using batch reaction data. In this case, the flow reactor produced higher surface area product than the batch reactor for a given residence time due to the increased calcium hydroxide availability.     

Development and Pilot Plant Evaluation of Silica- Enhanced Lime Sorbents for Dry Flue Gas Desulfurization

EPA’s efforts to develop low cost, retrofitable flue gas cleaning technology include the development of highly reactive sorbents. Recent work addressing lime enhancement and testing at the bench-scale followed by evaluation of the more promising sorbents in a pilot plant are discussed here.

The conversion of Ca(OH)₂ with SO₂ increased several-fold compared with Ca(OH)₂ alone when Ca(OH)₂ was slurrled with fly ash first and later exposed to SO₂ in a laboratory packed bed reactor. Ca(OH)₂ enhancement increased with the increased fly ash amount. Dlatomaceous earths were very effective reactivity promoters of lime-based sorbents. Differential scanning calorimetry of the promoted sorbents revealed the formation of a new phase (calcium silicate hydrates) after hydration, which may be the basis for the observed Improved SO₂ capture.

Fly ash/lime and diatomaceous earth/lime sorbents were tested in a 100 m³/h pilot facility incorporating a gas humidifier, a sorbent duct injection system, and a baghouse. The inlet SO₂ concentration range was 1000-2500 ppm. With once-through dry sorbent injection into the humidified flue gas [approach to saturation 10–20°C (18–36°F) in the baghouse], the total SO₂ removal ranged from 50 to 90 percent for a stoichiometric ratio of 1 to 2. Recycling the collected solids resulted in a total lime utilization exceeding 80–90 percent. Increased lime utilization was also investigated by the use of additives.     

Opacity Reduction Using Dry Hydrated Lime Injection

Abstract

This investigation studied the effects of injecting dry hydrated lime into flue gas to reduce sulfur trioxide, (SO₃) concentrations and consequently stack opacity at the University of Missouri-Columbia power plant. The opacity was due to sulf uric acid mist forming at the stack from high SO₃ concentrations. As a result of light scattering by the mist, a visible plume leaves the stack. Therefore, reducing high concentrations of SO₃ reduces the sulfuric acid mist and consequently the opacity. To reduce SO₃ concentrations, dry hydrated lime is periodically injected into the flue gas upstream of a baghouse and downstream of an induced draft fan. The hydrated lime is transported downstream by the flue gas and deposited on the filter bags in the baghouse forming a filter cake. The reaction between the SO₃ and the hydrated lime takes place on the filter bags. The hydrated lime injection system has resulted in at least 95% reduction in the SO₃ concentration and has reduced the opacity to acceptable limits. Low capital equipment requirements, low operating cost, and increased bag life make the system very attractive to industries with similar problems.     

Thiosulfate as an Oxidation Inhibitor in Flue Gas Desulfurization Processes: A Review of R&D Results

Sodium thiosulfate (Na₂S₂O₃) has been tested in a pilot plant as an oxidation inhibitor in flue gas desulfurization by lime and limestone slurry scrubbing with and without MgO and adiplc acid additives. The effectiveness of thiosulfate is proportional to the inhibitor product, defined as the product of thiosulfate concentration (M), calcium concentration (M), and the moles of SO₂ absorbed per hour per liter of hold tank volume. Gypsum saturation was less than 100 percent and scaling was eliminated when the inhibitor product exceeded 0.3 × 10^?6(gmol/L)³/h. Thiosulfate was relatively more effective in systems with chlorides and less effective in systems promoted by MgO. An inhibitor product greater than 10^?6(gmol/L)³/h significantly enhanced dewatering of solids from limestone scrubbing. SO₂ removal and/or limestone utilization were increased in systems that started with less than 10 mM dissolved calcium.     

Silica-Enhanced Sorbents for Dry Injection Removal of SO2 from Flue Gas

Novel silica-enhanced lime sorbents were tested in a bench-scale sand-bed reactor for their potential for SO₂ removal from flue gas. Reactor conditions were 64°C (147°F), relative humidity of 60 percent [corresponding to an approach to saturation temperature of 10°C (18°F)], and inlet SO₂ concentration of 500 or 1000 ppm. The sorbents were prepared by pressure hydration of CaO or Ca(OH)₂ with siliceous materials at 100°C (101 kPa) [212°F (14.7 psi)] to 230°C (2793 kPa) [446°F (405 psi)] for 15 min to 4 h. Pressure hydration fostered the formation of a sorbent reactive with SO₂ from fly ash and Ca(OH)₂ in a much shorter time than did atmospheric hydration. The conversion of Ca(OH)₂ in the sand-bed reactor increased with the increasing weight ratio of fly ash to lime and correlated well with B.E.T. surface area, increasing with increasing surface area. The optimum temperature range for the pressure-hydration of fly ash with Ca(OH)₂ was between 110 and 160°C (230 and 320 °F). The pressure hydration of diatomaceous earth with CaO did not offer significant reactivity advantages over atmospheric hydration; however, the rate of enhancement of Ca(OH)₂ conversions was much faster with pressure hydration. Scanning electron microscope (SEM) and x-ray diffraction studies showed solids of different morphology with different fly ash/lime ratios and changing conditions of pressure hydration.     

The Bechtel Confined Zone dispersion Process for FGD Retrofit Situations Proof-of-Concept Tests

The Bechtel Confined Zone Dispersion (CZD) process for FGD retrofit situations was tested at two sites: one at a level of 5 MWe; the other at 70 MWe. The CZD process involves injecting a finely atomized slurry of hydrated lime into a straight run of duct between a boiler's air heater and its electrostatic precipitator (ESP). The effect of process variables on SO₂ removal and ESP performance was investigated for dolomitic/calcitic lime. Removals of SO₂ in excess of 50 percent were achieved for either lime type at the 5 MWe site. A very short duct length limited injection rate at the 70 MWe site, limiting sulfur removals to a maximum of 30 percent. SO₂ removal data for both sites were successfully correlated on a common basis. ESP performance was not fully acceptable during lime injection at both sites, but it is felt that optimization of ESP operations should eliminate this problem. Additional testing is recommended to further explore ESP performance and to optimize lime injection parameters. The results obtained to date continue to indicate that the CZD process is an attractive and economical candidate for FGD retrofit situations.     

湿法烟气脱硫反应过程的实验研究

在石灰石/石膏湿法烟气脱硫中试台上,系统开展了浆液pH值、飞灰浓度、液气比、入口SO2浓度、烟气速度和氧化方式等对脱硫反应过程影响的实验研究。实验表明,脱硫效率随着石膏浆液pH值、液气比的升高而增加,且入口SO2浓度越高,液气比越低,影响效应越明显;脱硫效率随着烟气速度、烟气温度和入口SO2浓度的增加而下降;石膏浆液中飞灰含量对系统脱硫效率具有一定的促进作用:pH值>5.6,飞灰浸出液中Fe3+含量相对较低,Fe3+对脱硫反应过渡态催化氧化影响程度较轻,不同工况脱硫效率差别不大。pH值<5.6,飞灰浸出液中Fe3+含量随pH值降低而增大,增效效果逐渐显著;氧化方式对脱硫反应过程有明显的影响,强制氧化工艺的脱硫效率比自然氧化的高5%左右。     

A Combined Ca(OH)2/NH3 Flue Gas Desulfurization Process for High Sulfur Coal: Results of a Pilot Plant Study

The removal of SO₂ with atomization of a slaked lime slurry and supplemental injection of gaseous NH₃ were tested in a conventional spray dryer/baghouse system for SO₂ concentrations of 2000 ppm and 3000 ppm and a 30° F approach to saturation. Results at 3000 ppm of SO₂ showed an average SO₂ removal efficiency of 90.3 percent at a combined stoichiometric ratio of 0.95-1.10 and an average overall sorbent utilization of 91.6 percent. The overall molal ratio of NH₃/SO₂ reaction was found to be 2:1 under the test conditions Particle size analyses, and EP toxicity tests were conducted on the products of the reactions.     

Pore Structure Effects on Ca-Based Sorbent Sulfation Capacity at Medium Temperatures: Activated Carbon as Sorbent/Catalyst Support

Abstract

The reaction between three different Ca-based sorbents and SO₂ were studied in a medium temperature range (473–773 K). The largest SO₂ capture was found with Ca(OH)₂ at 773 K, 126.31 mg SO₂?g Ca(OH)₂ ^?1, and the influence of SO₂ concentration on the sorbent utilization was observed. Investigations of the internal porous structure of Ca-based sorbents showed that the initial reaction rate was controlled by the surface area, and once the sul-fated products were produced, pore structure dominated. To increase the surface area of Ca-based sorbents available to interact with and retain SO₂, one kind of CaO/activated carbon (AC) sorbent/catalyst was prepared to study the effect of AC on the dispersion of Ca-based materials. The results indicated that the Ca-based material dispersed on high-surface-area AC had more capacities for SO₂ than unsupported Ca-based sorbents. The initial reaction rates of the reaction between SO₂ and Ca-based sorbents and the prepared CaO/AC sorbents/cata-lysts were measured. Results showed that the reaction rate apparently increased with the presence of AC. It was concluded that CaO/AC was the active material in the des-ulfurization reaction. AC acting as the support can play a role to supply O₂ to increase the affinity to SO₂. Moreover, when AC is acting as a support, the surface oxygen functional group formed on the surface of AC can serve as a new site for SO₂ adsorption.     

One-part alkali-activated slag binder for cemented fine tailings backfill: proportion optimization and properties evaluation

In this study, a one-part alkali-activated slag (AAS) composed of ground-granulated blast furnace slag, desulfurized gypsum, and hydrated lime is proposed as alternative to cement for the production of cemented fine tailings backfill (CFTB), which is an environmentally friendly binder consisting of 93.72 wt.% industrial solid waste. Results show that AAS with 67.83 wt.% slag, 25.92 wt.% desulfurized gypsum, and 6.25 wt.% hydrated lime yields the highest strength, which is 1.7–3.2 times that of ordinary Portland cement (OPC). Aside from calcium silicate hydrate gel, appreciable quantity of ettringite characterized by interlocking needles structure and high bound water is also produced during the AAS hydration process. In addition, the hydration heat of the AAS binder is 48% less than that of OPC. Moreover, CFTB made of AAS provides better workability than that of CFTB with OPC up to 20 h. The findings of this study will contribute to the production of more cost-effective, durable, and environmental-friendly cemented fine tailings backfill.

     

Analysis of Industrial Boiler Solid Waste Impacts

This paper presents an examination of industrial coal-fired boiler waste products. Presently the atmospheric emissions from all new boilers larger than 250 × 10⁶ Btu/hr are controlled by existing New Source Performance Standards, and boilers smaller than 250 × 10⁶ Btu/hr are controlled to levels required by the regulations of the particular state in which the facility is located. The 1977 Clean Air Act Amendments, however, specify categories of sources for which EPA must develop revised New Source Performance Standards. Industrial coal-fired boilers are included as one of these categories, and a relevant issue concerns the potential amount of solid waste generated as a result of tightened emission standards that require flue gas desulfurization. This paper examines the air quality and solid waste impacts of moderate and stringent emission controls for particulate and SO₂ emissions from industrial coal-fired boilers.

Comparisons are presented of physical and chemical characterizations of the emissions and solid wastes produced when boilers are equipped with particulate and SO₂ control equipment. The SO₂ systems examined are lime spray drying, lime/limestone, double alkali, sodium throwaway, physically cleaned coal, and fluidized-bed combustion. The solid waste disposal alternatives and the disposal costs are discussed. The most common disposal methods used are landfill for dry wastes and impoundment for sludges, with special wastewater treatment requirements for the sodium throwaway aqueous wastes.     

氢氧化钠-钢渣双碱法烧结烟气脱硫工艺

在鼓泡反应器中考察了氢氧化钠-钢渣双碱法烧结烟气脱硫的主要影响因素。结果表明,在温度为常温,钢渣反应时间为2 h,钢渣加入量为40 g,SO2进口浓度为2 400 mg/m3,钢渣粒径为200目以上,烟气流量为0.05 m3/h,循环液pH保持在7～8,Na+浓度为0.5 mol/L,循环液为500 mL的条件下,脱硫率可长时间保持在80%以上。同时,对钢渣-氢氧化钠双碱法烧结烟气脱硫机理进行了探讨。     

Controlled Exposures of Volunteers to Respirable Carbon and Sulf uric Acid Aerosols

Respirable carbon or fly ash particles are suspected to increase the respiratory toxicity of coexisting acidic air pollutants, by concentrating acid on their surfaces and so delivering it efficiently to the lower respiratory tract. To investigate this issue, we exposed 15 healthy and 15 asthmatic volunteers in a controlled- environment chamber (21°C, 50 percent relative humidity) to four test atmospheres: (i) clean air; (ii) 0.5-μm H2SO4 aerosol at =100 μg/m³, generated from water solution; (iii) 0,5-μm carbon aerosol at =250 μg/m³, generated from highly pure carbon black with specific surface area comparable to ambient pollution particles; and (iv) carbon as in (iii) plus =100 μg/m³ of ultrafine H2SO4 aerosol generated from fuming sulfuric acid. Electron microscopy showed that nearly all acid in (iv) became attached to carbon particle surfaces, and that most particles remained in the sub-μm size range. Exposures were performed double-blind, 1 week apart. They lasted 1 hr each, with alternate 10-min periods of heavy exercise (ventilation =50 L/min) and rest. Subjects gargled citrus juice before exposure to suppress airway ammonia. Lung function and symptoms were measured pre-exposure, after initial exercise, and at endexposure. Bronchial reactivity to methacholine was measured after exposure. Statistical analyses tested for effects of H₂SO₄ or carbon, separate or interactive, on health measures. Group data showed no more than small equivocal effects of any exposure on any health measure. One individual's responses were consistent with a clinically significant excess airway constriction from H₂SO₄ plus carbon, and 2-3 others showed slight excess responses to the combined pollutants, but all these observations might have reflected chance variations. We conclude that coexisting carbon aerosol did not increase respiratory irritancy of H₂SO₄, in most healthy and asthmatic subjects exposed for 1 hr under simulated "worst-case" ambient conditions.     

The reductive degradation of 1,1,1-trichloroethane by Fe(0) in a soil slurry system

Most studies on the treatment of chlorinated contaminants by Fe(0) focus on aqueous system tests. However, few is known about the effectiveness of these tests for degrading chlorinated contaminants such as 1,1,1-trichloroethane (TCA) in soil. In this work, the reductive degradation performance of 1,1,1-TCA by Fe(0) was thoroughly investigated in a soil slurry system. The effects of various factors including acid-washed iron, the initial 1,1,1-TCA concentration, Fe(0) dosage, slurry pH, and common constituents in groundwater and soil such as Cl^?, HCO₃ ^?, SO₄ ^2?, and NO₃ ^? anions and humic acid (HA) were evaluated. The experimental results showed that 1,1,1-TCA could be effectively degraded in 12 h for an initial Fe(0) dosage of 10 g L^?1 and a soil/water mass ratio of 1:5. The soil slurry experiments showed two-stage degradation kinetics: a slow reaction in the first stage and a fast reductive degradation of 1,1,1-TCA in the second stage. The reductive degradation of 1,1,1-TCA was expedited as the mass concentration of Fe(0) increased. In addition, high pHs adversely affected the degradation of 1,1,1-TCA over a pH range of 5.4–8.0 and the reductive degradation efficiency decreased with increasing slurry pH. The initial 1,1,1-TCA concentration and the presence of Cl^? and SO₄ ^2? anions had negligible effects. HCO₃ ^? anions had a accelerative effect on 1,1,1-TCA removal, and both NO₃ ^? and HA had inhibitory effects. A Cl^? mass balance showed that the amount of Cl^? ions released into the soil slurry system during the 1,1,1-TCA degradation increased with increasing reaction time, suggesting that the main degradation mechanism of 1,1,1-TCA by Fe(0) in a soil slurry system was reductive dechlorination with 1,1-DCA as the main intermediate. In conclusion, this study provides a theoretical basis for the practical application of the remediation of contaminated sites containing chlorinated solvent.     

Digested sewage sludge solidification by converter slag for landfill cover

A new technology for solidification of digested sewage sludge referred to as converter slag solidification (CSS) has been developed using converter slag as the solidifying agent and quick lime as the solidifying aid. The CSS technology was investigated by analyzing the physicochemical properties of solidified sludge and determining its microstructural characteristics. The feasibility of using solidified sludge as a landfill cover material was considered in the context of the economical recycling of waste. Sludge solidified using the CSS technology exhibited geotechnical properties that are appropriate for replacing currently used cover soil. Microscopic analyses using XRD, SEM and EDS revealed that the main hydrated product of solidification was CSH (CaO . SiO2 . nH2O), which may play an important role in the effective setting process. Negligible leaching of heavy metals from the solidified sludge was observed. The solidification process of the hydrated sludge, slag and quicklime eliminated the coliform bacteria. Recycled sewage sludge solidified using CCS technology could be used as an effective landfill cover.     

New Fe-immobilized natural bentonite plate used as photo-Fenton catalyst for organic pollutant degradation

Novel photo-Fenton catalysts were prepared by immobilizing iron species on commercial bentonite plates via two methods: (1) ion exchange reaction (Fe³⁺ vs. Na⁺) by aqueous suspension powder-clay/FeCl₃ followed by plate preparation, and (2) forced hydrolysis of Fe(NO₃)₃ onto a prefabricated clay plate. The last method led to a more photo-active Fe-oxide/bentonite plate. This material allowed, at a non-adjusted initial pH of 5.5 and in the presence of H₂O₂, the total degradation of resorcinol and 55% mineralization in 80 and 100 min of irradiation, respectively. The reached degradation percentages were correlated to the presence of dissolved iron, demonstrating that in these processes, the homogeneous photo-Fenton reactions were mainly responsible for the resorcinol elimination.Likewise, in slurry system, where clay has normally an increased surface area, there was no increase in activity because of a reduced leached iron probably due to the diminished light penetration in the suspension. Despite the lower surface area, in comparison to that of the slurry, the clay plates have the advantage, as heterogeneous photo-catalysts, that separation of the reaction media after treatment is not needed, and thus, a potential use for batch and continuous reaction systems is proposed.     

Impact of acid mine drainages on surficial waters of an abandoned mining site

Weathering of sulphide minerals produces a great variety of efflorescences of soluble sulphate salts. These minerals play an important role for environmental pollution, since they can be either a sink or a source for acidity and trace elements. This paper aims to characterise surface waters affected by mining activities in the Sierra Minera of Cartagena-La Union (SE, Spain). Water samples were analysed for trace metals (Zn, Cd, Pb, Cu, As and Fe), major ions (Na⁺, K⁺, Ca²⁺ and Mg²⁺) and anions (F^?, Cl^?, NO₃ ^?, CO₃ ^2?, SO₄ ^2?) concentrations and were submitted to an “evaporation-precipitation” experiment that consisted in identifying the salts resulting from the evaporation of the water aliquots sampled onsite. Mineralogy of the salts was studied using X-ray diffraction and compared with the results of calculations using VISUAL MINTEQ. The study area is heavily polluted as a result of historical mining and processing activities that has produced large amount of wastes characterised by a high trace elements content, acidic pH and containing minerals resulting from the supergene alteration of the raw materials. The mineralogical study of the efflorescences obtained from waters shows that magnesium, zinc, iron and aluminium sulphates predominate in the acid mine drainage precipitates. Minerals of the hexahydrite group have been quantified together with minerals of the rozenite group, alunogen and other phases such as coquimbite and copiapite. Calcium sulphates correspond exclusively to gypsum. In a semiarid climate, such as that of the study area, these minerals contribute to understand the response of the system to episodic rainfall events. MINTEQ model could be used for the analysis of waters affected by mining activities but simulation of evaporation gives more realistic results considering that MINTEQ does not consider soluble hydrated salts.