FGD Gypsum Production Process

FGD Gypsum Production Process

FGD gypsum, also known as synthetic gypsum, is chemically identical to natural gypsum and is generated from flue gases captured in emission control systems of coal-fired power plants. This production process transforms harmful sulfur dioxide (SO2) emissions, primarily from coal burning, into a useful product while reducing environmental impact.

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The production of panel-grade synthetic gypsum involves a multistage process. Initially, when flue gas is created, it is funneled through an electrostatic precipitator, which effectively separates fine particulates, including fly ash, from the gas. This crucial first stage helps in minimizing pollutants before the gas proceeds to the next phase.

Following separation, the flue gas is directed to an absorber oxidation vessel where it interacts with a water-based solution containing finely ground lime or limestone. This scrubbing process allows the reaction of sulfur dioxide with lime or limestone, producing calcium sulfite sludge, commonly referred to as FGD sludge. While the cleaned flue gas is discharged into the atmosphere, the processed sludge undergoes further refinement for subsequent use in gypsum panel production.

The sludge undergoes oxidation by injecting clean, compressed air into it. During this crucial step, calcium sulfite sludge transforms into calcium sulfate (CaSO4), which reacts with water in the mixture to yield calcium sulfate dihydrate (CaSO4·2H2O). This product is known as “unwashed” FGD gypsum.

To achieve a high purity level, the unwashed gypsum is subjected to additional refinement. Gypsum crystals are concentrated and separated from residual limestone using hydroclones. The underflow from the hydroclones, which contains concentrated gypsum, is then taken to a belt filter for dewatering and further washing.

The final step in the production process involves washing the gypsum using a vacuum filtration system, which efficiently removes chlorides, salts, and extra moisture from the surface. This step is critical for producing high-quality gypsum suitable for gypsum panel manufacturing. The processed, high-grade, "washed" gypsum is then transported to manufacturing facilities, serving as a primary ingredient in the production of gypsum panels.

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