R.H. Carty | Geology Reports

USGS2005

Producing ammonium sulfate from flue gas desulfurization by-products

Emission control technologies using flue gas desulfurization (FGD) have been widely adopted by utilities burning high-sulfur fuels. However, these technologies require additional equipment, greater operating expenses, and increased costs for landfill disposal of the solid by-products produced. The financial burdens would be reduced if successful high-volume commercial applications of the FGD solid by-products were developed. In this study, the technical feasibility of producing ammonium sulfate from FGD residues by allowing it to react with ammonium carbonate in an aqueous solution was preliminarily assessed. Reaction temperatures of 60, 70, and 80??C and residence times of 4 and 6 hours were tested to determine the optimal conversion condition and final product evaluations. High yields (up to 83%) of ammonium sulfate with up to 99% purity were achieved under relatively mild conditions. The optimal conversion condition was observed at 60??C and a 4-hour residence time. The results of this study indicate the technical feasibility of producing ammonium sulfate fertilizer from an FGD by-product. Copyright ?? Taylor & Francis Inc.

Energy Sources↗

USGS1999

Utilization of the gypsum from a wet limestone flue gas desulfurization process

The authors have been developing a process which converts FGD-gypsum to ammonium sulfate fertilizer with precipitated calcium carbonate as a by-product during the conversion. Preliminary cost estimates suggest that the process is economically feasible when ammonium sulfate crystals are produced in a granular size (1.2 to 3.3 mm), instead of a powder form. However, if additional revenue from the sale of the PCC for higher-value commercial application is applicable, this could further improve the economics of the process. Ammonium sulfate is known to be an excellent source of nitrogen and sulfur in fertilizer for corn and wheat production. It was not known what impurities might co-exist in ammonium sulfate derived from scrubber gypsum. Before the product could be recommended for use on farm land, the impurities and their impact on soil productivity had to be assessed. The objectives of this phase of the study were to evaluate the chemical properties of ammonium sulfate made from the FGD-gypsum, to estimate its effects on soil productivity, and to survey the marketability of the two products. The results of this phase of the study indicated that the impurities in the ammonium sulfate produced would not impose any practical limitations on its use at application levels used by farmers. The market survey showed that the sale price of solid ammonium sulfate fertilizer increased significantly from 1974 at $110/ton to 1998 at $187/ton. Utilities currently pay $16 to $20/ton for the calcium carbonate they use in their flue gas scrubber system. The industries making animal-feed grade calcium supplement pay $30/ton to $67/m-ton for their source of calcium carbonate. Paper, paint, and plastic industries pay as much as $200 to $300/ton for their calcium carbonate filers. The increased sale price of solid ammonium sulfate fertilizer and the possible additional revenue from the sale of the PCC by-product could further improve the economics of producing ammonium sulfate from FGD-gypsum.

Conference Paper↗