E PA-600/2-76-273a
October 1976
EXPERIMENTAL AND THEORETICAL STUDIES
OF SOLID SOLUTION FORMATION
IN LIME AND LIMESTONE S02 SCRUBBERS
VOLUME I. FINAL REPORT
by
Benjamin F. Jones. Philip S. Lowell, and Frank B. Meserole
Radian Corporation
8500 Shoal Creek Boulevard
Austin, Texas 78766
Contract 68-02-1883
Program Element No. EHE624
EPA Project Officer: Robert H. Borgwardt
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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*	£ — — N ,-,r^
w' i. ?u -
This report describes the results of the theoretical
and experimental program, that Radian conducted to characterize
the coprecipitation of calcium sulfate with calcium sulfite
hemihydrate.
The existence of a coprecipitation product hac been
hypothesized to explain the mechanism by which sulfate could be
precipitated from a scrubber solution subsaturated with respect
to calcium sulfate. Long tern, steady-state operation of lime
and limestone SO: sc'ibb'ing systems with oxidation rates below
20% has been achieved with liquors subsaturated with respect
to all known calcium sulfate solid forms. Nevertheless, sulfate
is measured in the solids precipitated from these systems.
The existence of a calcium sulfate-calcium sulfite
solid solution has been confirmed experimentally and a theoretical
formulation has been established. Calcium sulfite hemihydrate
was precipitated under controlled laboratory conditions from
solutions subsaturated in calcium sulfate. Specific chemical
analysis and infrared spectroscopic techniques xcere used to
identify sulfate in the solids.
The sulfate content in the precipitate was studied
as a function of the relative saturation of calcium sulfate
and the precipitation rate of calcium sulfite hemihydrate.
Also, the effects of high magnesium and chlorides concentrations
anc limestone anc lime dissolution on the sulfate content of
the solids were measured.
ii

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TECHNICAL REPORT DATA
fl'r.jsc rccJ l, : l\ ia: co>r.r!ctinv
EPA-60C/2 - 76-273a f
3. RECIPIENT'S ACCESSION NO.
•I. " 1 Tut AND S7 1 T L E
Experimental and Theoretical Studies of Solid Solution
Formation in Lime and Limestone S02 Scrubbers-
Volume I. Final Report
S. RETORT OATE
October 1976
6. PERFORMING ORGANIZATION CODE
? A.THCRts) Benjamin Yt Jones, Philips. Lowell, and
Frank B. Meserole
8. PfcfiFORMlNG ORGANIZATION REPORT NO.
3 PERFORM'N'G O^OANIZATiON NAME AND ADDRESS
Radian Corporation
8500 Shoal Creek Boulevard
Austin. Texas 78766
*0. PRC-GRAM ELEMENT NO.
EHE624
11. CONTRACT/GRANT NO.
68-02-1883
IT. SPONSORING AGENCY NAME. AND ADDRESS
EPA. Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Final; Through May 1976
14. SPONSORING AGENCY CODE
EPA/600/13^
15. supplementary notes ierl-RTP Project Officer for this report is R.H. Borgwardt,
918/549-8411 Ext 2234, Mail Drop 65.
i 16. abs"*"sact The rep0rt gjves results of a theoretical and experimental study to charac-
; terize the coprecipitation of calcium sulfate with calcium sulfite hemihydrate. A
1 coprecipitation product had been suggested to explain the mechanism by which sulfate
could be precipitated from a scrubber solution subsaturated with respect to calcium
sulfate. Lime and limestone S02 scrubbing systems with oxidation rates below 20%
had been operated long-term at steady state with liquors subsaturated with respect to
all known calcium sulfate solid forms and yet sulfate was measured in the solids.
The existence of a calcium sulfate/calcium sulfite solid solution has been confirmed
experimentally and a theoretical formulation has been established. Calcium sulfite
hemihydrate was precipitated under controlled laboratory conditions from solutions
subsaturated in calcium sulfate. Specific chemical analysis and infrared spectroscopic
techniques were used to identify sulfate in the solids. The precipitate's sulfate content
was studied as a function of the relative saturation of calcium sulfate and the precip-
! itation rate of calcium sulfite hemihydrate. Also, the effects of high magnesium con-
1 centrations and limestone dissolution on the sulfate content of the solids were
; measured.
17. KEY WORDS AND DOCUMENT ANALYSIS
2. DESCRIPTORS
b. iDENTt F 1 E RS/OPEN ENDED TERMS
c. COSATi Field/Group
Air Pollution
Calcium Oxides
Limestone
Flue Gases
Scrubbers
Sulfur Dioxide
Air Pollution Control
Stationary Sources
13B
07B
08G
2 IB
07A
:3. TrMDJ*iCi- STATEMENT
19 SECURITY CLASS i fhn Reportj
Unclassified

Unlimited
20 SECURITY CLASS (This pafic)
Unclassified
22. PRICE
fioi
EPA Fern 2220-1 (9-73)

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ACKNOWLEDGEMENTS
The authors wish to thank Robert II. Borgwardt, EPA's
Project Officer on this contract, for his assistance and
cooperation in the completion of this project. We are indebted
to Larry A. Rohlack for technical assistance in designing and
operating the experimental apparatus and to Donny L. Heinrich
for performing the analytical work.
DISCLAIMER
This report has been reviewed by the Industrial
Environmental Research Laboratory, U. S. Environmental
Protection Agency, and approved for publication. Approval does
not signify that the contents necessarily reflect the views
and policies of the TJ. S. Environmental Protection Agency, nor
does mention of trade names or commercial products constitute
endorsement or recommendation for use.

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TABLE OF CONTENTS
Page
A3STRACT	 i
ACKNOWLEDGEMENTS	 ii
1.0	SUMMARY AND CONCLUSIONS	 1
1.1	Verification of the Existence of
the Calcium Sulfite-Sulfate Solid
Solution	 2
1.2	Quantitative Measurement of the
Sulfate Content of the Calcium
Sulfite-Sulfate Solid Solution	 3
1.3	Development of Sampling Methods
for Slurries Containing High-Liquid
Phase Magnesium Concentrations	 4
1.4	Effect of Relative Saturation of
Calcium Sulfate Hemihydrate	 4
1.5	Effect of the Calcium Sulfite
'Precipitation Rate	 5
1.6	Effect of Magnesium ana Carbonate
Liquid-Phase Concentration on the	!
Precipitation Rate of Calcium
Sulfite Hemihydrate	 6
1.7	Coprecipitation of Calcium Carbonate
with the Calcium Sulfite-Sulfate
Solid Solution	 6
2.0	BACKGROUND AND APPROACH	 7	j
3.0	THEORETICAL FRAMEWORK OF THE CALCIUM
SULFITE-SULFATE SOLID SOLUTION	 9
4.0	EXPERIMENTAL APPROACH	 14
4.1	Description of Equipment	 15	¦
4.2	Sampling Techniques Utilized 1
in Kinetic Experiments	 23
iv
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TABLE OF CONTENTS (Cont'd)
Page
4.3	Analytical Techniques		25
4.4	Experimental Calculations		27
5.0	RESULTS		29
5.1 Physical Characterization of the
Calcium Sulfite-Sulfate Solid Solution		41
6.0	DISCUSSION OF RESULTS		51
6.1	Effect of Relative Saturation of
CaSO, -%H£0		58
6.2	Effect of Calcium Sulfite Precipitation
Rate		62
6.3	Comparison of Lime and Limestone Tests
With Clear Liquor Results		64
6.4	Effects of High Levels of Chloride
and Magnesium		64
6.5	Effect of Temperature		65
7.0	REVIEW OF PLANT AND PILOT PLANT DATA		68
8.0	RECOMMENDATIONS		73
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LIST OF TABLES
Pago
TABLE 5-1	LIQUID AND SOLID COMPOSITION DATA
OF EXPERIMENTAL RUNS	 30
TABLE 5-2 SUMMARY 0? MOLAR COMPOSITION OF
LIQUID AND SOLID PHASES OF ALL
EXPERIMENTAL RUNS	 33
TABLE 5-3	SUMMARY OF CALCULATED DATA FOR ALL
EXPERIMENTAL RUNS	 36
TABLE 5-4	LIQUID AND SOLID COMPOSITION DATA
DATA FOR EQUILIBRIUM RUNS	 39
TABLE 5-5	SUMMARY OF RESULTS OF EQUILIBRIUM
RUNS Q-1 THROUGH Q-18	 40
TABLE 6-1	EXPERIMENTAL RESULTS INVALIDATED	 53
TABLE 6-2	EXPERIMENTAL RESULTS FOR CORRELATIONS	 55
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LIST OF FIGURES
Page
Figure 4-1 Schematic Representation of Data
Analysis	 16
Figure 4-2	Equilibrium Extraction Apparatus	 18
Figure 4-3 The Sampling Train Utilized in Equilib-
rium Studies	 20
Figure 4-4 Precipitation Apparatus for Kinetic
Studies	 21
Figure 4-5 Plexiglas Reactor Used in the Kinetic
Studies	 22
Figure 5-1 Infrared Spectra of Pure Calcium Sulfite
Kemihydrate and Calcium Sulfate
Dihydrate	 43
Figure 5-2	Infrared Spectra of Reactor Products.... 44
Figure 5-3 Results of Infrared Quantitative Correla-
tion of Sulfate Mole Fraction with the
Ratio of the Absorbance of the Sulfate
Band (1220 cm *) with the H20 Band
(1620 cm"1)	 47
Figure 5-4 Differential Scanning Calorimetry Pattern
of Precipitated Solids of Kinetic Run 37. 49
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LIST OF FIGURES (Cont'd.)
Page
Figure 6-1 Sulfate Content of Solid Solution as
a Function of CaSCK'^l^O Relative
Saturation in Solution, Clear Liquor
Studies	 59
Figure 6-2 Comparison of Lime and Limestone Experi-
ments with the Clear Liquor Runs	 61
Figure 6-3 Sulfate Content of Solids as a Function
of CaS03'%H20 Precipitation Rate	 63
Figure 6-4 Effect of High Chloride and Magnesium
Concentrations of Sulfate Content of
Solid Solution	 66
Figure 6-5 The Effect of Temperature on Sulfate
Concentration in the Solids	 67
Figure 7-1 Concentration of Sulfate in the Solids
as a Function of the CaS0i*-%H20 Relative
Saturation in the Aqueous Phase	 70
Figure 7-2 Example of Relationship between Sulfate
Mole Fraction and Gypsum Relative Saturation
for Shawnee TCA-Limestone Runs 	 72
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1.0
summary and conclusions
An experimental and theoretical study of tne calcium
sulfite-sulfate solid solution formation has been conducted for
the Environmental Protection Agency (EPA) by Radian Corporation.
Radian has confirmed the hypothesis of R. K. Borgwardt and others
that the sulfate is removed from solution during subsaturated
(CaSO• 2K?0) operation in pilot plant tests by the formation of
a "solid solution" of calcium sulfite and calcium sulfate. The
sulfite oxidation rate has been identiried by Radian as tne
critical control parameter for operation of the S02 scrubber
subsaturated with respect to gypsum.
This report does not contain a complete explanation
of all of the experimental and field data that have been
accumulated relating to the coprecipitatior. of sulfate with
calcium sulfite hemihyarate. Nor is a theoretical expression
offered that accounts for all of the experimental results ob-
tained from this program. The problem may be a result of
several factors including:
•	difficulties associated with control
of all experimental variables and
•	incomplete understanding of all the
factors involved in the phenomenon of
coprecipitation.
The experimental data of this program are presented
in this report along with a critical assessment of the validity
of the data. On the positive side , this study has shown that
the strongest correlating factor relating tc the sulfate content
of the coprecipitate is the relative saturation of calcium
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sulfate hernihydrate in the aqueous phase. This and the
demonstrated absence of a ir.ajor kinetic effect indicate that
the coprecipitation of sulfate with calcium sulfite hernihydrate
is basically an equilibrium controlled process.
This work has successfully shown the existence of a
solid solution of sulfate with calcium sulfite hernihydrate by
direct verification using infrared spectroscopy. A relationship
has also been formulated to predict the sulfate content of the
solids during subsaturated (gypsum) operation based on the solution
composition.
A summary of the results of this program follows.
1.1	Verification of the Existence of the Calcium
Sulfite-Sulfate Solid Solution
Chemical analyses of solids precipitated from solutions
prepared under controlled laboratory conditions to be super-
saturated in CaS0 3*%H20 and subsaturated in CaS0i,'2H20 have
verified the presence of sulfate. Infrared spectral analysis
was also used to confirm the presence of sulfate in the solids.
X-ray diffraction patterns of the sulfate-containing
solids were essentially indistinguishable from the patterns of
pure CaSCh-^HiO. No separate crystalline phase containing
sulfate could be identified by this method.
The infrared spectra not only were used to substantiate
the presence of sulfate in the solids, but also provided direct
evidence of the existence of a coprecipitation product. The ab-
sorption patterns in the 1100-1200 cm": region assigned to the
sulfate ion are quite different for sulfate as a pure gypsum
phase from sulfate in solid solution.
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To determine whether the coprecipitate is in
thermodynamic equilibrium with the solution from which it is
grovm cr is a result of kinetic effects, some long-term
equilibration tests were conducted. Solids were allowed to
cone to equilibrium with solutions containing calcium, sulfate
and magnesium concentrations identical to their concentrations
in the solutions from which the solids were precipitated. After
as long as four weeks, the liquid phase was found to be saturated
with calcium sulfite henihvdrate and still subsaturated in
calcium sulfate cihydrate. The sulfate content of the solids
did not change substantially during these tests.
1.2	Quantitative Measurement of the Sulfate Content of
the Calcium Sulfite-Sulfate Solid Solution
An analytical technique was developed during this
program fcr the specific determination of sulfate in solids
typically precipitated in lime and limestone-based SO? scrubbers.
Previously, the sulfate concentration measurements were obtained
by a difference technique. A portion of the sample was analyzed
for total sulfite. A second portion treated to oxidize all of
the sulfite to sulfate was then analyzed for sulfate. The
difference in these two values gives the original sulfate value.
When the sulfate level is low compared to the sulfite concentra-
tion, the error of this technique becomes quite large.
The specific sulfate technique selected for this
program can be used to determine sulfate concentrations in the
range of interest to within ±5% of the actual value, e.g. 10+.5"c.
Infrared analysis was also used to quantitatively
measure the sulfate concentrations in the solid solution samples.
The infrared spectral technique was calibrated by initially
ratioing the solid solution sulfate absorptivity at 1220 cm 1
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to the absorptivity of the water of hydration band at 1620 cm 1.
A correlation was then established relating this ratio to the
sulfate content as determined chemically. Though not as sensi-
tive as the specific sulfate technique, the infrared technique
is much faster and can also be used to distinguish the forms of
sulfate present.
1.3	Development of Sampling Methods for Slurries
Containing High-Liquid Phase Magnesium
Concentrations
One of the difficult problems in characterizing the
solics precipitated from solutions containing high magnesium
concentrations is the contamination of the solids by the high
concentration of dissolved magnesium sulfate. This contamina-
tion results from the adhesion of the liquid phase to the
filtered solids with subsequent crystallization of the magne-
sium sulfate during drying. Sampling and sample handling tech-
niques have been developed which minimize this interference.
1.4	Effect of Relative Saturation of Calcium Sulfate
- Hemihvdrate
The calcium sulfate hemihydrate (CaSOi* •%H20) relative
saturation has been determined to be the most significant
correlating variable associated with the formation of the
calcium sulfite-sulfate solid solution in the laboratory studies
conducted by Radian. These studies have shown that the sulfate
content of the solids, i.e., the sulfate mole fraction of the
precipitated solids, varies most rapidly from 0 to 0.12 as the
calcium sulfate hemihydrate relative saturation ranges from
0 to 0.20. The sulfate mole fraction in the solid solution
rises to 0.16 at a hemihydrate relative saturation of 0.45, the
point at which the solution is also saturated with respect to
gypsum.
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These results are consistent with the theory developed
in e-r.rlv phases of Che experimental program which states that the
equilibrium contribution to the sulfate content of the solid
solution will be a function of the calcium sulfate hemihydrate
relative saturation. The relationship that predicts the sulfate
nole fraction from the relative saturation is given in Equation
1-1.
(1-1)
RSCaSO, ¦	= xCaSO.. • vH.O ' exP (¦ SxCaSO. • %H ? C —
where,
RSCaS0i, • -'H-0 = ttie re^£tive saturation of calcium
sulfate hemihycrate in the liquid
phase, and
x o	r. = z^e Kcle fraction of sulfate in the
UaoU w • -in : «-
solid phase.
1.5	Effect of the Calcium Sulfite PreciDitation P.ate
Experimental results have shown the calcium sulfite
precipitation rate does not have a measurable effect on the amount
of sulfate coprecipitated with calcium sulfite as a solid solution
This was true for precipitation from solutions both high and low m
magnesium concentration-. In other words, kinetic effects co
not appear to be significant in the composition of solid solution
witnin the precipitation range studied, namely 0.001-1.7 milli-
moles/g-min. These results in conjunction with the calcium
sulfate relative saturation data imply that for all practical
purposes the composition of the calcium sulfite-sulfate solid
solution is determined by an equilibrium condition and not
simrlv bv inclusion.
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1.6	Effect of Magnesium and Carbonate Liauid-Phase
Concentration on the Precipitation Rate of Calcium
Sulfite Hemihydrate
Preliminary data from several kinetic experiments show
that liquid-phase magnesium and carbonate ions may inhibit the
precipitation rate of calcium sulfite hemihydrate. Nucleation
in a calcium chloride-sodium sulfite system normally occurs at
a calcium sulfite hemihydrate relative saturation of approxi-
mately 3.0. With the addition of magnesium, calcium sulfite
hemihydrate relative saturations of 8-15 have been observed at
precipitation rates significantly lower than those observed in
the pure system indicating a decrease in the nucleation rate.
The addition of the carbonate ion to a calcium sulfite-sulfate
system required a CaS0 3-%H20 relative saturation of 5.3 to ob-
tain the same precipitation rate measured at a relative satura-
tion of 2.3 in a carbonate-free solution.
The implication of these observations may have a
significant impact on SO2 scrubber system design and warrant
additional experimental studies.
1.7	Coprecipitation of Calcium Carbonate with the Calcium
Sulfite-Sulfate Solid Solution
Qualitative results from infrared spectral analyses
of solids precipitated from liquors containing carbonate indi-
cate that carbonate is coprecipitated with the calcium sulfite-
sulfate solid solution. This is particularly evident in the
I.R. spectra of scrubber solids from Pennsylvania Power &
Light's Sunbury pilot unit where evidence of matrix isolated
carbonate was observed. This coprecipitation of carbonate im-
pacts on the maximum limestone utilization which can be achieved
and may have an effect on the sulfite to sulfate ratio that can
be coprecipitated. Based on these results, additional study of
the coprecipitation of carbonate with the calcium sulfite-
sulfate solid solution is recommended.
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BACKGROUND A;hD APPROACH
Pilot plant studies conducted by EPA. at Research
Triangle Park and full-scale operation at various plants in the
U.S., Japan and England have demonstrated that both lime and
limestone S02 scrubbers can operate unsaturated with respect to
gypsum even under tight "closed-loop" operation. This fact
offers an opportunity, if the phenomenon responsible can be
understood and controlled, to effectively reduce gypsum-scaling
potential which has persisted as cr.e of the principal reliability
problems of lime and limestone flue gas desulfurization systems.
The formation of a "solid solution" of calcium sulfite
and calcium sulfate has been suggested by R. H. Borgwardt and
others as the probable mechanism responsible for the sulfate
purge which leads to unsaturated operation. Several variables
such as sulfate concentration, sulfite precipitation rate anc
concentration of chloride and magnesium have been identified from
field studies as influencing the composition of the solid solu-
tion.
Radian has conducted a theoretical and experimental
study to characterize the chemical factors which affect the
formation of the solid solution. The objectives of this study
were tc:
q develop a consistent theoretical basis
for examining field and laboratory data,
• review available field data relative to
unsaturated operation.
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•	develop, if necessary, sampling, sample
handling, and analytical methods which
are consistent with accurate measurement
of sulfite and sulfate in both liquid
and solid phases,
•	study the application cf physical and
analytical techniques which can be
usee to establish direct evidence of
the ccprecipitatior. of sulfate with
calcium sulfite hemihydrate,
o conduct equilibrium studies to establish
whether or not a solid solution will
precipitate from various solutions
near equilibrium,
•	conduct kinetic studies using a lime or
limestone slurry and a clear liquor
characteristic of either lime or lime-
stone scrubbers to determine the effects
of the sulfite precipitation rate,
temperature and scrubber liquor compo-
sition with emphasis on magnesium and
chloride, and
•	develop a theoretical framework for
liquid/solid equilibrium or kinetics
in such a manner that it can be used
for predicting conditions necessary
for unsaturated operation of lime and
limestone scrubbers as a function of
liquor composition and oxidation.
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3.0	THEORETICAL FRAMEWORK Or THE CALCIUM SULFITE-SULFATE
SOLID SOLUTION
Coprecipitation nay be controlled by equilibrium
effects, kinetic effects, or a combination of the two. If a
true solid solution is formed as a result of the coprecipita-
tion of calcium sulfite and calcium sulfate, then fundamental
thermodynamics can be used to describe the equilibrium rela-
tionships which control solid and liquid phase compositions.
On the other hand, if sulfate tends to be incorporated into
the solid phase by inclusion, then the kinetics of sulfite
precipitation should be an important factor. In this latter
case., the sulfate/sulfite ratio in the coprecipitated solids
would be expected to be a direct function of the growth rate
of calcium sulfite solids.
It is important to distinguish between these two
possibilities for the following reasons. If the formation of
a solid solution is the dominant mechanism of coprecipitation,
the system sulfite oxidation rate will determine whether sub-
saturated operation is possible. On the other hand, if kinetic
effects are significant, then system design (in addition to
oxidation control) can be used to optimize coprecipitation
and avoid sulfate scaling.
The existence of a solid solution in equilibrium with
a liquid phase can be described thermodynamically through
t"
chemical potentials. The chemical potential, y.., of the i^-
component in the	phase may be written as.-
¦j. . = u? . + RTIna. .	(3-1)
ij	ij
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aw iv
= the standard state chemical potential,
R = iceal gas constant,
T = the absolute temperature, and
a. . = the activity of the i— component in the
th
j— uhase.
In this analysis, the following designations will
i = 1 «> CaS'C3-^HL0
i = 2 -> CaSCu • -VH?0
j = s =-> Solid
j = I -¦> Liquid
The standard state of the solid phase will be defined as the
pure component. For a solid solution mixture, deviations frox
ideal solutions will be based on mole fractions. Solid phase
activity coefficients,	are defined by Equation 3-2.
ais " °ix:	(3-2a)
a2S = c2x2	(3-2b)
where the x's are the solid phase mole fractions.
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The choice of the hemihydrate of calcium sulfate
as the forn of the solid phase was selected since the calcium
sulfite host matrix is a hemihydrate. This situation can be
imagined by simply replacing a sulfite ion with a sulfate ion.
However, the mathematical formulation could be developed for
the aihydrate of calcium sulfate equally as well. Direct
measurement of the solids subsequently gave a mole ratio of
total S to water of 2:1 which is consistent with the hemihydrate
model.
The activities of CaSOr-'^KiO and CaSCK*%H:>0 in the
liquid phase are defined in Equation 3-3:
2
V " £Ca++ aS0= aH2 0	(3"ja
" aCa-H- aS0= aH 0	(3" 3b)
U	2
The liquid phase is in equilibrium with the solid
phase when the chemical potentials of all components in both
phases are equal. Equating chemical potentials gives
Equation 3-4.
y. - v-o	(3'A)
IS	xl
Substituting the definitions in Equations 3-1 and
3-2 into 3-4 gives Equation 3-5.
^? + RT £n c.x. = w_° o + RT In a.,	(3-5)
is	l 1	1
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Equation 3-5 may be solved for the activities:
ai I
cixi
e
-(u;,-[j/rt
K. IS
(3-6a)
= K-	(3-6b)
The equilibrium cons cant, K^, is the solubility
product constant. This nay be seen by considering the limiting
cases of the pure components and by noting that;
lirn o. = 1.
X-i =1
(3-7)
The relationship between the solid and liquid at
equilibrium for both species is written out in explicit form
in Equation 3-8.
aCa++ aS0= aH,0 K;Cl XCaS03-%K20	(3 8a)
aCa"H" aSOr aH20 K:°2 xCaSO„-3£H;0	(3-8b)
Dividing both sides of Equation 3-8b by the solubilit
product constant, K?, gives Equation 3-9, the left-hand side of
Equation 3-9 is, by definition, the relative saturation of
CaSCU-%H; in the liquid phase.
S' CaSO.^-H.O	32 xCaS0,.%K20	(3"9)

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The mathematical form of the solid phase activity
coefficient can be estimated from the empirical correlation of
the liquid phase calcium sulfate relative saturation with the
sulfate mole fraction in the corresponding solids. The relation
given ir. Equation (3-10) gives the desired functional form to
Equation (3-9),
-V.cn. .«.0 = M + 012 XCaS0.,-%H:0 (3-10)
where the constants n: and ^2 are calculated from the experimental
data.
Substituting this relationship for the activity
coefficient into Equation (3-9) gives:
R-S CaSO.-hY-tO xQ:SO.-%H20'eX?(Cl1 + &2xCaS0. • J2H2(P
The mole fraction of sulfate in the solids can be
calculated from Equation (3-12) given the relative saturation of
calcium sulfate hemihydrate in the aqueous phase from which the
s d»ids are precipitated.
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4.0
EXPERIMENTAL APPROACH
An experimental program was established to characterize
the nature of the mechanism leading to coprecipitation of sulfate
with CaS03-%H20. Controlled experimental conditions were used to
first verify the existence of a coprecipitation product and then
to measure the effects of solution composition. The precipitation
rate and some measure of the sulfate concentration were the primary
variables t.o be studied.
The experimental apparatus and sampling and analytical
techniques used during this program are described in this section.
Additional details are presented in Appendix C.
The experimental studies were divided into the following
areas:
0 selection and development of sampling anc
analytical methods which are consistent
with the accurate measurement of sulfite
and sulfate in both the liquid and solid
phases,
•	a series of experiments at lew sulfite
precipitation rates to establish whether
or not a solid solution will precipitate
from solutions near equilibrium,
•	a series of experiments at higher precipita-
tion rates to determine if kinetic effects
are significant,
m investigation of the effects of:
dissolved magnesium
temperature
ionic strength (NaCl),
dissolving limestone and lime
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# investigation of the applicability of	f
selectee physical techniques in the identi-	•
fication, characterization and measurement
of the solid solution.
Results of this program are compared to results
obtained in field studies to obtain a consistent theoretical
framework for predicting conditions necessary for unsaturated	r
operation (gypsum) of lime and limestone scrubbers. A schematic
flew of the correlation of all available data is shown in Figure
4-1.
A . 1	Description of Equipment
r
Experimental equipment utilized during this program
consisted of two equilibrium apparatuses, a kinetics reactor
and appropriate sampling trains for each.
Earlv Phase Equilibrium Apparatus
i
The first equilibrium apparatus constructed was designed	1
to establish whether a solid solution would precipitate from
various solutions near equilibrium and to establish a quantitative
relationship between the equilibrium liquid and the solid phase
compositions.
t
This equilibrium apparatus consisted of a closed-loop	1
system in which water could be removed from a solution containing
calcium sulfite and calcium sulfate by means of evaporation. The
evaporated water was condensed and passed through a calcium sulfite
saturator and then the solution was sent back to the precipitation
vessel. Evaporation was regulated by solution temperature and
system vacuum control.
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LITCRATURE
PHYSICAL
review
MEASUREMENT
CHARACTERIZATION
or
SOLID
SOLUTION
FORMATION
1	
THEORETICAL'
FRAMEWORK
data
FIELD
ANALYTICAL
STUDIES
KINETIC
EQUILIBRIUM
STUDIES
PROCEDURES
PROCESS
DESIGN
CORRELATION.
DATA
FIGURE 4-1.
SCHEMATIC REPRESENTATION OF DATA ANALYSIS

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This experimental approach in the equilibrium studies
was terminated in the early phases of the test program due to
the impracticality of long experimental run tines (one to four weeks).
Oxidation and other operational problems also prevented the
practical application of this equilibriurn approach over the re-
quired run tir.es .
Ecuilibration Apparatus
This equipment, Figure 4-2, was designed to obtain
equilibrium data from solids grown during the kinetics phase oi
this project:. The solids were equilibrated with a liquor similar
to that i: which it was grown, thus allowing the relative influence
cf the equilibrium and kinetic effects on the sulfate content of
the solids to be separated and quantified.
An experimental apparatus was designed and constructed
to accommodate six experimental runs simultaneously at a con-
trolled temperature in an inert atmosphere. A large plexiglas
box was fabricated and served as the enclosure. Heat lamps
connected to a temperature controller and thermistor system
maintained the enclosure at a controlled temperature while two
fans circulated nitrogen to minimize temperature gradients within
the box. Thermometers suspended from the top of the box at
several locations were used to monitor the temperature. Nitrogen
entered the enclosure on the back side of the fans providing a
constant oxygen purge cf the enclosure.
Plexiglass cylinders with an internal volume of 570 ml
were charged with appropriate solids and liquors. These solu-
tions then were thoroughly mixed on a tumbling device designed
especially for horizontal rotation of the cylinders at a constant
-17-

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i h n n m i s t o n
rilEflMOMIITCn
- T H L n M O M [• T I- n
TEMP t: H A T U 11 b
	I'
cnNTnoLirn
I	
HF AT
J A M P
pU n gc
CIRCULATING
TANG
PLE X I - GL A S
BOX
670 ML
P t. F X I - G I AS
I VCSSCI.S
0 O1 r LE
FIGURE 4-2. EQUILIBRIUM EXTRACTION APPARATUS

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speec for long periods of time. Ceramic cylinders were used within
the containers to produce grinding to expose new surfaces of the
crystals for dissolution and precipitation. Additional details
of this experimental technique are contained in Appendix C.
A sampling procedure was designed to ensure consistent
and accurate, nieasurenents of sulfite and sulfate in both the
liquid and solid phases. A pictorial representation of the
sampling train utilized in these equilibrium studies is shown
in rigurc 4-3. Temperature and pH measurements of the equili-
brated solutions were taken just prior to sample collection.
Rapid liquid phase sampling to provide an aqueous sulfite sample
and a diluted filtrate sample was accomplished by usir.g a peri-
staltic pump anc a 47 mm filter. All sampling lines were kept
as short as possible and a constant purge of nitrogen was
directed at the sample port in the vessel at all tines during
sampling to minimize any liquid contact with air. After
collection of the two liquid samples, the equilibrated solids
were obtained by filtration of the slurry. The filtration was
done ir. a nitrogen atmosphere.
Kinetic Apparatus
The kinetic apparatus, shown in Figures 4-4 and
4-5, served as a precipitation device to quantify the influence
of solution composition on the formation of the coprecipitate.
with this flow-through system, experimental conditions such as
temperature, calcium sulfite precipitation rate and relative
saturation of calcium sulfate can all be varied independently
to simulate the reactor compositions necessary for this study.
-19-

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N? I'UHGb
10
0
1
COMBINATION B
Fl. FCTPODE I
riLTrn
[© ©_ ~~U (O) {o
I-T
METER
5 7 0 ML
PLL.X1-GLAS
VESSEL

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p ®
PARASTALTIC
PUMP AND CONTROLLER
ROTOMETER
PA^ASTALTIS PJV>

CONTROLLED
TEMPERATURE
BATH
f.^lNOFR D^IV^
PA3A3IAI Ti:
SAMPLE
CO
UH MONITOR
PARASTALTIC pump
AND CONTROLLER
FIGURE 4-4. PRECIPITATION APPARATUS FOR KINETIC STUDIES

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I
STIRRER
SUPPORT
STIRRER
T HERMOMETER
•-STIRRER
S HAFT
PROPELLOR
baffle
baffle
PROPELLOR
PLEXI'GLAS
REACTOR
FILTER
FIGURE PLEXIGLAS REACTOR USED IN THE KINETIC STUDIES
-22-
K

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The primary components of Che kinetics apparatus are:
•	a continuous liquid/slurry feed system,
•	a reactor,
•	a grinder,
•	a continuous mixed product removal system
and
•	a pH monitor.
The continuous liquid/slurry feed system provided two well-defined
feed streams to the reactor where precipitation occurred. A
continuous mixed product removal system and grinder were incor-
porated into the kinetics apparatus in order to maintain a constant
slurry density and particle size in the reactor. The pH of
the reactor effluent was monitored in a flow-through cell immediately
downstream of the filter.
Each component of the kinetics apparatus was periodically
checked to ensure that consistent and accurate measurements of
the individual test parameters were being maintained. Additional
details of the kinetics apparatus are given in Appendix C.
4.2	Sampling Techniques Utilized in Kinetic Experiments
The sampling train and procedures were designed to
obtain consistent and accurate measurements of the composi-
tions of both the liquid and solid phases. All sampling
lines and fittings were nalgon and teflon to minimize chemical
changes in the samples. For the most part sampling provisions
were incorporated in the experimental apparatus flow system
(see Figure 4-4).
-23-

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I
Feed scream samples were obtained by diverting the
feed liquors through three-way stopcocks located in front of
the reactor into prepared sample bottles. The reactor effluent
liquor passed through the pH monitor and was collected for
analysis. Precipitated solids were recovered from the reactor
by filtering a portion of the slurry removal stream.
Sufficient samples were taken during each run to
characterize the streams entering and leaving the reactor.
Diluted filtrate samples were taken from the two feed streams
and the reactor effluent after the line-out period of approxi-
mately three solids residence times. Aqueous sulfite samples
were taken in a similar fashion and were used with the pH
measurements to monitor the approach to steady state. Periodic
slurry samples were taken and filtered to obtain the weight
percent solids in the reactor. After the system had been operated
for three solids residence times, the reactor solids were
collected, washed and dried.
!
A sampling procedure was developed to minimize	i
contamination during sampling of the solids from high magnesium
sulfate liquid phase concentrations. Basically this technique
consists of a rapid separation of the precipitated solids
from the liquid phase. This separation was achieved with a
pressurized filtering system using polycarbonate filter membranes.
The solids are then twice slurried in a saturated calcium	^
sulfite solution and filtered. Next the solids are rinsed
with acetone and allowed to dry in an inert atmosphere.
Detailed descriptions of this and other sampling techniques are
included in Appendix C.
F
i
-24-
I

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-r. 3	Analytical Technique
The analytical methods used during this program are
breifly discussed in this section. A more detailed description
of each procedure is included ir. Appendix D.
For the most part the analytical techniques used were
those previously selected and modified by Radian for S02 scrubber
slurry analyses. A more sensitive sulfate procedure for solids
analysis was developed especially for this program.
Chemical Analysis of Liquid Phase Samples
Calcium, sodium and magnesium analyses on the filtered
feed and reactor effluent streams were performed by atomic ab-
sorption spectroscopy. Liquid phase sulfite measurements were
made using an iodometric back titration with sodium arsenite.
The end point of the titration was determined amperimetrically.
Aqueous sulfate concentrations were measured by
substracting the sulfite concentration from a total sulfate plus
sulfite measurement. The latter value was obtained by first
oxidizing the sulfite to sulfate and then measuring the resultant
total sulfate. The sulfate analytical procedure consists of an
initial cation exchange process followed by an evaporation step
at 75°C. The resulting sulfuric acid is then titrated with a
standard NaOH solution to determine the quantity present.
The chloride analyses of the aqueous samples were made
using a pcter.tiometric titration technique using a standardized
silver r.i:ra:s solution as the titranc. Carbonate analyses
were made by first acidifying the solution. A nitrogen sweep
gas was then passed through the acidified solution. The C02
content of the sweep gas was measured with a noncisoersive
infrared analyzer.
-25-

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Analytical Techniques for Solids Characterization
Both chemical and instrumental techniques were used
to determine the chemical composition of the solids precipitated
in the laboratory studies. These techniques were also applied
to some solids field samples from lime- and limestone-based SC2
scrubbing units. Specific chemical analyses of the solids were
made to determine the calcium, sulfate and sulfite concentration
Magnesium, chloride and carbonate analyses of the solids were
run periodically. Additional characterization of the solids
was accomplished using such instrumental techniques as infrared
spectroscopy, differential scanning colorimetry, X-ray diffraction
and thermogravimetry.
The specific sulfate, sulfite and carbonate analyses
were carried out directly on a portion of the sample. The
remaining chemical species were determined subsequent to the
dissolution of a portion of the sample. The solids were dissolved
in an acidic peroxide solution. Aliquots of this solution were
then analyzed for calcium, magnesium, sodium, chloride and total
sulfur using the same procedures described for the liquid phase
analyses.
A specific sulfate analytical procedure was developed
during this program to accurately measure the sulfate concentra-
tions in the precipitated solids. A weighed quantity of solid
samples was dissolved in an oxygen-free acidic solution.
COi was bubbled through the solution to remove the sulfite as
SOz. Once the dissolution was complete the solution was removed
and the sulfate level was determined by the ion-exchange, titri-
metric sulfate method. This technique provided improved accuracy
ir. the sulfate determinations over the concentration range en-
countered in ccprecipitate solids.
-26-

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The presence of large excesses of calcium carbonate
with the coprecipitate solids tends to cause some error in this
sulfate determination. This situation developed during some
of the limestone slurry tests where low utilization was encountered
Additional characterization of the solids was done
using infrared spectroscopy (IR), differential scanning colorimetry
(DSC), X-ray diffraction, and thermogravimetric analysis (TGA).
Infrared spectroscopy was used to qualitatively and quantitatively
measure the sulfate in the solid solution samples. The presence
of gypsum ir. the solids was identified by IR, DSC or X-ray
diffraction.
X-ray diffraction was used to measure the crystalline
phases present in the precipitated solids. However, the
diffraction Datterns for the solid solution samples were indis-
tinguishable from that of Dure calcium sulfite hemihydrate.
The dehydration temperatures as well as the quantities
of water lost from the solids were determined using DSC and TGA
methods.
4.4	Experimental Calculations
This section contains a brief description of the
calculations utilized in the data analysis of the experimental
runs. Liquid phase calculations included computation of the
activities of each of the ions and relative saturations of
calcium sulfite hemihydrate and calcium sulfate hemihydrate
and dihydrate by Radian's aqueous ionic equilibrium program.
The calcium sulfite precipitation rate was calculated from
inlet and effluent aqueous sulfite concentrations and flow rates.
-27-

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Solid phase calculations included the determination
of the sulfate and sulfite mole fractions of the precipitated
product based on the chemical analysis of the solids. The sulfite
precipitation rate was also calculated from the measured
slurry removal rate, weight percent solids and the solids analysis.
The sulfate precipitation rate was based on- the sulfite preci-
pitation rate and the sulfate to sulfite ratio in the solid.
These rates were normalized by dividing by the mass of the
seed crystals in the reactor.
Solid and liquid mass balances across the reactor
were calculated to evaluate the reliability of the data collected
for each experimental run. Total solid and liquor inlet molar
rates were calculated and compared to total outlet solid and liquid
molar rates. Agreement within expected experimental error of
the total inlet and outlet mass rates supported the accuracy of
the measured flowrates and chemical analyses. The calcium,
sulfite, and sulfate precipitation rates based on liquid analyses
were compared for consistency with the corresponding precipita-
tion rates based on solids analyses. Detailed equations used in
calculations are presented in Appendix C.
-28-

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5.0	RESULTS
This section presents the results of the experimental
studies designed to characterize the formation of the calcium
sulfite/sulfate coprecipitation phenomenon. Results of the
physical techniques used to identify, characterize and measure
the solid solution are also presented. The qualitative and
quantitative effects of the following variables on the solid
solution composition were evaluated:
•	relative saturation of calcium sulfate
hemihydrate,
•	calcium sulfite precipitation rate,
•	lime and limestone slurries,
•	magnesium concentration,
•	temperature, and
•	ionic strength or sodium chloride
concentration.
The experimental results of these parameter studies were inter-
preted within the framework of the theoretical relations describ
previously. Namely, the activity product of the aqueous phase
calcium sulfate was correlated to the sulfate content of the
precipitated solids. The precipitation rate had no measurable
effect on the amount of sulfate incorporated into the solids.
A summary of the analytical results as well as the
calculated values for the experiments conducted during this
program are presented in Tables 5-1, 5-2, 5-3, 5-4 and 5-5.
-29-

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TABLE

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TABLE
Run
f>nl r	Number
7/(11/7'. F S
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n/iK./7r»	iv in
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9/|f./;,«	K - R
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k in
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9/79/7' K t?
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lo/ni/7r» k- I'.
10/70/7'.	K-1r»
10/77/7S	K If.
10/7 1/7'.	K- 17
10/77//',	K-in
IO/7R//'»	K-»9
10/70/7"»	K • 70
1 1 /0«/7%	K 71
1 I/II'.//'.	K 77
11/u'/7'¦	r-jj
(cont ilined)
SUMMRY C
Temp.
	Eli		CO
ft. 77	'.f,
7.71
7.RR	/,o
R.'.O	/, \
R. 111	/,'»
R.'i/	'.9
n.7()	'i
R.70	Ml
nil	'»9
R.or,	/i9
i. m	f,9
R.(19	A 9
R.I?	il'
7.10	A9
n.'.n	/.9
n.R	/.r.
8 . IH	'-7
R.OR	AR
n.OR	4R
R.no	vi
7.90	6')
R.10	/»n
R.S7	Sfl
R.R7	S?
MOLAR COMPOSITION OF LiqUIJ>_AND SOIJD PIIASF.n OF ALL LXPF.RIMKNTAL RUNS
I <">. 1
r. in
». 7'I
1.17
R. V.
9. in
n.o
17.7
II./
9. i
17.1.
17 0
11.1
I.IS
I . I 1
I l.R
1 . 9
19.9
17. 1
17.1
I 7.4
17. n
17.P
F.I f I urn I I.I »I <| An;i I y ^rnim. 1 r i/ I 11 n )
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10.'.
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7 7
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7'. '.
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79 f.
70.1
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17.f»
11.R
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91
1.11
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.07
in. 7
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17. 1
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11.9
11.7
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M	f. .1'.
a;
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70	r, .or,
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77.11
17
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1
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Run
l)>il e NuhMti
x!L
Temp.
* »
I I /!«/?'»
1 1/711 /7S
17/01/7"
17/01/7S
i7/oi//s
17/07/7%
17/07/7'.
17/OS/7'.
1 7/os//s
l?/o«/r»
1 7/nn/7 "»
17/17/r.
I 7 / 19 / 7 r»
1 7/77/75
17/10/7'.
17/11/7".
1 7/ 11 //"t
1 /07/7ft
7/o7/;r»
2/oi/7ft
7/oi//ft
7/OA/7ft
?/in/7ft
7/1 7/7ft
7/17/7
7/17//
7/17/7
K -7'.
K 7ft
K 7/
k- 7A
K 79
K- HI
K 11
K- 17
K- n
K 1A
K IS
K 17
k • M
K-
K-All
K-AI
k-A7
K AA
K-AS
K-Aft
K-A7
K AA
K A9
K - SO
V SI
K • S7
K S »
fl.A'>
h.07
fi. 1?
7.90
r.. n i
fi. 11
ft. 17
ft. 11
s.<»n
ft. (HI
fi. 17
S.9A
ft. 17
5.fti
ft.77
r.. ftO
S. 7*
f.. 71
ft. IP
ft. ?n
ft. 70
ft. 74
ft. 21
7.9S
v jn
n. 11
a. in
so
Aft
so
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in
so
so
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so
M
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a a
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SO
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si
so
AO
A 1
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n. r i
71 .0
?n. n
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17.1
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17.6
11.0
17.0
1 7.ft
17.1
11.1
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29.7
7V'»
70. 1
7S. 7
77. 7
7 A . ft
77. 7
10. R
7S.9
9 S 1
1.07
9.0|
ft.9/
Ft I In.
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7 A A
ftl.O
I '.ft.
1 / ».
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1 MA
7H .
'.ft. 7
A ft. R
9A . fl
7000.
ftO.
77R.
101.
7»0.
1 IS.
ftO. 7
AA.
AO.
A S. A
AO.
A A . A
AO. A
A I . 0
A?. A
A I. ft
front" Inupd)
TABI.K 3-2 (rnntimiod)
U'lul.l
Mbl'_!	
An.i I ysrs (r»in
CI '
no
7ft. 0
A 7. ft
9ft. A
9 1.0
ia . n
7ft. S
A1.9
HR.A
7 V A
7ft . 01
ftSft.
17.fi
S9A .
S/9.
ft 19.
SI8.
7ftft.
Al 1
inA.
ft 1A.
SAO.
nsi.
A 1. I
A I O
AO f,
l'l. ft
I«s/l Wvt)
r.o,
r:o,,
in
11
r.«« i i.i a»« »i
_!!&''
i:o
n.
I . A 9
1. r.ft
A. ftn
i /
7.A1
11.1
10.1
nr.
K. 1
7.0
ft ft
ni. s
S.12
SO. ?
2 1. A
V.. ft
IS. I
17.1
1A . 9
10. 1
17.9
10. 1
7 . ft'l
1 . 90
I .*A
1
1 A A
11.1
A . SS
1A . 0
7 V
VI A
1/.A
ft 1. r.
7ft. I
7A.R
19.7
A 7 7 .
71 .ft
177.
17 V
7 17.
7S7.
700.
707.
I 1 A .
MM.
A S. A
9 1.
7.R
A . '.ft
7. 0*i
7 . V.
7.7/
ft. nr.
ft. HA
ft ;n
?.s%
7. in
A . 70
7. 1ft
n.f,7
n. 7 7
7. 7S
7. 1
7. IS
ft. A1
/. 79
7 . ;s
7. 7A
S . SR
7 17
/. 17
1. Oft
/./•*»
7. 1ft
7. 1A
7. M
*1 ftf, 7 AO
0 7
l>.
1)7S
07S
OS 7
O 77
0	IS
1	A
07
O 1
o;
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ha I c
Ifi.n
NomiIh'T
iliL
Toiip.
C<:)
c.»
K 'ft
K 'iH
K-MI
K-fil
K (>?
K r,i
k - I n
K <>'>
K f.f.
K r» 7
K-ftn
K-f»9
k- 7n
k- ;i
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f.. 7 '»
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r». 71)
s.f.9
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S. 70
-i.9»
v mi
van
v 79
f>7
7.91
R. 17
M
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51
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7. 7f»
7'.
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7.0
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M«<- «:<»I I«l•: tro r.o lilfli |o I Iwrsf«»nr Hi »l
TABI.F) 5-2 (cont inucd)
i < i it*.-in
H.i* _
in.R
f,r,. r,
7o.>.
i/n.
1 in
v,n.
I'.70.
no.
117.
117.
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ft ft .ft
f, i. r.
I f '| ii (<1 An .i I y'
	(¦
M.I).
M
7n;
N.I).
M f>
ft lfc
'AU,
n n.
(mm.• 1 I I I I | )
co"i so" : t»
>11 'I An;t I y.r-r- (imm I / j; t im )
IB.4
in.7
M I).
r». 2
m.B
N.t>.
ft.)
i. r>
f*. 7
N.n.
7 *» 1
7. on
1. 7(t
\n.n
7f). r>
17.«
1 9 ft
97.
IB. 7
1 '»'».
I'.B
I'.9
97.
. 70
. 73
7.7/.
n
I '.
I'l
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v
M
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700
f,'.7
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4'ifl
7
9
9
In
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n -in
7. v.
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n. nr.
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n. -»7
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67 7 . f>t
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fi . 7
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1 . 70
117
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III'
f.
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I I «l t»i 1 f 11 «• .mi i I \	it «• in u « iir.il r ,

-------
TAM.K 5-3. SUMMARY OF CALCULATED DATA VOR ALL EXPEP.fMI-NTAL RUNS
Hit p
Run
Nni'iU^i
I.I 'l«tor
rvpg'
HL
Tr""|'
_QJ_
i
LO
l
7/0 1/ 7 '
7 / I fl / 7 r»
7/?9/r»
n/o'i/ 7s
n/n/7*
«/."!//'»
0/«r./7S
9/17/7S
«> / K. / 7 '»
9/1 ///'i
i/;'»//r»
/7*»
HI/01/7S
io/i) i/;1*
10/70/75
10/77/ 7<>
10 / 7 J / 7 '>
10/77/7'
10/?fl/7^
10/7*1/ 7S
I I/ 1/7S
I l/A/7',
I- '»
K ft
1- 9
r. lo
t 11
K-.'
K 1
k r,
K - n
v- 9
k-11>
K-II
K I?
K- I 1
K-I'i
*• r»
K If.
K • I 7
K IR
K-|9
K-70
r. ?i
K 77
K 71
C.I.,
I..
c I
r I
c . I..
i: I.,
i 1..
r.i„
I .

Af.
a'
an
A \
AO
a 9
am
vi
A 9
A 9
A 9
A9
'.I
4
6
A
AR
AR
AR
A 9
a 9
10
JJJLll
~.	n r,
;.a'»
i. r»
n. v;
l in
7. 7'.
MJO
7 99
* RO
A. nf,
7.R0
1. 7f1
S7
1. ir.
0.	A 1
i). m
1.Rl
A . A n
~.(11
71
A.'»1
A.
7. 77
7. M
n	r»	I vr S.itui.il Iimi
"O,	SO.,	ro-. M
(to '') (|o ')	• 7ii2o c.iso,, Vi':" 11.t«t
n. ?%
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t,. ?r.
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7. V.
7 . 10
7.?n
7_71
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7.M
7.r»a
7. A "»
7.S9
7 . ?9
7. r>A
1.77
7. 77
7. r>r»
7.91
7. f.r,
7. f»f.
1. 77
i. r»
0. 97
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71
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77
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. 77
. 77
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I . 7H
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".iii mi >•
I'l ' I |- I I II I
i: ti r-
^imiii • I ' • / [• ¦' I mJI_ _«
n. ii«' i
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t>'»7
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TAIJLIi
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n/mm
H/7i>//',
17/01/?',
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I7/OS/7'.
17/imm
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1?/l?/r>
i7/i«>/r.
i2/;2/r»
i?/ m/;r»
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I
2/07/76
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7/0 1/7*
7/04/7ft
7/
k in
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K •(*}
K
K
K-r,f>
K hi
r-'iR
K '.y
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K	'1
K	' '
K	r. I
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r«-ni|i
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chl_!1
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n.-'.o
ft.117
ft. 17
7 . 90
ft.HI
ft il
ft. I?
ft. n
rt, <>n
ft. fin
r,. i?
6. 17
ft. 72
"».ftO
V 71
fi. ia
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ft, ?o
ft, 74
*•-7|
7.9r»
R . 70
* ! 1
fl. Ill
4ft
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r>d
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41
t,n
vi
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1
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n.ii r	Hniiiln-r l/]M*	
TAJU.K 5-j |c().uiiuic(l)
7t?'.n
1/1o/ /
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1/71/7
1/11/7
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*	A / 0 *> / 7
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1*17 J11
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K-r, i
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on
I. lhrro lypn-J of lienor* wore n^cil to qf.iily Mm* fniiw.il I <>n '»[ 11»" c«»| 1.1 nnliillmi: C.I.. rlcnr llijimr rnnl .i I.«I1»|*. liilll.il 		III!"
crrH Hi.irp.n; I.. - llmr slurry < onl .i | ii t tip, .-in lnltl.il r.ilr Inm nulfltr irp.l .li.npo; rin.l I..S. • I Im-r I i.n«> slmry '<"»! n I n I i»p. .it» lnlH.il • il.hn»
rntfll*1 '.foil H'.irp.n.
7. o ' < •; thi* in.it1.cnnllr.il r'jti.itlmi ccf'i «•*:¦: l»'l» tin* ll.nl Inn «.f lull III <";iSO f • ' lljO -irffl |>tr':cnl In tin' 1 .• .1 I «:«'M»I*: »• ' «•"•! "I III" I"".
* Tin | ImoctoiK* .rxit^nt ,.f | |,t> ^olltl-: I r	ft I pit th.it ll.r -.r.ll.l n.ilf I •iiii1v".i '; .11 f (11 i< < 111 .11 >• .

-------
TAH1/E 3-4. I.ICJUID AN!) SOLID COMPOS I'll ON DATA TOR K(}U I I.I HKAT ION RUNS
I/K.//6 7/71/76
Run
Ho.
I >m|».
Q-l
0-?
Q I
9-/.
0-1
0-ft
in
7. u
1. II
7. in
i
to
vo
I
I / 11 //r» - 2/1 I /7fi «?-7 7. *>I	'il.l
Q-fl 7.on	r»o.o
7.71?	'.9.II
1 n 7.11	/.n.'>
9-1! 7.11	An. 7
0-17 fi.o'i	/,n.o
11
£l|	( C) C.I
J. 7'1 r»0.0	VM
J.w r.o.o
'»n o
r.o. n
*>o. n
',o o
r, in
mo
6**0
r.;n
ftHO
/. r.
/.ftn
6/o
~Ml)
tin
1. t f|i 11 <1 /Nn.ilyqrq (r»f»/I 11 «-r )
N.i
'•Ml
'.70
/. 7C1
7'.0
7 so
1/10/76 - 4/07/76 Q-H	ft.PCI	V7.0	/.SI	/. 71
Q-1A	1.71	r»7. i	/.r>i	">on
1/7/./76 - 4/07/76 O-I'i	6.77	r»7.0	/.ftr»	/.n'l
*• Q-ift	ft.ni	-fi.;	r»oi	/.*.'.
0-1/	7.70	s?.t	/.fti	'.no
" ib	f».so	s7.o	r.n	v. I

cl
r»o

7*»()
?r.o
7 70
I. I r»n
1 ,1 SO
I ,160
7ft.<1
7%. 9
71.1
II.'.
17. S
7S.'i
0,1 _
, 7 SO
,.>('0
. ino
.ftno-
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. 700
7 no
7ft 7
nr.
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17. A
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1'i 0 0	/»7 . ft	/.S	10 ?
s i o o 710	7*«.n	i.of.o	7'».q
10.700	71.SHO	7 SR.	11, 700	n .7
11.600	21.700	?nn.	in.ftoo	77 '1
11,600	71,/.no	?n'i.	in.100	?n.n
- - 11.700 7i.?on	yni.	1 q,r.oo
77.7
17.^
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0
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0.7
0.1
0.1
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r»l>.0
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sn.
sn.',
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vi.	1
Ml ft
67 . M
l'». I
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I.	7

-------
TAHU5 r)-r'>. SUMMARY OF Rl-SUI.TS 01- K(}U 11.1 NR I HM RUNS <}-I TIIROIICll Q- I K
Mill :lI I mi «>f P.qnl 1
				
i /o
I ;o
i ;o
iju
i /o
1 70
Rtiti
No.
<) 1
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l>-1
I? 'i
*)'
t) f,
K I t lr
Niimlx-i
K 0
K '>
k- in
K A I
K • A I
K-11.70

NC
e:
c
N«:
<:
I'"
7;H ut ;tl I»m
• V1?0	• Sd^i* ( «-os ;u,o
1
1
I
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1
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.77
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0.1.0
M
f.O
H/
. 7«
. R7
O.	'1-.1
ft .i< I I «»n
o. «r»
.Hfi
MA
.ns
. RS
. RR
'If I r<
O. I 'l
. I A
. If.
. I'i
.is
. i /
'.in I I H.i f • »o*
. I r ' f .'il l I i'»i
I
0
1
/
7'.A
;i«A
7f»A
7
. f.AR r.'.R 117 JI7 117 117 o-/ on (}-n to o n «?-l? ij-ifi Q-IB flnsn , • ty|,n c.iso, • V'j" CnSO\ %1I7«> IC-A1 K A A K-AA r.i^o, tyi.o K-AI K-AI ¦Ml fa Wl, V'?° c.isn, Vb" i)-W c.»r:o, V" n 1 7. SI /. on 7. 70 7. n 7. 11 r..T> /. 70 f..SO r». flit 7.77 ft. 77 7.77 AH. I SO /,') Afi.9 Aft. i An. 1.70 I. 00 1-27 I . 7R I . 77 I . 70 0.9 1 I . V. I .(»'• 1 ?n .K9 1 IA OTi . 77 . 7S .A I .61 A 1 .?A .77 .71 ? 1 . 7 A . 7U .WW . A'> .s; . sn . 1A .Of, . sr» . r.i l. oo 1 . 00 I Of) .HS .«r» . nc» 1. no l oo I .Of) n'» I. oo H'i .OO . oo .00 . is . I A . 1A .OO .00 . IS .oo . I*. O'l . R'» .»/ .R7 I .(><1 1 .11(1 . T. . w> Ol .01 Ol . r. 11 i \ C '•rlinllnp. K* m1 ** T:««iitiri| wllli lliiro l>n I 1 n i«i t n r w I •:«*, 1H !~: p.r 1 ml I up. villi 10 l»:» I I rli.tij't NiNi> p>r I n«l I Mp..
-------
The operating conditions for each nest are included in Tables
5-1 and 5-2 with the steady-state liquid and solid analyses.
The aqueous compositions are given in milligrams per liter in
Table 5-1 and in millimoles per liter in Table 5-2.
The computer calculated activities and relative
saturations of the pertinent aqueous constituents are given in
Table 5-3. The weight percent suspended solids, calcium sulfite
precipitation rate and the dilution fraction of the product
solids are also induced in this table.
Experimental results obtained in the equilibration
studies are presented in Tables 5-4 and 5-5. The duration of
equilibration of precipitated solids with their mother liquor
is given in minutes. The original sulfite and sulfate mole
fractions of the solids before equilibration are reported as
are the mole fractions after equilibration.
5.1	Physical Characterization of the Calcium Sulfite-
Sulfate Solid Solution
5.1.1	Qualitative Application of Infrared Spectral Analysis
Infrared spectroscopy was successfully used to confirm
the presence of sulfate in the calcium sulfite solids. The
infrared absorption due to the sulfate ion showed that the
incorporation occurred by the substitution of a sulfate ion for
a sulfite ion in the crystal lattice. The vibrational spectral
structure of any pure phase sulfate compound such as CaS0n-2H20
in the 1100 cm"1 region is characteristically broad with little
or no resolution of the three component bands. In case of the
matrix isolation as occurs in a solid solution, the peak positions
shift and a greater degree of resolution can be observed. Solids
-41-

-------
identified as containing sulfate by chemical analysis and spectro-
scopically appeared to be solid solutions were analyzed by X-ray
diffraction and differential scanning colorimetry. Both techniques
failed to show the presence of a pure phase sulfate compound,
specifically indicating that no gypsum was present.
For comparative purposes, the IR spectra of pure calcium
sulfite hemihydrate and calcium sulfate dihydrate are shown in
Figure 5-1. The absorption structures of interest are the major
sulfite band at approximately 980 cm"1 and the sulfate band near
1130 cm"1. The structure in the 3200-360C cm"1 and 1600-1700 cm-1
ranges are a result of the waters of hydration of the two solids.
The absorption bands in the 600-700 en"1 region are due to the
sulfite and sulfate ions but are not as distinctive as the major
bands.
The infrared spectra of two solid samples from the
experimental precipitation studies are shown in Figure 5-2. The
upper spectrum is that of the solids precipitated from a solution
supersaturated in calcium sulfite hemihydrate and subsaturated
with respect to calcium sulfate dihydrate. The band structure
encircled is indicative of the IR absorption due to matrix
isolated sulfate ion.
The lower spectrum is that of the solids precipitated
from a solution supersaturated in both calcium sulfite hemihydrate
and calcium sulfate dihydrate. In this case, the structure in
the sulfate sorption region shows the presence of sulfate as both
pure phase gypsum and in solid solution with calcium sulfite
hemihydrate. The presence of gypsum was verified using X-ray
diffractions and DSC analyses.
The following is a simplified explanation of the spectral
differences of the sulfate ion in a pure phase crystal or in solid
-42-

-------
CcSO 3.1/2 h2d
Co SO4 • 2 H oO
<000
2000
1000
4C0
FRtCLTIVCY (C'.r1 }
FIGURE 5-1 INFRARED SPECTRA OF PURE CALCIUM SULFITE
HEMIHYDRATE AND CALCIUM SULFATE DIHYDRATE
-43-

-------
(/)
to
2
CO
r
<
c
K
SOLID SOLUTION
MATRIX-ISOLATED
SULFATE
'	'	I	I	I	L
Solid Solution +
Matrix
Isolated Sulfat
Gypsum Sulfate +
Masked Matrix
Isolated Sulfate 3
1120 and 1140
4 0 0 C
2000
1000
400
FREQUENCY (CM*1)
FIGURE 5-2 INFRARED SPECTRA OF REACTOR PRODUCTS
-44.

-------
-^clutior. -with another compound. In the first place, the absorp-
tion of electromagnetic radiation in this spectral region results
from a coupling of the incident radiation with the vibrational
modes of the sulfate ion. Quantum theory predicts three different
frequencies. In the case of a pure phase sulfate compound, the
frequency range of these vibrations is broadened due to the
interaction or coupling of the vibrational modes of neighboring
sulfate ions. The matrix isolation of sulfate ions in the solid
solution effectively dilutes the sulfate ions as compared to a
pure phase system anc thus reduces the coupling effect. The
frequency shifts and narrowing of the bands are a direct result
of the decoupling of the intermolecular interaction of the
sulfate ion vibrational modes.
Thus, the combination of these instrumental techniques
has been used to verify the existence of the coprecipitation of
sulfate with calcium sulfite as a solid solution. In addition,
it was demonstrated that the IR spectroscopy can be used to
distinguish between the sulfate in a solid solution or as gypsum.
5.1.2	Quantitative Application of Infrared Spectral Analysis
Infrared analysis was also used to quantitatively
measure the sulfate concentration in the solid solution. The
technique was initially calibrated by comparison of the ratio
of the sulfate absorbance at 1220 cm-1 to that of the water band
at 1620 cm"1 with sulfate concentrations determined by the
specific chemical method. In the absence of gypsum, the following
equation is used to calculate mole fraction of sulfate, x _2
in a solid from the infrared sorption measurements:
-45-

-------
'SO
- 2
wso
2G. n
n ? 0
kSO
(log T ) S0u~2
A,
= k
H 2 0
(log ^ ) H20
(5-1)
m
where,
Cc- _2 = the concentration of sulfate in the solids
(mole SOu"2/g sample),
C_, = the concentration of sulfate plus sulfite in
s the solids (mole SO*"2 + SOs~^/g sample),
= concentration of the hydration water in the
rlrO
solids (mole H20/g sample),
k = a constant,
AS0 = t^ie absorbance at 1220 cm"1 ,
Ar 0 = the IR absorbance at 1620 cm"1, and
Tv/T = the ratio of the percent transmission values at
d m
the base line and transmission minimum for the
appropriate band.
The correlation of the spectral and chemical results
are shown graphically in Figure 5-3. The accuracy limits at the
95% confidence level is ±.02 in the sulfate mole fraction based
on a linear least square fit to the data.
5.1.3 Thermal Analysis
Two instrumental techniques based on the thermal
properties of solids were evaluated as methods to characterize
-46-

-------
0.20
47
j7-1
c
o
•H
U
ic —
(U
o
X ©" 063-»
Cv ©io
©69

-------
the calcium, sulfite-
waters of hydration
was investigated by
sulfate solid solution,
to the total sulfur for
these techniques.
The ratio of the
the solid solutions
The thernogravimetric analysis (TGA) determines the
weight change upon the loss of water as the temperature of the
sample is raised past the dehydration temperature. Both the
weight loss and the temperature of dehydration are useful to
characterize the solids. The other thermal technique is differ-
ential scanning colorimetry (DSC). The enthalpy change as a
function of sample temperature is measured by this method.
Quantitative TGA measurements were made on the solids
precipitated from Experiments K-47 and X-53. From the weight
loss associated with the dehydration of the solid solution
samples, solids from Run K-47 were found to contain 3.8=.2 mmole
H20/gram and those from Run K-53 consisted of 3.9±.2 mmole H20/
gram. These two values give a mole ratio of waters of hydration
to total sulfur of .50 and .52 respectively. If the sulfate had
been associated with two waters of hydration, a mole ratio of
approximately .7 would be expected.
Differential scanning colorimetry was also used to
characterize the precipitated solids by monitoring the enthalpy
change as a function of temperature. Phase changes, marked by
rapid changes in the heat capacity, were observed in the temper-
ature ranges of 12C-140°C for gypsum and 350-430°C for calcium
sulfite hemihydrate and the solid solutions. These changes are
associated with the loss of wTaters of hydration. A DSC scan of
solids from Run K-37 is shown in Figure 5-4. Additional scans
of the solids from other runs are included in Appendix E.
-48-

-------
r_A_XJ_Li
=>r.-Ai.i-. <:/n> 40
rueki ha t r •>:/	 ' "
ii;at i.rnii «.n
*^i ur t	0
TA I >S(
i n.A
Mil ' DATE
I)' 't.MA It >' f
ALL- l./m	
I....	»/«•» . ? . . s
Wt:«y »r ..Ml ? -J*1
¦ ir rjr i	Im'JL'I y_ I>i»
At il» 1 t-n t.	C
K- 17
III -H;|R/I.-I.S
ATM	t» .
LI.IW HA II
0. ") iiic.i I />;cc Sens i
V ! t V
:::¦ 0.2 inraL/see Sur5 1 L ' v ' 'A';
ii
I MA
;A| I'. .tWn/io ... ...
N'fit 	
'.AM> I P •;¦/!	_
I MAI \ ri
(IV, I *)* I. I • ¦ . .(>•./>>.,>> 1 /!#.
I'M
i! i i
in*
:n
1 i!
R
.L.1
01"
'!!
:Li
ij!!
I
Ml
ill
I
I
Lii.:
i:
U_!
ill
ill
i!:
! i1
iT:V
ih
jj.l.
KM
i:
I Ti
¦ i
:.l i.
,:ji
-"4hrr
TtMntDAHIMI1, C IO if IOMGI /AI.LIMEl.»
FIGURE 5-4 DIFFERENTIAL SCANNTNG CALORIMETRY PATTERN OF PRECIPITATED
SOLIDS OF KINETIC RUN 37

-------
The change in enthalpy at 120-140°C for the solics
from K-37 results from the endothermic dehydration of gyp suit.
The second change at 350-400°C is the dehydration of the solid
solution. Solids in which no gypsum was found also showed no
enthalpy change at 120-140°C.
Three distinct patterns have been observed in the
350-430°C range which result from the dehydration of CaS0 3-%H20
and solid solution. These include an endotheroic reaction at
410°C, and a complex endothermic reaction in the range of 350-
400°C. Possible explanations for the three different patterns
include a different crystal structure of the calcium sulfite
hemihydrate resulting from impurities, such as sulfate, in the
crystal and/or particle size. X-ray powder diffraction patterns
eve identified only one crystalline structure of calcium sulfir
henihycrate. This pattern is consistent with literature values
(TE-055) and standards prepared in the laboratory. The complex
endothermic reactions oetveen 350-400°C were observed only in
runs utilising the grinder in line. This is a strong indication
that particle size may have an effect on the temperature
of dehydration of the calcium sulfite hemihydrate during analysi
by DSC.
-50-

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5.0
DISCUSSION OF RESULTS
The interpretation of the experimental results presentee
in Section 5.0 are discussed in this section. The effects of
the tested parameters on the sulfate content of the precipitated
sclics are evaluated and correlations are made where appropriate.
Xuch of the experimented data reported in Section 5.0
is invalidated by the occurrence of one or mere operational
dirficulti.es. While these results were reported for complete-
ness, they were not included in the data used to arrive at the
conclusions presented in tr.is section. Possible reasons for
seme of these difficulties are discussed.
A series of long term equilibration studies were
conducted to determine the stability of the solid solutions
in the presence of solutions of similar concentrations as the
liquors from which they were initially precipitated. In addition,
pure calcium sulfite hemihydrate crystals were also subjected
to long tern contact with these liquors to determine the degree
of sulfate incorporation near the equilibrium of calcium sulfite
hemihydrate. Solid solution solids were placed in water saturated
with calcium sulfite but with no sulfate present.
The solids and test solutions were sealed into cylindrical
plexiglas vessels with several ceramic grinding cylinders. The
containers were maintained in an inert atmosphere at 50°C for
the duration of the tests. The samples were mechanically rotated
to provide grinding of the solids to expose fresh surfaces
throughout the test period.
The solid solution in contact with the liquor containing
no sulfate showed a small decrease, ^0.01 mole fraction, in sulfate
confirm. The sulfite in contact with licuor almost saturated with
-51-

-------
rypsurr. gained a snail amount of sulfate ('-0.01 mole fraction).
Solid solutions in contact with their equilibrium liquors shoved
no change. Solids containing gypsum had the gypsum dissolved
when ir. contact with the subsaturatec liquors.
This indicates that:
e once formed the interior of a solid
solution particle is protected from
the solution by low solid state
diffusion and
• gypsum cannot co-exist with solid
solution in a subsaturatec solution.
The specific classifications of experimental difficulties
experienced were:
o supersaturation of the reactor liquor
with respect to gypsum,
•	the presence of gypsum in the precipitated
solids as identified by infrared
spectroscopy, x-ray diffraction or differential
scanning colorimetry,
•	calcium carbonate in the solids in excess
of 60 weight percent, and
•	insufficient approach to system lineout
with respect to the precipitated solids,
i.e., e"T/f • > .35.
The experiments disregarded on the basis of these
criteria are listed in Table 6-1. The remainder of the experi-
mental runs which were used to develop the correlations presentic
ir. this se j".art givc-r. in Table 6-2.
-52-

-------
TAPtLK r,-K
1.1 rf(i | it	("wolei/'t)
Run I	rn '
F	K». 1
K-1	1.1
it-if	i.n
K 77	l?.fi
K-?i	17.n
R-?f>	fl.m
i-?;	?u»
*-?*	7R.U
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K-11	11.0
R-14	12-0
R-15	17.ft
r-i/	12.1
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K-41	7^.9
K 44	25,7
K-45	??. 7
K-59	7.7*
HrM N.l*
I.	1
II.4
5.5
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74.4
fl 1.0
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5ft. 7
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f»i? m
517	7BO
sr.o r»», i
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A,10	1.7%
f»2. /«	i.n?
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?f..n	i.'.n
fl?.6	/«.r.f»
96.1	7.17
91.0	7.41
flfl.A	H.I
75.4	7.0
76.0	fi.fi
656	1*1.5
5?9
619	54.6
766	17.1
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9.76
as
r». r,
R.4
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56.	i
4. ".r>
14.0
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7)7
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701
14.4
(conttnuori)
KXPKRIMF.NTAf, KI-SUI.TS 1.NVAM HATI-D
RH Jit I VP Snturat Ion
CaSni-tll?!)
I. 76
7.1«
7.54
1.77
i. r,
4. ri?
n.-t?
R.71
5.5',
11.1
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ft.7
fl.n
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Hole 1'rnrt Ion
!t»i|	lit
Snl l
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    TATU.F 6-7. KXPRUIMKNTAT, RF.SW/rS FOR CORRELATIONS
    
    
    I.lqulil Ann 1 jr-M
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    -------
    '¦ -	Effect of Relative Saturation of CaSO.-^cH C
    The aqueous phase relative saturation of calcium sulfate
    hemihycrate was found to exhibit the most significant effect on
    the composition of the solid solution based on the results of the
    laboratory studies conducted by Radian. These measurements
    showed that the sulfate content of the solid solution varies most
    rapidly with the calcium sulfate hemihydrate concentration between
    relative saturation values of 0-0.2. At values higher than 0.2,
    the change in solid composition is less rapid. At compositions
    above a relative saturation of 0.45, the solution becomes super-
    ---."urated ir. gypsum. Further precipitation of sulfate may occur
    as gypsum as well as in the solid solution. The presence of
    gypsum in the solids complicates the determination of the sulfate
    err.tent of the solic solution^
    The relation between the sulfate mole fraction in the
    solids and the relative saturation of .CaSOn-%H20 in the aqueous
    phase is shown graphically in Figure 6-1. This correlation
    represents only the experiments referred to as clear liquor runs
    in Table 6-2.
    A theoretical fit of the data was made based on the
    equilibrium relationship derived by P. S. Lowell as developed in
    Section 3.0. At equilibrium, the relation between the liquid and
    solids compositions with respect to sulfate can be written as:
    aCa~r">" aS0,= a\;Q _ ,	(6-1)
    R C.aS0,-%H-0 K r qh Ui o	^CaS0.-%K20 CaS0i.'%H20
    Sp LaM)i(,~»n2U
    The form of tne solid phase activity coefficient, o, was empiricall
    chosen as:
    ln - aj + 3:xt.a?c_v^0	(6-2 a)
    -58-
    

    -------
    Figure 6-1 Sullale ConlenL of" Solid Solution as a Kunrtion of CaSO., *
    Relative Saturation in Solution, Clear I.irjuor Studies
    15
    Statistical Kit of the Data
    oo
    GO
    10
    05
    0.2
    0. t
    Relative Saturation of CaSOi, • -VlzO
    

    -------
    = cxp(i- + i2XCaSo,.%K,0)	(6- 2d)
    7.1 e arbitrary constants , ai and oi , must be determined from
    experimental data. The mole traction of sulfate in the solids
    may be written implicitly as a function of the relative saturation
    of CaS0,'%H20.
    x
    or
    CaS0,-%H20 " ex? ( a: " C2XCaS0it-%H20) R'S"CaSO,-%H:0	(6"3)
    Cxp <:n + :	(6-A)
    NCaS0»-?H;O ' ' ' '	. }
    Based upon the data in Figure 6-1, a least squares fit
    gave values of oi and a: of -1.94 and 22.5, respectively. Given
    the sulfate mole fraction, the relative saturation may be cal-
    culated directly from Equation 6-4. Given the relative saturation,
    the sulfate mole fraction may be calculated by an iterative pro-
    cedure.
    The relationship between the mole fraction of solid
    solution sulfate and the relative saturation of calcium sulfate
    hemihydrate for all of the acceptable experimental tests, see
    Table 6-2, is shown in Figure 6-2. A least squares fit gave values
    of cm and c*2 of -1.45 and 15.9, respectively. The theoretical
    fit to the clear liquor data is included for comparison in
    Figure 6-2.
    Although a slight increase is noted in the predicted
    sulfate content in the solids from a fit to all of the data as
    compared to the clear liquor data, the difference is small
    compared to the overall scatter in the data.
    -60-
    

    -------
    ()• ir',• 'mis'-';) i° ! i i' in ii s ,,A! m' i-'fi
    l-*o	<;•<}	i •(>
    j t.
    o ~
    oo
    .XI
    ~o
    u;
    Dili
    1 i 1 : M '• ilK)lu ! J*"lx;.| .hiu is.no ; *| pin.* . im i - j jo uosi ji.'il.im;) 7-<) ¦"1-* < i •< j •(
    

    -------
    The precipitation rate cf the solid solution appears
    to be a function of the sulfite relative saturation. The sulfate
    precipitation rate would be equal to the solid solution precipi-
    tation rate tines the mole fraction sulfate as calculated from
    liquation 6-3.
    6 . 2	Effect of Calcium Sulfite Precipitation Rate
    The possibility exists that the inclusion of sulfate
    in the calcium sulfite hemihydrate lattice is a kinetic phenomenon.
    if this is the case, one would expect a dependence of sulfate in
    the ;= olic as a function of precipitation rate.
    E.adian laboratory experimental results do not show any
    discernible dependence of sulfate content on the precipitation
    rate. This lack of dependence cf sulfate in the solids as
    a function of precipitation rate is shown graphically in Figure 6-2.
    The data in Figure 6-3 span a range of precipitation
    rates from 0.001-1.73 rmoles/g-min. The sulfate content of the
    solids in this correlation was corrected for the effect of
    calcium sulfate hemihydrate relative saturation by dividing the
    measured sulfate mole fraction by the mole fraction predicted
    by Equation 6-4. A linear least square fit was made of the data
    which showed the results to be uniformly scattered about a
    mole fraction ratio of one. This indicates that even though
    there is considerable scatter in the data no consistent dependence
    on the precipitation rate is evident.
    -62-
    

    -------
    -£9-
    Ratio of Observing to Calculate Sulfate Molt; Fractions
    (x obs/x calc)
    0
    
    ¦£>
    Cu-
    0
    ^gP
    QD ©
    o' """2D c
    0
    q
    o
    o.
    °o°
    0
    O
    r^
    0
    o
    o
    O I
    0
    o
    9
    i
    o
    

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    n . 3	Comparison of Lime and "Li ma stone T e. ?. r s 1 r. h
    Clear Li.ouor Results
    Experimental studies were conducted to measure the
    influence cf lime and limestone on the formation of the calcium
    sulfite-sulfate solid solution. Any effects of lime and lime-
    stone were expected to result from increased precipitation
    effects resulting from localized areas of high calcium sulfite
    hemihydratc relative saturations. Such concentration gradients
    may arise from the dissolution of lime or limestone solids.
    The experimental data are compared graphically to the clear
    liquor results in Figure 6-2. The mole fraction of sulfate
    \n the solids precipitated from the lime experiments are higher
    than in the clear liquor solids. However, due to the limited
    number of data points and the coincidence of high levels of
    magnesium and chloride concentrations in the test solutions
    with most lime runs, the evidence is inconclusive that the
    presence cf lime substantially enhance the sulfate content of
    the solid solution.
    The limestone data scatter around the clear liquor
    line and appear to have an enhanced sulfate mole fraction.
    The relatively small number of data points again makes drawing
    conclusions risky. Again coincidence of high magnesium and
    chloride concentration cloucs the issue.
    6.4	Effects of High Levels of Chloride and Magnesium
    The effects of magnesium and chloride on the sulfate
    content of the solids is difficult to ascertain from the experi-
    mental data. The primary problem arises from the fact that the
    only successful reactor test at high magnesium and chloride
    levels were also lime runs. These results are displayed
    graphically in Figure 6-4. Further characterization of the
    - 64-
    

    -------
    pr ;rc ipi ta ci or from solutions high in magnesium and chloride
    are needed tc quantify the effects of these iens.
    ihe ti'rtcj..'j11citor. rate, or calcium suli__e appeared
    be inhibited by the high concentrations of these icr.s. A
    similar effect was also found when low concentrations of
    carbonate were present in the liquor.
    6.5	Effect of Temperature
    Experimental measurements carried out at 4C, 50,
    and 60°C showed only a slight effect of temperature on the
    coprecipitation of calcium sulfate and sulfite. This conclusion
    is based on results from five experimental runs, K-50, 51,
    
    
    In order to normalize the results the ratio of observe;
    to calculated values of sulfate mole fraction in the solid was
    computed. This ratio is presented in Figure 6-4 as a function
    of temperature. The temperature effect in Figure 6-4 represents
    a deviat ion of 0. per degree C from 50°C which is the tempera-
    ture at wh.ch most of the data were taken.
    -65-
    

    -------
    0.211,
    Hgure 6~l\ Kffoit of High Chloride and Magnesium ConcealraL Ions
    Of Sulfate Com out of Solid Solution
    0. 1
    a)
    5 °-10"
    D
    CO
    0.03
    o
    o o
    o oo
    o
    oo° o
    o o
    o
    o
    o
    o
    o o
    o
    o
    o
    o
    o
    oo	o
    oo
    o o
    o
    High Chloride and High Magnesiuit
    Low Chlorfdc and Low Magnesium
    t 1
    0.1
    0.2
    0.1
    0./i
    .5
    Relative Saturation of CaS0»» * ^l!?0
    

    -------
    I.
    0
    I .r»
    .~?e-
    o
    . s
    0
    cr>
    ~^s
    . f.
    TiMiipiT.-il uro ( (*)
    f)(»
    !• i j',11 iv *>-') lit*' Ktlrri nl" Tiiii|m* t .1 l 111 i on Sull.ilc CfMnrnt r.U ion in (lie Solid:
    

    -------
    7. C
    As par: of this program pilot plant and full-scale
    system performance data relating to the coprecipitation
    phenomenon, which were available to EPA were reviewed by Radian.
    The purpose cf this data review was twofold:
    © to define ranges of operation conditions
    under which coprecipitation is observed
    to occur. This information is important
    because it identified the variables to be
    considered in the expe rimer, tal phases
    of the program, and
    v to provide a basis for comparing the
    results obtained in the Radian
    laboratory experiments with actual
    scrubber perfornar.ee.
    The Environmental Protection Agency has obtained a
    considerable amr>unt of data cn calcium sulfite/sulfate coprecip-
    itation in line and limestone wet scrubbing systems in pilot
    plant studies conducted at Research Triangle Park, North Carolina.
    In addition, data have been supplied to EPA by Imperial Chemical
    Industries (ICI) 0:1 their Eankside Power Plant, by Arthur D.
    Little, Inc. (ADL) in the report "Scale Control in Limestone Wet
    Scrubbing Systems", by Bechtel Corporation on the Shawnee Test
    Facility, and by Louisville Gas and Electric (LG&E) on their
    Paddy's Run Scrubber.
    The ICI and ADL data transmitted to us were incomplete
    as far as this program was concerned since no liquor compositions	•
    or hold tank data were reported. Complete liquid and solid phase	1
    analyses for a significant fraction of the LG&E test runs were
    68-
    

    -------
    also not available. For this reason, almost: all of the nest clata
    considered are based upon EPA/RTP pilot plants and B e ch t e 1 - Sharaee
    s tudi. e.s .
    Review of EPA/RT? data included conversion of reported
    liquid and solid concentrations from a weight basis to a molar
    basis. These concentrations were then input to Radian's aqueous
    ionic equilibrium program for calculation of solution activities
    and relative saturations. Sulfite and sulfate mole fractions
    were calculated from solids concentrations. Calcium sulfite
    precipitation rates in the sealed held tanks were calculated
    from reported inlet and outlet, liquor compositions and flow rates.
    Calcium sulfate precipitation rates were calculated from the
    system oxidation rate and sulfite precipitation rate. EPA/RTP
    and LG>LK data are presented in Appendix B along with calculated
    activities, relative saturations and ir.cle fractions. These
    values were used in defining the variables considered in the
    experimental phase of this project.
    The EPA/RTP-, LG&E and Shawnee data were analyzed
    according to the theoretical framework developed by Radian and
    in view of the laboratory results of this experimental program.
    The theoretical framework and Radian experimental data suggest
    that the sulfate mole fraction is best correlated with the
    relative saturation of calcium sulfate hemihydrate. The results
    of a graphical analysis of this correlation for the EPA/RTP
    and LG&E data is shown in Figure 7-1.
    There is a significant degree of scatter in the data.
    Part or this scatter is very likely due to analytical inaccuracies
    in the determination of the sulfate content c: the solids.
    Correlation of these pilot unit data with liquid phase properties
    is difficult since a change in one parameter is usually accom-
    panied by other changes. The high, degree of scatter observed in
    -69-
    

    -------
    VnlldntcO Fwidian Dota
    Lonst square fit of all
    Rndinn Dntn
    GO
    ~ OO
    CfD
    o
    T
    T
    .10	.20	.30	.AO	.50
    UGllKE 7-1 CON'f.H-.MTKATION OF SULFATE IN THE SOLIDS AS A FUNCTION OF THE
    C:tSO:,	RELATIVE SATURATION IN THE AQUEOUS PHASE
    

    -------
    the field 1 iT.esrone runs made at high liquid phase magnesium
    concentrations cannot be solely explained by analytical inac-
    curacies. This scatter can bo explained by the experimental
    difficulties associated with the sampling and sample handling
    of slurries containing high liquid phase magnesium sulfate
    concentra tions .
    The EPA/RT? pilot plant data show that gypsum
    unsaturated operation is possible and that the relative satura-
    tion of calcium sulfate docs
    solids even in unsaturated operation.
    Experimer,tal data from EPA's alkali scrubbing test
    facility located at TVA's Shawnee Fo:;er Station in Pacucah,
    Kentucky, were also examined. These data covered testing
    batwcan June l'-J75 and January 1976 and were furnished to Radian
    by Bechtel Corporaticn. The report included experimental data
    from lime and 1imestone runs.
    Liquid arid solid phase analytical data for this period
    of Shawnae operation have been examined. The sulfate content of
    the solids has been compared with the liquid phase relative
    saturation of calcium sulfate as a function of time for both
    limestone a.id lime runs. This allows the solids residence time
    to be included in the analysis as the residence time of the solids
    is in the order of days. Graphical results of these comparisons
    are presented in Appendix B. An exan.ple is shown in Figure 7-2.
    j'.r. genera], an increase in the calcium sulfate relative satura-
    tion was accompanied by an increase in the sulfate mole fraction
    of the solids. Also, a decrease in gypsum relative saturation
    to subsaturated operation was accompanied by a general decrease
    in the sulfate concentration in the solics.
    -71-
    

    -------
    00
    'J o
    V) r-j
    00
    0.30
    u.
    xb
    . <
    00
    IS
    10
    8
    June, 1975	Jane, 1973	June, 1975
    Pel I* P
    FIGIJKK 7-1' FX AMP I.F OF RFI.AT 10NS11 IP RKTWI'XN SU1.KATF. MOf.F. FRACTION AND C.YPSUM
    nFI.ATlVF. SATFKAT I ON' FOR SilAWNFK TCA-1.! MHS'I'ON'K KUNS
    

    -------
    3 • 0
    Many c: the factors influencing the sulfate content
    of the- solid solution have bee-n characterized during this program.
    However, rr.oro precipitation measurements are required to fully
    quantify the effects of high concentrations of magnesium and
    chloride.
    role that the dissolution of line or lir.es tone may
    have on th;-; air^iini ::f sulfate coprecipitaiec vith calcium sulfite
    hc.ihyc.--.'-; r . Modification of the f ] cw-through remoter usee. :n
    the program just cc-n.pictec vould be required in order to attain
    greater linestone utilization. The large excesses of limestone
    .v. c	v oduct crystals interfered with the chemical character!
    
    ration of the solid solut .on solids precipitated in this program.
    Kvc-n though sor.« refinement may still be required to
    silev: enrol prediction of the sulfate content of the solid
    solution, the results produced thus far provide a basic under-
    standing of these factors that most significantly influence the
    composition of the coprecipitate.
    Development of a relationship to predict the sulfate
    content of the solid solution which includes the effects of
    such species as chloride anc magnesium and the dissolution of
    lime or limestone may explain more of the field scrubber results.
    However, nr.r.y of the apparent inconsistencies between laboratory
    results and field data may, in fact, be due to sampling and
    analytical difficulties arising under field conditions.
    During the experimental phase of this program, two
    related nhencmera were encountered. First, the presence of
    -73-
    

    -------
    high concentration of magnesium and chloride in the solution
    appear to have an overall inhibiting effect on the precipitation
    rate of calcium sulfite and/or the solid solution. The presence
    of small quantities of dissolved carbonate also exhibited an
    inhibitive effect on the precipitation rate. Since this rate
    is very important in the overall design and operation of lime and
    limestone scrubbers operating at low oxidation, an understanding
    of the exact effect of these species on the precipitate rate
    is needed.
    The second finding relates to the apparent coprecipita-
    tion of carbonate with calcium sulfite. Some preliminary assessments
    of infrared spectra of some of the limestone products indicate
    the presence of carbonate in the calcium sulfite hemihydrate
    crystal. This could have a significant effect on the maximum
    utilization of limestone achievable at low oxidation conditions.
    Since the subsaturated operation of an S02 scrubbing
    system based on the addition of lime or limestone will depend
    or. the degree of oxidation of sulfite to sulfate, an understanding
    of the parameters important in this oxidation process is important.
    A full characterization of the sulfite oxidation mechanism may
    lead to a method of controlling the oxidation rate. For example,
    some Russian studies, in which sulfite oxidation rates were
    measured as a function of pH and transition metal concentrations,
    have shown that under certain conditions the presence of some
    of these metals can actually inhibit the oxidation. It is
    recommended that a controlled laboratory study be conducted to
    more fully investigate these preliminary findings and relate
    this information to the control of oxidation in an actual
    scrubbing system.
    -74-
    

    -------