PRODUCTION OF CONSTRUCTION AGGREGATES FROM FLUE GAS DESULFURIZATION SLUDGE

Through a cooperative agreement with DOE, the Research and Development Department of CONSOL Inc. (CONSOL R and D) is teaming with SynAggs, Inc. and Duquesne Light to design, construct, and operate a 500 lb/h continuous pilot plant to produce road construction aggregate from a mixture of wet flue gas desulfurization (FGD) sludge, fly ash, and other components. The proposed project is divided into six tasks: (1) Project Management; (2) Mix Design Evaluation; (3) Process Design; (4) Construction; (5) Start-Up and Operation; and (6) Reporting. In this quarter, Tasks 1 and 2 were completed. A project management plan (Task 1) was issued to DOE on October 22, 1998 . The mix design evaluation (Task 2) with Duquesne Light Elrama Station FGD sludge and Allegheny Power Hatfields Ferry Station fly ash was completed. Eight semi-continuous bench-scale tests were conducted to examine the effects of mix formulation on aggregate properties. A suitable mix formulation was identified to produce aggregates that meet specifications of the American Association of State High Transport Officials (AASHTO) as Class A aggregate for use in highway construction. The mix formulation was used in designing the flow sheet of the pilot plant. The process design (Task 3) is approximately 80% completed. Equipment was evaluated to comply with design requirements. The design for the curing vessel was completed by an outside engineering firm. All major equipment items for the pilot plant, except the curing vessel, were ordered. Pilot plant construction (Task 4) was begun in October. The Hazardous Substance Plan was issued to DOE. The Allegheny County (PA) Heat Department determined that an air emission permit is not required for operation of the pilot plant