THE EFFECT OF MERCURY CONTROLS ON WALLBOARD MANUFACTURE

Pending EPA regulations may mandate 70 to 90% mercury removal efficiency from utility flue gas. A mercury control option is the trapping of oxidized mercury in wet flue gas desulfurization systems (FGD). The potential doubling of mercury in the FGD material and its effect on mercury volatility at temperatures common to wallboard manufacture is a concern that could limit the growing byproduct use of FGD material. Prediction of mercury fate is limited by lack of information on the mercury form in the FGD material. The parts per billion mercury concentrations prevent the identification of mercury compounds by common analytical methods. A sensitive analytical method, cold vapor atomic fluorescence, coupled with leaching and thermodecomposition methods were evaluated for their potential to identify mercury compounds in FGD material. The results of the study suggest that the mercury form is dominated by the calcium sulfate matrix and is probably associated with the sulfate form in the FGD material. Additionally, to determine the effect of high mercury concentration FGD material on wallboard manufacture, a laboratory FGD unit was built to trap the oxidized mercury generated in a simulated flue gas. Although the laboratory prepared FGD material did not contain the mercury concentrations anticipated, further thermal tests determined that mercury begins to evolve from FGD material at 380 to 390 F, consequently dropping the drying temperature should mitigate mercury evolution if necessary. Mercury evolution is also diminished as the weight of the wallboard sample increased. Consequently, mercury evolution may not be a significant problem in wallboard manufacture