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To cite this article: H. L. Wang , M. J. Hedley & N. S. Bolan (1995) Chemical properties of fluidised
bed boiler ash relevant to its use as a liming material and fertiliser, New Zealand Journal of
Agricultural Research, 38:2, 249-256, DOI: 10.1080/00288233.1995.9513125
H. L. WANG INTRODUCTION
M. J. HEDLEY Fluidised bed boiler ash (FBA) is a waste from
N. S. BOLAN fossil fuel-fired boilers. The fluidised bed boiler is
Soil Science Department very similar in construction to a modern-day
Massey University conventional coal-fired boiler except that it has a
Palmerston North, New Zealand bed of finely divided fuel and sorbent supported by
compressed air in place of a grate (Lawson 1987).
An advantage of fluidised bed boilers is that
Abstract A by-product from the New Zealand granular limestone can be used as the sorbent to
Dairy Corporation (NZDC) factory at Te Awamutu, reduce sulphur (S) emissions from the stack. When
fluidised bed boiler ash (FBA), contains agro- the temperature is raised, the limestone calcines
nomically useful amounts of lime and sulphur (S). and the sulphur dioxide (SO2) released during
The FBA is produced from injection of limestone burning of the coal is chemically captured by the
into the combustion chamber to absorb and reduce calcium oxide (CaO) resulting in the formation of
sulphur dioxide (SO2) emission from burning high calcium sulphate (CaSO4) (Equations 1-3).
S coal. NZDC FBA, an alkaline material (pH in CaCO 3 -> CaO + CO 2 (1)
water = 12.4, 51.8% calcium carbonate (CaCO3)
equivalent), contained 6.2% S, 25.4% calcium (Ca), CaO + SO 2 -> CaSO3 (2)
and negligible amounts of phosphorus (P), 2CaSO3 + O 2 H> 2CaSO4 (3)
potassium (K), and magnesium (Mg). Approx-
imately 50% of the S in the slaked FBA was water- The efficiency of the chemical reaction is
soluble (gypsum, CaSO4.2H2O) with the remainder temperature-dependent so the fluidised bed is
being ettringite [Ca6Al 2 (SO 4 ) 3 (OH) 12 .26H 2 O] operated at temperatures between 815 and 870°C
which has low solubility in water. The soluble to obtain optimum S capture thus minimising the
fraction had release characteristics similar to the limestone usage. The bed inventory is continuously
gypsum in single superphosphate. The "lime" in replenished with fresh limestone that is fed at a
FBA is mainly in hydroxide form and it is a quicker- rate to provide a Ca:S weight ratio of 2. This
acting, more caustic liming material than limestone. results in 75% SO2 absorption and minimises SO2
The concentrations of heavy metals were low in emission from the stack (Lawson 1987). Such
NZDC FBA (< 6.5 mg/kg) and are unlikely to boilers thus have a potential for meeting air-quality
cause toxic problems at normal rates of S fertiliser standards without the high costs of installing
application and lime requirement. scrubbers to remove SO2 from stack gases resulting
from combustion of high-S coal.
FBA commonly includes both bed discharge
Keywords aqueous extraction; calcium; fluidised
and trapped fly ash. In the United States, large
bed boiler ash; gypsum; lime; sulphur; single
quantities of FBA are produced as a waste product
superphosphate
of electrical power generation plants. Agricultural
uses are required for its disposal because of its
high content of CaSO4 and CaO (Korcak 1988;
Korcak & Kemper 1993). Various FBAs have been
used as liming material and as Ca and S sources
A94082 (Terman et al. 1978; Korcak 1979; 1980b; 1982;
Received 10 August 1994; accepted 19 December 1994 1984; Sidle et al. 1979; Stout et al. 1979; Wrubel et
250 New Zealand Journal of Agricultural Research, 1995, Vol. 38
al. 1982; Edwards et al. 1985a; Cochran et al. chamber is approximately 6:1, coal to limestone.
1991;McCartyetal. 1994; Stehouwer et al. 1994). This maintains the required Ca:S ratio of 2 for
Their specific characteristics and therefore uses efficient SO2 capture. The resultant ash, which is
are, however, mainly influenced by the fuel source slaked with whey effluent, is described below.
used.
The need for more steam-generating capacity FBA material
at the New Zealand Co-operative Dairy Company The FBA utilised in this study was obtained from
Limited (NZDC) Wholemilk Powder Project Te Te Awamutu Milk Powder Factory, New Zealand
Awamutu site, the availability of a large reserve of Dairy Company (NZDC). It was initially an
high-S coal (Kawhia deposit), and the ability to anhydrous product in a dry, dusty state. To make it
burn this coal within environmentally acceptable more acceptable to farmers and spreading
emission standards resulted in the establishment contractors, Foremost Fertilisers Ltd slaked the
and operation of the first industrial fluidised bed FBA with another liquid waste material from the
steam generating plant in New Zealand (Lawson factory, the whey sludge from the oxidation pond.
1987). Approximately 15000 t of anhydrous The whey waste and FBA are mixed using a pug
NZDC FBA is produced annually (P. Shannon mill and allowed to stand in a bin to cool for 24 h.
pers. comm.). During slaking, the major chemical components of
Although NZDC FBA is being used as S anhydrous FBA, anhydrous CaSO4 and CaO change
fertiliser and liming material, which is usually to gypsum (CaSO4.2H2O) and calcium hydroxide
surface-broadcast onto pastures, there is little [Ca(OH)2] (Equations 4 & 5). Before it is sold to
known about the chemical properties of NZDC farmers, the slaked FBA is usually crushed
FBA and its potential value in agriculture. The CaSC-4 + 2H2O -> CaSO4-2H2O (4)
objective of this study was to examine the properties
of NZDC FBA relevant to agricultural utilisation. CaO + H2O -> Ca(OH)2 (5)
In this paper, the nutrient release characteristics of with a hammer mill (Maiden 1992). The sample
FBA are compared to those of single super- used in this study was a slaked and crushed
phosphate (SSP). commercial product.
Analysis of FBA
MATERIALS AND METHODS The moisture content of FBA was measured by
oven-drying at 105 ± 5°C. The pH was determined
Chemical analysis of coal in water suspension (FBA:water = 1:5). Elemental
The typical analysis of the Pirongia coal used as a compositions were analysed by inductively coupled,
fuel (Table 1) shows its characteristically high S argon plasma, atomic emission spectrometry (ICP-
and relatively high sodium (Na) content (see coal AES). The sample for total elemental analysis was
ash analysis). The fuel mixture for the combustion prepared by HF-HNO3 digestion (Lee 1993). Acid-
soluble elements were extracted by shaking 0.5 g
FBA in 25 ml 10% HC1 (1:3 V/V) overnight.
Liming value (CaCC>3 equivalent) was measured
Table 1 Typical analysis of Pirongia coal (Kawhia by neutralisation—0.500 g FBA sample was gently
Deposit)'. boiled with 50 ml of 0.5M HC1 in a 300 ml conical
Coal Coal ash flask for 5 min. The mixture was allowed to cool
and 3 drops of phenolphthalein indicator were added
% %
Item (as received) Element (dry basis) and titrated against 0.5M NaOH to the end point
(pH 8.0). A similarly boiled control containing
Moisture 27.5 Si 12.4 only 0.5M HC1 was prepared as a blank.
Ash 9.1 Al 4.8
Volatile matter 33.1 Fe 7.5 Particle size distribution was determined using
Fixed carbon 30.3 Ca 12.4 dry-sieving with a set of stainless sieves (0.075,
Sulphur 2.3 Mg 1.9 0.150, 0.250, 0.50, 1.0, and 2.0 mm).
Na 3.1 Subsamples of FBA were ground to less than 1
K 0.2 mm particle size and the mineralogical character-
'Source: T. MacRae, Anchor Products, Te Awamutu, istics were determined by X-ray diffraction analysis
New Zealand. using a Phillips P W 9840 Diffractbmeter.
Wang et al.—Agronomic properties of fluidised bed boiler ash 251
Sequential aqueous extraction of FBA and SSP (Table 2). The bigger particles were probably
FBA is used mainly as a source of S that is present residual limestone grains.
as gypsum. Traditionally SSP is used as a source The major elements in FBA were silicon (Si),
of S that is also present as gypsum. The rate of aluminium (Al), iron (Fe), Ca, and S, together with
dissolution of each material in de-ionised water lesser amounts of Na, Mg, boron (B), strontium
was measured. The SSP used contained 12.0% S. (Sr), and K. The concentrations of potentially toxic
The aqueous extracts of these two fertilisers were elements, such as cadmium (Cd), chromium (Cr),
prepared by shaking 5.08 g of FBA and 2.08 g SSP nickel (Ni), lead (Pb), and arsenic (As) were very
(both containing 250 mg S) with 20 ml water low in NZDC FBA (Tables 1 & 3) and are unlikely
(S:water = 1:80) for 1 h at approximately 20cC. to cause problems for animal health at normal
The extracts were centrifuged and the supernatant maintenance rates of fertiliser S and lime appli-
liquids were filtered through a Whatman No. 40 cation. For example, even at a very high application
paper. The extraction was repeated maintaining a rate of 5000 kg anhydrous FBA/ha, only 32.5 g As/
constant ratio of fertiliser:water until the ha are added to soil. This level is much less than
concentration of S in FBA extracts decreased the threshold level suggested for the heavy metal
markedly. loading in agricultural soils (200 g/ha per year,
Department of Health 1992). Similar elemental
After measuring the pH and electrical con-
composition and lack of toxicity to animals in
ductivity (EC), each collected filtrate was acidified
feeding and grazing trials has been found in studies
with 5 ml concentrated HC1 to prevent microbial
with American FBA (Cahill et al. 1988; Whitsel et
growth. The concentration of S, Ca, magnesium
al. 1988; Cochran et al. 1991; Marsh & Grove
(Mg), potassium (K), and Na was measured in the
1992; Vona et al. 1992). All the elements in NZDC
acidified filtrate. S concentration was determined
FBA were fully HCl-extractable, except Al, Fe,
by a bismuth sulphide precipitation method on an
and zinc (Zn) that were partially HCl-insoluble
autoanalyser (CSIRO Division of Forest Research,
(Table 3). This suggests that most of the elements
Method No. PS17). The concentration of Ca, Mg,
in FBA are not in insoluble silicate compounds.
K, and Na was determined using atomic absorption/
emission spectrophotometry. Gypsum (CaSO4.2H2O), portlandite [Ca(OH)2],
ettringite [Ca6Al2(SO4)3(OH)12.26H2O], and quartz
(SiO2) were the major diffracting minerals in slaked
RESULTS AND DISCUSSION NZDC FBA (Table 4). Gypsum and portlandite
could be removed by sequential water extraction.
Physical and chemical properties of FBA Mineralogical analysis of anhydrous FBA in the
NZDC FBA used in this study had a moisture United States has indicated that CaO, CaSO4, and
content of 27.1 %. It consisted of mostly sand size quartz are the major minerals (Terman et al. 1978;
particles (76%, 0.075-2 mm; Table 2). The CaCO3 Korcak 1980a; Edwards et al. 1985b). During
equivalents and S content varied with changes in slaking, some gypsum can be converted to water-
particle size. The finer particles contained less lime insoluble ettringite that forms a protective coating
and S, suggesting more coal ash in these fractions material (ACI 225 committee 1987; Table 4).
Table 2 Particle size distribution of fluidised bed boiler ash and its
composition (27.1% moisture content).
Particle size Weight Sulphur1 CaCO3 equivalent
(mm) (%) (%) (%)
<0.07 5.4 4.5 29.1
0.075-0.150 9.7 4.6 33.1
0.150-0.250 12.2 4.6 36.5
0.250-0.50 20.4 5.0 37.0
0.50-1.0 19.9 5.3 36.8
1.0-2.0 14.2 5.6 40.0
>2.0 18.2 4.2 35.4
10% HCl-extractable S.
252 New Zealand Journal of Agricultural Research, 1995, Vol. 38
An aqueous suspension of FBA is very caustic CO2 gas (0.0003 parts CO2, Lindsay 1979).
(pH in water = 12.4), because of the presence of The major alkaline material in anhydrous FBA
basic oxides and hydroxides, e.g., Ca(0H)2. FBAs is CaO, which hydrates to form Ca(OH)2
commonly have high CaCO3 equivalent values (portlandite) during slaking. Ca(OH)2 is readily
(51.8% CaCO3 in NZDC FBA) and are considered transformed into CaCO 3 (calcite) through
as good liming agents in the United States (Terman absorption of atmospheric CO2. The CO2 level at
et al. 1978; Edwards et al. 1985a). which calcite and portlandite can co-exist is
calculated as follows (Lindsay 1979):
pH value of the aqueous extracts pK
The objective of the aqueous extraction experiment CaCO 3 +2H + Ca 2 + +CO (g) -9.74
was to investigate the time sequence of elemental 2+ +
dissolution from FBA, particularly with respect to Ca + 2H2O Ca(OH)2 + 2H 22.80
the caustic nature of the fertiliser suspension and j + H,O-> Ca(OH)2 +CO 2 (g) 13.06
the release of useful plant-available S. The Where pK (-logK) is the equilibrium constant
dissolution pattern of FBA was compared with that expressed in terms of chemical activities. From
of a standard S fertiliser, SSP. Equation 6,
The possible existence of Na2CC>3 and K2CO3 CO 2 (g)=10- 13 - 06 (7)
accounts for the high pH of 9.39 in the first FBA
Thus when CO2 (g) drops to 10" 1306 atm, both
extract, which was much higher than those in
calcite and portlandite can co-exist. Calcite becomes
subsequent extracts (between 8.37 and 8.47, Fig.
metastable to portlandite only if CO2 (g) drops
1). pH buffered in the latter range indicates a CaO-
below this level. In this study the reaction of
CO2-H2O system in equilibrium with atmospheric
Equation 6 would be to form CaCO3 since the CO2
in the air (about 0.0003 atm) is much more than the
equilibrium criterion. Thus it is expected that all
Table 3 Main elemental concentration of fluidised portlandite particles would be coated with calcite.
bed boiler ash. Therefore, it was calcite that had a dominating
Concentration1 influence on the pH of the FBA extracts. The pH of
the extracts remained around 8.40, even after 24
Element Total HCl-extractable
extractions when there was little portlandite left in
the residue (Table 4).
Ca 25.4 25.4 In contrast to FBA extracts, the pH of the first
S 6.2 6.2 extract of SSP (pH 3.15) was much lower than
Fe 3.6 2.2 those of the rest (pH 4.30-5.56). The first extract
Al 1.8 1.4 had pH, phosphate, and Ca concentrations similar
Na 0.7 0.7
Mg 0.6 0.6 to the stable triple-point solution (TPS) when
K 0.3 0.3 monocalcium phosphate monohydrate [MCP,
Ca(H2PO4)2.H2O] dissolves in water (Lindsay
rng/kg
1979). During dissolution, MCP initially reaches a
B 1360 1360 metastable triple-point solution (MTPS) (Lindsay
Sr 1250 1250 et al. 1959). MTPS is the solution approaching
P 875 875
Mn 88 88 equilibrium with dissolving MCP and precipi-
Zn 72 65
As 6.5 6.5
Se <3 <3 Table 4 Effect of water extraction on the main
Pb <2 <2 mineralogical composition1 of fluidised bed boiler ash.
Cu <0.3 <0.3 Mineral Before extraction After extraction
Sn <0.3 <0.3
Ni <0.2 <0.2 Quartz Present Present
Co <0.2 <0.2 Gypsum Present Absent
Cr Portlandite Present Absent
Mo Ettringite Present Present
Cd Calcite Not major peak Present
'Dry matter basis 'Examined using a X-ray diffractometer.
Wang et al.—Agronomic properties of fluidised bed boiler ash 253
10 6000
\ 4500
\ -*-*-* ^3000
£
B
£1200
c i
1 900
u
u
300
100 200 300 400 500 100 200 300 400 500
Cumulative volume (ml) Cumulative volume (ml)
Fig. 1 pH change in sequential water extracts of FBA Fig. 2 Ca and S concentrations in sequential water
and SSP. extracts of FBA and SSP. The equilibrium concentrations
of Ca and S maintained by pure gypsum are about 611
and 489 mg/litre, respectively (Glas et al. 1979).
tating dicalcium phosphate dihydrate (DCPD, and may be attributed to the higher SSP:water ratio
CaHPO 4 .2H 2 O). The solution composition which resulted in more gypsum dissolution.
remained at MTPS for more than 24 h, then slowly
shifted up the MCP isotherm to the TPS that Sulphate concentration in the aqueous extracts
represented final equilibrium with MCP and
dicalcium phosphate (DCP, CaHPO4). Gypsum and ettringite were the major sulphate
compounds in FBA (Table 4). Ettringite is an acid-
The solution resulting from the dissolution of
soluble but water-insoluble material. Gypsum was
pure MCP is highly acidic, since during the
therefore the main water-soluble S-containing
dissolution of MCP, the precipitation of DCPD
compound in FBA. FBA might also contain small
releases H3PO4 according to the reaction:
amounts of Na2SO4 and K2SO4 that are more
Ca(H2PO4)2H2O + -> CaHPO4-2H2O + H3PO4 (8) soluble than gypsum because the SO42" concen-
The released H3PO4 accounts for the low pH of trartion of the first extract was higher than those in
MTPS (pH 1.48). Similarly precipitation of DCP the subsequent extracts (Fig. 2). It was also higher
to give TPS reflects even greater release of H3PO4 than the equilibrium concentration maintained by
as the pH drops to 1.01 (Lindsay 1979). pure gypsum i.e. about 489 mg S/litre (Glas et al.
Using SSP instead of pure MCP, Williams 1979). From the second to twelfth extracts, the
(1971) reported that the pH of saturated aqueous sulphate concentrations were around 450 mg S/
extracts of SSP at MTPS (pH 1.60-1.92) was higher litre (between 400 and 494 mg S/litre), a range
than in pure MCP solution (pH 1.45) and he expected for a saturated solution of gypsum
explained that the higher pH (0.15-0.47) was containing minor contaminants (Bolan et al. 1991).
probably the result in part of the presence of CaSO4 The S concentration in a pure system containing
in SSP since the addition of anhydrous CaSO4 or only water and excess solid gypsum is between
gypsum to pure MCP increased the pH of the 476.8 and 505.6 mg S/litre (Glas et al. 1979).
equilibrium solution by 0.15 units (Williams 1971). Lower values in FBA extracts could result from
The initial pH value in this study (Fig. 1) was the high pH and a Ca common-ion effect (Kemper
higher than in the data reported by Williams (1971) et al. 1975), i.e. the Ca ions dissociated from
254 New Zealand Journal of Agricultural Research, 1995, Vol. 38
80 the seventeenth extract were well above the
equilibrium concentration maintained by gypsum
(about 611 mg Ca/litre, Glas et al. 1979) because
of the presence of more soluble portlandite in FBA.
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