
CASE STUDY - First Energy Corporation
(Shippingport, PA)
Bruce Mansfield Plant Uses Geotextile Tubes
Coal
Fired Power Plant Dewaters Gypsum
By: William A. Smallwood II, VP-Engineering (Flint Industries)
The Shippingport Pennsylvania coal fired power plant Bruce
Mansfield, a 2400 Megawatt Pennsylvania Power Company (a
division of First Energy Corp.) facility, produces gypsum as a
by-product. The gypsum, a fine particle calcium sulfate, is
produced inside the towers as a "wet paste" as the power plant
scrubs its high-sulfur coal emissions. This is contrary to the
more common and naturally occurring gypsum that comes in rock
form and requires crushing prior to use in wallboard or other
commercial products. The Bruce Mansfield facility formerly
produced 408233 metric-tons of gypsum per year that ended up at
First Energy's residual waste processing center, the Little Blue
Run Landfill.
One perfect example of companies "partnering" to preserve
the environment by recycling is First Energy Corporation and
National Gypsum teaming up in order to divert this First Energy
by-product into a primary ingredient in National Gypsum’s
wallboard production. However, surplus gypsum does occur and
would rapidly overload the existing landfill were it not for
geotextile tubes. These tubes retain the solid particles while
allowing the water to filter through, thus providing for reduced
disposal volume and associated costs.
The Bruce Mansfield plant utilizes the TitanTubeTM
geotextile tube manufactured by Flint Industries, Inc. (Metter,
GA) and marketed by ACF (Richmond, VA). The style of tube
utilized in this case has a length of 200 feet, and incorporates
a 45x68 newton-meters PP fabric.
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