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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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