Direct transformation of FGD gypsum to calcium sulfate hemihydrate whiskers: Preparation,simulations, and process analysis

Calcium sulfate hemihydrate (CSH) whiskers were synthesized by phase transition in CaCl₂ solution under atmospheric pressure. Analytical-grade calcium sulfate dihydrate (AR CSD) was used as the raw material for the synthesis of CSH whiskers, according to orthogonal experiments. The effects of reaction temperature, AR CSD content, H₂SO₄ content, and reaction time were investigated, and the crystallization conditions were optimized. The as-prepared CSH whiskers displayed a regular morphology and a highly uniform size, with an aspect ratio of 105. A simulation system was also established by blending various sulfates with AR CSD, to evaluate the effects of impurities in flue gas desulfurization (FGD) gypsum. The main aim was to prepare CSH whiskers directly from FGD gypsum, without any purification, using the optimized conditions. This is a facile potential alternative process for large-scale production of CSH whiskers using abundant FGD gypsum as source materials.