Commercial Production and Recovery
The main sources of calcium sulfate are naturally occurring gypsum and anhydrite which occur at many locations worldwide as evaporites. These may be extracted by open-cast quarrying or by deep mining. World production of natural gypsum is around 127 million tonnes per annum.
In addition to natural sources, calcium sulfate is produced as a by-product in a number of processes:
- In flue-gas desulfurization, exhaust gases from fossil-fuel power stations and other processes (e.g. cement manufacture) are scrubbed to reduce their sulfur oxide content, by injecting finely ground limestone or lime. This produces an impure calcium sulfite, which oxidizes on storage to calcium sulfate.
- In the production of phosphoric acid from phosphate rock, calcium phosphate is treated with sulfuric acid and calcium sulfate precipitates.
- In the production of hydrogen fluoride, calcium fluoride is treated with sulfuric acid, precipitating calcium sulfate.
- In the refining of zinc, solutions of zinc sulfate are treated with lime to co-precipitate heavy metals such as barium.
- Calcium sulfate can also be recovered and re-used from scrap drywall at construction sites.
These precipitation processes tend to concentrate radioactive elements in the calcium sulfate product. This is particularly the case with the phosphate by-product, since phosphate rocks naturally contain actinides.
Read more about this topic: Calcium Sulfate
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