Thermal Power Plant Flue Gas Desulfurization (FGD) Gypsum Waste Particulates Reinforced Injection Molded Flexible Composites

Low density, thermally insulative and moisture resistant flexible polymer composites were developed using Flue Gas Desulfurization (FGD) gypsum waste particulates with Low Density Polyethylene (LDPE) under injection molding technique without any additive or filler modification. The moisture content, particle size, specific gravity, density, pH, electrical conductivity and Fourier-Transform Infrared Spectroscopy (FTIR) analysis of FGD gypsum waste particulates were evaluated together with mineralogical, morphological and elemental analysis by X-Ray Diffraction (XRD) and Field Emission Scanning Electron Microscopy with Energy Dispersive X-Ray Spectroscopy (FESEM-EDS) studies. Developed composites were tested for Density, Water absorption, thermal conductivity and mechanical strength. Density of FGD-LDPE composites varied from 0.91±0.01 to 1.33±0.01 g/cm³ with different concentrations of FGD gypsum filler (10–70 weight %). The water absorption showed 0.69±0.04% for maximum (70 weight %) filler concentration and the corresponding thermal conductivity was found to be minimum (0.3964 W/m/K). The composites were very flexible and exhibited lower tensile strength (6.17±0.05 to 7.15±0.09 MPa), flexural strength (11.25±0.14 MPa) and impact strength (22.70±1.57 KJ/m²) with 50% and 10% filler content. Findings of these results have showed a new path for making flexible composites potentially having applications in sports ground, staircase and instrumentation rooms as a thermal insulation flooring material using FGD waste particulates generated from thermal power plants.