Services
Synthetic Materials offers a solid list of services designed to reliably underpin all aspects of the Flue Gas Desulfurization industry:
- Design and Build
- Operations and Maintenance
- FGD Laboratory
- Landfill / Pond Management
- Gypsum Marketing
Design & Build of FGD Systems
Synthetic Materials is an industry recognized expert in the design and construction of FGD systems. We create well designed plant layouts and environments as well as utilize standardized equipment to enable efficient processing and production. Our expertise and experience in operations and maintenance is fully incorporated into each of our designs. 
Our Gypsum Design Specification
- Purity
- 95% Minimum
- Free Moisture
- 10% Max - 8% Target
- Chlorides - Total Water Solubles
- 120 ppm Max
- Particle Size
- d50 - 45 microns
- Impurities
- Unreacted limestone
- Silica
- Iron, Alumina, Clay Minerals
- Flyash
Operations and Maintenance
At Synthetic Materials we have accumulated an extensive cache of Operations and Maintenance experience and knowledge. Our experience includes: 
- FGD Limestone Ball Mill
- Limestone Classifiers
- Gypsum Hydroclones
- Gypsum Dewatering
- Waste Water Effluent Treatment
- Solid Waste Handling and Disposal
Our Operations and Maintenance model is built on and incorporates the following:
- Standardized operating procedures
- Shared overhead expense
- Qualified and experienced personnel
- Training opportunities at the various SynMat locations
- The creation and maintenance of operation manuals
- Hiring of qualified operators
- Lab design
- Testing and sampling procedures
Maintenance
Experience coupled with a deep knowledge base allows Synthetic Materials to offer and provide superior FGD System maintenance capabilities. Our expertise in maintenance dovetails smoothly with our operations skill set to provide our customers with the best in quality maintenance service. Here are some of our Maintenance areas of competency:
- Reduced stock of common spares
- Centralized maintenance planning
- Upgrades to eliminate root cause of downtime
- Sharing of lessons learned
- Maintenance process designed around best maintenance practices including preventative, predictive, reliability centered
- 12 years experience with never more than a 24 hour outage; 99.9% availability
FGD Laboratory Services
Another layer within our experience and expertise cache is FGD Laboratory Services. Our core capabilities include:
- Limestone
- Particle size distribution
- CaCO3
- MgCO3
- Acid Insolubles
- Scrubber
- pH
- Density
- Chlorides IC
- Sulfites (liquid phase)
- Fluoride
- Gypsum
- Moisture (free)
- Purity
- Chlorides
- Ammonia
- Foreign material
- Water soluble K expressed as K2O
- Water soluble Na expressed as Na2O
- Water soluble Mg expressed as MgO Acid soluble Mg expressed as MgCO3
- Acid soluble
- Ca expressed as CaCO3
- pH
- Waste Water Effluent
- pH
- Total Suspended Solids (TSS)
- Total Dissolved Solids (TDS)
- Conductivity
- Turbidity
Landfill / Pond Management
Synthetic Materials offers landfill and pond management as an integral part of an FGD System implementation. Our knowledgeable engineering staff assures proper landfill and pond management. Some of our major customers are: 
- Tennessee Valley Authority (TVA) Cumberland City, TN
- 12+ years managing the gypsum wet stack and pond
- Dredge recovery of more than 4 million tons of gypsum
- Kentucky Utilities Ghent, KY
- 7+ years managing the gypsum wet stack and pond
- Dredge recovery of more than 1 million tons of gypsum
- Contract with Duke Cayuga Station to manage gypsum landfill
Marketing
Since its inception, Synthetic Materials has experienced a continued annual growth rate of 15%. A portion of that success is directly attributable to our Gypsum Marketing service capability. We possess marketing expertise and contacts throughout the wallboard, fillers, and cement markets and were actively engaged in the agricultural market.The following is a sample of the gypsum processed and marketing for our current utility customers that we service:
- Tennessee Valley Authority (TVA) Cumberland City, TN - up to 1,500,000 tons
- Louisville Gas & Electric (LG&E) Trimble Co., KY - up to 325,000 tons
- Duke Energy Cayuga Station, IN - up to 300,000 tons
- Alcoa Warrick Station, Newburgh, IN - up to 425,000 tons
- Kentucky Utilities(KU) Ghent KY Station - up to 800,000 tons
- Mirant Morgantown, MD - up to 450,000 tons
- Mirant Dickerson, MD - up to 200,000 tons
- Mirant Chalk Point, MD - up to 200,000 tons
SynMat Customers
- Gypsum Wallboard
- CertainTeed
- Lafarge
- National
- Temple
- Georgia Pacific
- USG
- Cement
- Cemex
- Holcim
- Lafarge NA
- Lehigh
- Agriculture
- Fillers
FGD Gypsum Logistics
- Primary Method of Transport: River Barge
- Secondary Method of Transport: Ocean Going Barge
- Tertiary Methods of Transport: Dump Truck, Ocean Going vessel