Carbonation of steel slag for CO2 sequestration: leaching of products and reaction mechanisms

Characterisation of arsenic levels in acid-treated arsenic-containing sludge after steel slag-fly ash gel curing

Arsenic-containing sludge (ABG) is a common hazardous waste in the metallurgical industry and poses a serious threat to environmental safety. However, its instability and mobility have a significant impact on the environment. Traditional curing methods are time-consuming and costly, often resulting in incomplete curing. In this study, we introduce a curing/stabilisation method with a steel slag-fly ash gel material after ABG acid treatment. The toxic leaching of arsenic from ABG was reduced to 220 mg/kg by treating the sludge with acids (H2SO4-H3PO4) at different solid-to-liquid ratios. Afterward, H2O2 was added to oxidise As(III) to As(V). The ABG was cured/stabilised using an alkali-activated steel slag-fly ash gel material. The cured product exhibited optimal arsenic fixation under an ABG/steel slag/fly ash mass ratio of 1:4:2, a curing temperature of 60°C, a curing time of 20 h, and an ambient pH of 12.5. Under these conditions, steel slag-fly ash facilitated Ca-As precipitation, resulting in a hydration reaction that produced C-S-H gel. Additionally, the reaction generated calcium hydroxide, calcium and iron pyroxene, silica, and iron ferrite, which adsorbed part of the free arsenic, completing the curing of the acid-treated ABG and stabilising arsenic leaching toxicity. The leaching of arsenic in the ABG was much lower than the Chinese 'Hazardous Wastes Leaching Toxicity Identification Standard' (GB5085.3-2007) (5 mg/L), with an arsenic curing rate exceeding 99%. The mechanism of arsenic solidification involves the combined effects of chemical precipitation, physical encapsulation, and adsorption. Collectively, our findings demonstrated that the use of steel slag-fly ash gel as a functional material for ABG curing holds considerable environmental and economic benefits. Therefore, this study provides theoretical guidance and provides insights into the experimental feasibility of ABG treatment.

Interpretation and Prediction of the CO2 Sequestration of Steel Slag by Machine Learning

The utilization of steel slag for CO2 sequestration is an effective way to reduce carbon emissions. The reactivity of steel slag in CO2 sequestration depends mainly on material and process parameters. However, there are many puzzles in regard to practical applications due to the different evaluations of process parameters and the lack of investigation of material parameters. In this study, 318 samples were collected to investigate the interactive influence of 12 factors on the carbonation reactivity of steel slag by machine learning with SHapley Additive exPlanations (SHAP). Multilayer perceptron (MLP), random forest, and support vector regression models were built to predict the slurry-phase CO2 sequestration of steel slag. The MLP model performed well in terms of prediction ability and generalization with comprehensive interpretability. The SHAP results showed that the impact of the process parameters was greater than that of the material parameters. Interestingly, the iron ore phase of steel slag was revealed to have a positive effect on steel slag carbonation by SHAP analysis. Combined with previous literature, the carbonation mechanism of steel slag was proposed. Quantitative analysis based on SHAP indicated that steel slag had good carbonation reactivity when the mass fractions of "CaO + MgO", "SiO2 + Al2O3", "Fe2O3", and "MnO" varied from 50-55%, 10-15%, 30-35%, and <5%, respectively.

Potential of major by-products from non-ferrous metal industries for CO2 emission reduction by mineral carbonation: a review

By-products from the non-ferrous industry are an environmental problem; however, their economic value is high if utilized elsewhere. For example, by-products that contain alkaline compounds can potentially sequestrate CO₂ through the mineral carbonation process. This review discusses the potential of these by-products for CO₂ reduction through mineral carbonation. The main by-products that are discussed are red mud from the alumina/aluminum industry and metallurgical slag from the copper, zinc, lead, and ferronickel industries. This review summarizes the CO₂ equivalent emissions generated by non-ferrous industries and various data about by-products from non-ferrous industries, such as their production quantities, mineralogy, and chemical composition. In terms of production quantities, by-products of non-ferrous industries are often more abundant than the main products (metals). In terms of mineralogy, by-products from the non-ferrous industry are silicate minerals. Nevertheless, non-ferrous industrial by-products have a relatively high content of alkaline compounds, which makes them potential feedstock for mineral carbonation. Theoretically, considering their maximum sequestration capacities (based on their oxide compositions and estimated masses), these by-products could be used in mineral carbonation to reduce CO₂ emissions. In addition, this review attempts to identify the difficulties encountered during the use of by-products from non-ferrous industries for mineral carbonation. This review estimated that the total CO₂ emissions from the non-ferrous industries could be reduced by up to 9-25%. This study will serve as an important reference, guiding future studies related to the mineral carbonation of by-products from non-ferrous industries.

Understanding landfill gas behavior at elevated temperature landfills

Landfill gas (LFG) wellhead data were compared to understand the range of observations due to unique conditions at five elevated temperature landfills (ETLFs) in the U.S. Correlations of the primary gas ratio, CH₄:CO₂, show distinct compositional indicators for (1) typical operation, (2) subsurface exothermic reactions (SERs), (3) high moisture content, and (4) air intrusion that can help operators and regulators diagnose conditions across gas extraction wells. ETLFs A, B, D, and E showed similar trends, such as decreasing CH₄ and increasing CO₂, CO, and H₂ that have been previously described. ETLF C uniquely exhibited elevated CH₄ and temperatures simultaneously due to carbonation (i.e., CO₂ consumption) of a steel slag which was used as alternative daily cover (ADC). At the maximum gas well temperature, T = 82 °C/180 °F, CH₄ and CO₂ concentrations were 47% and 28%, respectively. At ETLFs A, B, and E, H₂ > 50% were regularly observed in affected gas wells for several years. At the five ETLFs, maximum CO concentrations ranged from 1400-16,000 ppmv. Like the analysis of CH₄:CO₂, it is hypothesized here that H₂ (%):CO (ppmv) may infer the types of waste that are thermally degrading. Co-disposal of industrial wastes and MSW and the use of potentially reactive ADCs should remain an important consideration for landfill operators and regulators because of their potential long-term impacts to LFG quality.

Nano- to Global-Scale Uncertainties in Terrestrial Enhanced Weathering

Enhanced weathering (EW) is one of the most promising negative emissions technologies urgently needed to limit global warming to at least below 2 °C, a goal recently reaffirmed at the UN Global Climate Change conference (i.e., COP26). EW relies on the accelerated dissolution of crushed silicate rocks applied to soils and is considered a sustainable solution requiring limited technology. While EW has a high theoretical potential of sequestering CO₂, research is still needed to provide accurate estimates of carbon (C) sequestration when applying different silicate materials across distinct climates and major soil types in combination with a variety of plants. Here we elaborate on fundamental advances that must be addressed before EW can be extensively adopted. These include identifying the most suitable environmental conditions, improving estimates of field dissolution rates and efficacy of CO₂ removal, and identifying alternative sources of silicate materials to meet future EW demands. We conclude with considerations on the necessity of integrated modeling-experimental approaches to better coordinate future field experiments and measurements of CO₂ removal, as well as on the importance of seamlessly coordinating EW with cropland and forest management.

An innovative accelerated carbonation process for treatment of incineration bottom ash and biogas upgrading

Incineration is the main technology used for the management of municipal solid waste, in parallel to various recycling programs. However, incineration should not be considered as the final step for waste management as the ash still needs to be treated and disposed properly. In this work, an innovative accelerated carbonation of incineration bottom ash (IBA) using simulated biogas composition from anaerobic digestion processes (a mixture of CH₄ and CO₂) has been applied to lower the leaching of heavy metals from the carbonated IBA and its associated toxicity. Various temperatures and reaction times were explored for carbonation optimization and it was found that the carbonation at 25 °C for 8 h was the optimal reaction condition by taking into account the degree of carbonation and time constraint. The mineral content, functional groups, thermal stability, leaching patterns and ecotoxicity of both raw IBA and carbonated IBA were tested. It was found that carbonated IBA leached out less heavy metals than the raw IBA due to the locking of heavy metals in the calcite matrix. Cost-benefit analysis was also conducted on the industrial-scale process with a capacity of processing 10 tons of IBA per day. The results indicated that the proposed process had great economic potential.

Impact of carbonation on leaching of constituents from a cementitious waste form for treatment of low activity waste at the DOE Hanford site

Carbonation can be a major aging process during disposal of alkaline cementitious waste forms and can impact constituent leaching by changes in material alkalinity, pore structure, and controlling mineral phases. The effect of carbonation on the leaching of major and trace constituents from Cast Stone, a cementitious waste form developed to treat high salt content low activity waste, was studied through a combination of leaching experiments and reactive transport simulations. Diffusive transport of constituents in the waste form was evaluated using reactive transport modeling of diffusion-controlled leaching test results and a geochemical speciation model derived from pH-dependent leaching. Comparisons between Cast Stone materials aged under nitrogen, air, and 2% carbon dioxide in nitrogen showed that carbonation impacts solubility, physical retention and observed diffusivity of major and trace constituents. Carbonation under 2% CO₂ decreased the diffusion-controlled leaching of chromium by two orders of magnitude. Modeling results suggest that carbonation may also decrease solubility of technetium while changes to microstructure by carbonation increases effective diffusivity of constituents in Cast Stone.

The influence of redox conditions on aqueous-solid partitioning of arsenic and selenium in a closed coal ash impoundment

A closed coal ash impoundment case study characterized the effects of field redox conditions on arsenic and selenium partitioning through monitoring of porewater and subsurface gas in conjunction with geochemical speciation modeling. When disposed coal ash materials and porewater were recovered for testing, oxidation led to lower arsenic and higher selenium concentrations in leaching test extracts compared to porewater measurements. Multiple lines of evidence suggest multiple mechanisms of arsenic retention are plausible and the concurrent presence of several redox processes and conditions (e.g., methanogenesis, sulfate reduction, and Fe(III)-reduction) controlled by spatial gradients and dis-equilibrium. Geochemical speciation modeling indicated that, under reducing field conditions, selenium was immobilized through the formation of insoluble precipitates Se(0) or FeSe while arsenic partitioning was affected by a progression of reactions including changes in arsenic speciation, reduction in adsorption due to dissolution and recrystallization of hydrous ferric oxides, and precipitation of arsenic sulfide minerals.

Leaching and Geochemical Modelling of an Electric Arc Furnace (EAF) and Ladle Slag Heap

Old metallurgical dumps across Europe represent a loss of valuable land and a potential threat to the environment, especially to groundwater (GW). The Javornik electric arc furnace (EAF) and ladle slag heap, situated in Slovenia, was investigated in this study. The environmental impact of the slag heap was evaluated by combining leaching characterization tests of landfill samples and geochemical modelling. It was shown that throughout the landfill the same minerals and sorptive phases control the leaching of elements of potential concern, despite variations in chemical composition. Although carbonation of the disposed steel slags occurred (molar ratio CO₃/(Ca+Mg) = 0.53) relative to fresh slag, it had a limited effect on the leaching behaviour of elements of potential concern. The leaching from the slag heaps had also a limited effect on the quality of the GW. A site-specific case, however, was that leachates from the slag heap were strongly diluted, since a rapid flow of GW fed from the nearby Sava River was observed in the landfill area. The sampling and testing approach applied provides a basis for assessing the long-term impact of release and is a good starting point for evaluating future management options, including beneficial uses for this type of slag.

Slurry-Phase Carbonation Reaction Characteristics of AOD Stainless Steel Slag

Argon oxygen decarburization stainless steel slag (AOD slag) has high mineral carbonation activity. AOD slag carbonation has both the resource utilization of metallurgical waste slag and the carbon reduction effect of CO2 storage. This paper aimed to study carbonation reaction characteristics of AOD slag. Under the slurry-phase accelerated carbonation route, the effect of stirring speed (r) and reaction temperature (T) on AOD slag’s carbonation was studied by controlling the reaction conditions. Mineral composition analysis and microscopic morphology analysis were used to explore the mineral phase evolution of AOD slag during the carbonation process. Based on the unreacted core model, the kinetic model of the carbonation reaction of AOD slag was analyzed. The results showed that the carbonation ratio of AOD slag reached its maximum value of 66.7% under the reaction conditions of a liquid to solid ratio (L/S) of 8:1, a CO2 partial pressure of 0.2 MPa, a stirring speed of 450 r·min−1, and a reaction temperature of 80 °C. The carbonation reaction of AOD slag was controlled by internal diffusion, and the calculated apparent activation energy was 22.28 kJ/mol.

Production, characterisation, utilisation, and beneficial soil application of steel slag: A review

Slags are a co-product produced by the steel manufacturing industry and have mainly been utilised for aggregates in concreting and road construction. The increased utilisation of slag can increase economic growth and sustainability for future generations by creating a closed-loop system, circular economy within the metallurgical industries. Slags can be used as a soil amendment, and slag characteristics may reduce leachate potential of heavy metals, reduce greenhouse gas emissions, as well as contain essential nutrients required for agricultural use and environmental remediation. This review aims to examine various slag generation processes in steel plants, their physicochemical characteristics in relation to beneficial utilisation as a soil amendment, and environmental implications and risk assessment of their utilisation in agricultural soils. In relation to enhancing recycling of these resources, current and emerging techniques to separate iron and phosphorus slag compositions are also outlined in this review. Although there are no known immediate direct threats posed by slag on human health, the associated risks include potential heavy metal contamination, leachate contamination, and bioaccumulation of heavy metals in plants, thereby reaching the food chain. Further research in this area is required to assess the long-term effects of slag in agricultural soils on animal and human health.

Hydration Activity and Carbonation Characteristics of Dicalcium Silicate in Steel Slag: A Review

Dicalcium silicate is one of the main mineral phases of steel slag. Ascribed to the characteristics of hydration and carbonation, the application of slag in cement production and carbon dioxide sequestration has been confirmed as feasible. In the current study, the precipitation process of the dicalcium silicate phase in steel slag was discussed. Meanwhile, the study put emphasis on the influence of different crystal forms of dicalcium silicate on the hydration activity and carbonation characteristics of steel slag. It indicates that most of the dicalcium silicate phase in steel slag is the γ phase with the weakest hydration activity. The hydration activity of γ-C2S is improved to a certain extent by means of mechanical, high temperature, and chemical activation. However, the carbonation activity of γ-C2S is about two times higher than that of β-C2S. Direct and indirect carbonation can effectively capture carbon dioxide. This paper also summarizes the research status of the application of steel slag in cement production and carbon dioxide sequestration. Further development of the potential of dicalcium silicate hydration activity and simplifying the carbonation process are important focuses for the future.

Development of a Geochemical Speciation Model for Use in Evaluating Leaching from a Cementitious Radioactive Waste Form

Cast Stone has been developed to immobilize a fraction of radioactive waste at the Hanford Site; however, constituents of potential concern (COPCs) can be released when in contact with water during disposal. Herein, a representative mineral and parameter set for geochemical speciation modeling was developed for Cast Stone aged in inert and oxic environments, to simulate leaching concentrations of major and trace constituents. The geochemical speciation model was verified using a monolithic diffusion model in conjunction with independent monolithic diffusion test results. Eskolaite (Cr₂O₃) was confirmed as the dominant mineral retaining Cr in Cast Stone doped with 0.1 or 0.2 wt % Cr. The immobilization of Tc as a primary COPC in Cast Stone was evaluated, and the redox states of porewater within monolithic Cast Stone indicated by Cr are insufficient for the reduction of Tc. However, redox states provided by blast furnace slag (BFS) within the interior of Cast Stone are capable of reducing Tc for immobilization, with the immobilization reaction rate postulated to be controlled by the diffusive migration of soluble Tc in porewater to the surface of reducing BFS particles. Aging in oxic conditions increased the flux of Cr and Tc from monolithic Cast Stone.

Kinetics model adaptability analysis of CO2 sequestration process utilizing steelmaking slag and cold-rolling wastewater

Better adaptive kinetics model for CO₂ sequestration utilizing wastes in steelmaking plant has a big significance for establishing green out-circulating network system. This work investigated the effect of temperature, L/S ratio and cold-rolling wastewater concentration on carbonation degree in basic oxygen furnace slag and CRW carbonation process, then their kinetics was discussed by surface coverage model and shrinking core model, respectively, in order to evaluate their adaptability and accuracy. Furthermore, CO₂ sequestration intensifying factor was originally proposed for considering the carbonation depth, through comparing diffusion coefficient of CO₂ between water carbonation and wastewater carbonation. The results showed that carbonation conversion increased as temperature and CRW concentration increased except for L/S ratio, and the maximum carbonation could reach 41.499 ± 1.240%. Because higher prediction error existed in surface coverage model, the shrinking core model had a better adaptability and accuracy for analyzing carbonation process in autoclave. Meanwhile, the CO₂ sequestration intensifying factor was 1.6 times as big as carbonation process in distilled water as a result of D_CO2 value. CO₂ sequestration reaction in our work was controlled by calcium diffused because of D_CO2 (0.700-0.976 × 10^-4 cm² s^-1) and D_Ca (0.935-1.149 × 10^-5 cm² s^-1). The results above will be helpful for us to better comprehend the reaction kinetics at micro-scale, when the idea of triple wastes self-circulation system network will be established to industrial application.

Calcination-free production of calcium hydroxide at sub-boiling temperatures

Calcium hydroxide (Ca(OH)₂), a commodity chemical, finds use in diverse industries ranging from food, to environmental remediation and construction. However, the current thermal process of Ca(OH)₂ production via limestone calcination is energy- and CO₂-intensive. Herein, we demonstrate a novel aqueous-phase calcination-free process to precipitate Ca(OH)₂ from saturated solutions at sub-boiling temperatures in three steps. First, calcium was extracted from an archetypal alkaline industrial waste, a steel slag, to produce an alkaline leachate. Second, the leachate was concentrated using reverse osmosis (RO) processing. This elevated the Ca-abundance in the leachate to a level approaching Ca(OH)₂ saturation at ambient temperature. Thereafter, Ca(OH)₂ was precipitated from the concentrated leachate by forcing a temperature excursion in excess of 65 °C while exploiting the retrograde solubility of Ca(OH)₂. This nature of temperature swing can be forced using low-grade waste heat (≤100 °C) as is often available at power generation, and industrial facilities, or using solar thermal heat. Based on a detailed accounting of the mass and energy balances, this new process offers at least ≈65% lower CO₂ emissions than incumbent methods of Ca(OH)₂, and potentially, cement production.

A calcination-free route to produce calcium hydroxide from alkaline industrial wastes including leaching, concentration, and temperature-swing precipitation.

Co-treatment of Waste From Steelmaking Processes: Steel Slag-Based Carbon Capture and Storage by Mineralization

The iron and steel industry is an energy-intensive sector, and large amounts of waste/ by-products are generated during the steelmaking process, such as CO₂, metallurgical slag, and wastewater. Enhancing the development and deployment of treating waste from the steelmaking process will be environment friendly and resource-saving. Capturing CO₂ by steel slag (SS) via mineralization is regarded to be an excellent choice due to the high basicity of the slag. In this paper, recent research on the steel slag-based carbon capture and storage (SS-CCS) by mineralization was summarized. Three routes of SS-CCS are compared including, direct gas-solid carbonation, direct aqueous carbonation, and indirect carbonation, respectively. Furthermore, the challenges and prospects for further development of the SS-CCS were discussed.

Understanding dissolution characteristics of steel slag for resource recovery

Steel slags are generally alkaline with a high calcium content and are viewed as a potential feedstock for carbon dioxide sequestration and utilization, mostly through aqueous mineral carbonation routes. For recovery of multiple metals such as Ca, Fe, Mg, and Si, and generation of value-added products by dissolution and precipitation reactions in aqueous media, enhancing the metal selectivity and extraction efficiency are important. However, there is limited understanding of independent parameters that influence these important characteristics. In this work, a systematic attempt was made to correlate these key dissolution characteristics of basic oxygen furnace slag in acidic media with its mineralogical and physical characteristics, the changes in aqueous chemistry, and the role of potential secondary precipitates. The findings from this study substantiate that steel slag is a potential feedstock because of the calcium being mainly present as orthosilicates, which were found to leach congruently without forming a leached layer that might hinder calcium extraction. The leaching of Fe(II) from the slag is the main source of impurity and its slow oxidation-precipitation leads to a pH plateau at the end of the dissolution step. Oxidation-precipitation of Fe(II) is controlled by hydroxyl concentration in the aqueous solution, which necessitates a pH-swing step by addition of a base after dissolution. Use of surface complexing agents, such as sodium molybdate, can significantly reduce iron impurity in the leachate and obtain an iron-rich slag residue for recycle to iron and steel industry.

Closed-circulating CO2 sequestration process evaluation utilizing wastes in steelmaking plant

The wastes network system exploration in metallurgical process imposes of great significance for advancing green circular economy in steel plant. This paper originally proposes a closed-circulating CO₂ sequestering process for wastes appreciation and harmless disposal, and the effect of two circulation strategy, i.e. Slag circulation strategy and cold-rolling waste water(CRW) circulation strategy, on the CO₂ uptake efficiency, carbonation degree and desalination rate were systemically discussed. Then, their kinetics are analyzed by model and molecular simulation in detail, respectively. In addition, the energy consumption and the cost are simulated for comprehensively evaluating its superiority. The experimental and molecular simulation results all show that the peak values for both strategies could be achieved when circulation times is in the range of three to five. CRW circulation strategy has a better CO₂ uptake efficiency than slag circulation strategy, the CO₂ uptake efficiency is about 487kgCO₂/tslag and corresponding desalination rate is 48.9%, when CRW is circulated for five times at 60 °C and 20 L/g for 90 min. Adopting CRW circulation strategy, the CO₂ sequestration efficiency is averagely doubled comparing to previous results. 129%-183% energy consumption and 35.6% cost would be reduced, which represents that the proposed routine is economical to step forward to industrial application.

Effect of Different Hydration Time on Carbonation Degree and Strength of Steel Slag Specimens Containing Zeolite

Steel slag partially substituted by zeolite (SZ) was beneficial for improving the compressive strength and carbonation degree of SZ specimens after a combined curing (hydration and then carbonation) process due to pozzolanic reaction between them. By previous work results, the zeolitic substitution ratios of 5 wt.% and 15 wt.% in steel slag specimens (SZ5 and SZ15) gained the optimum compressive strength and carbonation degree, respectively, after 1 day hydration and then 2 h carbonation. This study investigated the effect of previous hydration time (1, 3, 7, 14, and 196 days) on carbonation degree and strength of SZ specimens after subsequent carbonation curing. Two zeolitic substitution ratios (5 wt.% and 15 wt.%) were selected and pure steel slag specimens were also prepared as controls. Compressive strength results revealed that the optimum hydration curing time was 1 day and the optimum zeolitic substitution ratio was 5 wt.%. The pozzolanic reaction happened in SZ specimens was divided into early and late pozzolanic reaction. In the late hydration, a new mineral, monocarboaluminate (AFmc) was produced in SZ15 specimens, modifying the carbonation degree and strength further. And the mechanism of pozzolanic reaction in early and late hydration in SZ specimens was explained by several microscopic test methods.

Steel Slag Characterisation—Benefit of Coupling Chemical, Mineralogical and Magnetic Techniques

Steel-making slag is largely used today in road construction and other applications, but significant volumes are landfilled and cannot be recycled for excessive contents in hazardous metals, such as chromium or vanadium. The long-term behaviour of this material is still little known, and the characterisation of large volume slag dumps remains an environmental challenge. In this study various analytical techniques are used to characterise Electric Arc Furnace (EAF) slag landfilled for several decades and exposed to chemical weathering and erosion. Coupling chemical, mineralogical and magnetic techniques helps to understand the relations between hazardous metals and mineral phases. A special interest is given to Fe-bearing minerals microstructure so as to link the magnetic properties of the material to its mineralogical composition. The studied slag presents high amounts of chromium (between 1 and 3 wt. %) and very high magnetic susceptibility values (near 60 × 10−6 m3/kg), explained by the presence of magnetite and a spinel solid solution. Some correlations are found between magnetic susceptibility and potentially hazardous metals, providing new perspectives for future environmental investigations.

Tailoring the FeO/SiO2 Ratio in Electric Arc Furnace Slags to Minimize the Leaching of Vanadium and Chromium

Based on recently published research on leaching control mechanisms in electric arc furnace (EAF) slags, it is assumed that a FeO/SiO2 ratio of around one leads to low leached V and Cr concentrations. This ratio influences the mineral phase composition of the slag toward higher amounts of spinel and a lower solubility of calcium silicate phases by suppressing the formation of magnesiowuestite and highly soluble calcium silicate phases. To evaluate this hypothesis, laboratory and scaled up tests in an EAF pilot plant were performed on slag samples characterized by elevated V and Cr leaching and a high FeO/SiO2 ratio. Prior to the melting experiments, the optimum FeO/SiO2 ratio was calculated via FactSageTM. In the melting experiments, the ratio was adjusted by adding quartz sand, which also decreased the basicity (CaO/SiO2) of the slag. As a reference, remelting experiments without quartz sand addition were conducted and additionally, the influence of the cooling rate of the slag was examined. The remelted (without quartz sand) and the remelted modified slags (with quartz sand) were analyzed chemically and mineralogically and the leaching behavior was investigated. The modification of the slags yielded a minimized release of V and Cr, supporting the hypothesis that the FeO/SiO2 ratio influences the mineralogy and the leaching behavior.

Atmospheric Carbon Capture Performance of Legacy Iron and Steel Waste

Legacy iron (Fe) and steel wastes have been identified as a significant source of silicate minerals, which can undergo carbonation reactions and thus sequester carbon dioxide (CO₂). In reactor experiments, i.e., at elevated temperatures, pressures, or CO₂ concentrations, these wastes have high silicate to carbonate conversion rates. However, what is less understood is whether a more "passive" approach to carbonation can work, i.e., whether a traditional slag emplacement method (heaped and then buried) promotes or hinders CO₂ sequestration. In this paper, the results of characterization of material retrieved from a first of its kind drilling program on a historical blast furnace slag heap at Consett, U.K., are reported. The mineralogy of the slag material was near uniform, consisting mainly of melilite group minerals with only minor amounts of carbonate minerals detected. Further analysis established that total carbon levels were on average only 0.4% while average calcium (Ca) levels exceeded 30%. It was calculated that only ∼3% of the CO₂ sequestration potential of the >30 Mt slag heap has been utilized. It is suggested that limited water and gas interaction and the mineralogy and particle size of the slag are the main factors that have hindered carbonation reactions in the slag heap.

Leaching behavior of aluminum, copper, iron and zinc from cement activated fly ash and slag stabilized soils

The use of industrial by-products such as fly ash and slag have become very prevalent in soil stabilization owing to its suitable physical and mechanical properties, and economical advantages. However, fly ash and slag have been identified as the potential source of toxic substances, and may pose environmental risk by leaching heavy and trace metals into soil, surface and groundwater. Toxicity characteristic leaching procedure (TCLP) tests were conducted to investigate the environmental hazards associated with the leaching of aluminum (Al), copper (Cu), iron (Fe) and zinc (Zn) from fly ashes, slag, type I/II cement and cement activated fly ash and slag stabilized soils. Sulfate (SO₄), dissolved inorganic carbon (DIC) and dissolved organic carbon (DOC) concentrations were also quantified to evaluate their influence on metal leaching. To understand the effect of pH on the leaching behavior, pH-dependent leach tests were conducted at the pH ranges of 2-14. Results indicated that an increase in fly ash or slag content may not necessarily increase the effluent metal concentrations. Al, Cu, Zn and DOC followed an amphoteric leaching pattern where concentrations increased in both acidic and basic conditions. In contrast, maximum DIC concentrations occurred at neutral or near neutral pH values. Fe and SO₄ showed cationic leaching behavior where concentrations decreased with an increase in effluent pH. Additionally, the leaching controlling mechanisms of the metals were identified by implementing geochemical modeling program Visual MINTEQ. The geochemical analyses indicated that the solubility of Al³⁺ and Fe³⁺ were controlled by precipitation/dissolution reactions of oxide/hydroxide minerals at all pH values. Leaching of Cu²⁺ was only solubility controlled at pH higher than 7, whereas Zn²⁺ leaching was solubility controlled in the pH range of 8-12.

The efficacy of pH-dependent leaching tests to provide a reasonable estimate of post-carbonation leaching

pH is a vital factor related to the heavy metal leaching from wastes. Over time, waste materials may be naturally weathered in the presence of water and carbon dioxide, reducing their pH and altering their mineralogy. Here we evaluate whether conducting a pH-dependent leaching test on wastes expected to carbonate sufficiently reflects the leaching of these wastes upon carbonation. Certain elements, such as Al and Sb, exhibited different leaching trends for carbonated and un-carbonated samples of two different waste materials. XRD results observed different mineral phases as a result of carbonation in incineration bottom ash. The application of pH-dependent leaching tests on fresh waste samples (at neutral pH values) were found to potentially mischaracterize leaching from carbonated waste samples at similar pH values for some elements and waste materials.

Comparison of long-term stability under natural ageing between cement solidified and chelator-stabilised MSWI fly ash

Cement-solidification and chelator-stabilisation of municipal solid waste incineration fly ash (MSWI-FA) are two main treatment techniques to immobilise heavy metals. Differences in the long-term stabilities of those two methods of heavy-metal immobilisation were explored to aid in determining the better MSWI-FA treatment. However, few comparative studies have been conducted on 6-year-old cement-solidified FA (Ce-6-FA) and chelator-stabilised FA (Ch-6-FA). In this study, we compared the physicochemical and heavy metal leaching characteristics of Ce-6-FA and Ch-6-FA. The chemical speciation of heavy metals was modelled using geochemical software to assess long-term stability. The results showed weaker long-term stability in Pb immobilisation under the chelating system. The leaching concentrations of target heavy metals, acetic acid leaching tests, acid neutralising capacity, and pH-dependent leaching results indicated that Ce-6-FA had higher long-term stability than Ch-6-FA. A column experiment indicated that the cumulative release rates of Pb in Ce-6-FA and Ch-6-FA were 2.49% and 4.72%, respectively. The phase-controlled leaching of Pb in Ce-6-FA mainly occurred through Pb₂(OH)₃Cl and chloropyromorphite (Pb₅(PO₄)₃Cl), whereas that in Ch-6-FA mainly occurred through Pb₅(PO₄)₃Cl. The decomposition of heavy metal chelates in Ch-6-FA and salt generation in this process led to the release of Pb via the inorganic complex.

Opportunities for Mineral Carbonation in Australia’s Mining Industry

Carbon capture, utilisation and storage (CCUS) via mineral carbonation is an effective method for long-term storage of carbon dioxide and combating climate change. Implemented at a large-scale, it provides a viable solution to harvesting and storing the modern crisis of GHGs emissions. To date, technological and economic barriers have inhibited broad-scale utilisation of mineral carbonation at industrial scales. This paper outlines the mineral carbonation process; discusses drivers and barriers of mineral carbonation deployment in Australian mining; and, finally, proposes a unique approach to commercially viable CCUS within the Australian mining industry by integrating mine waste management with mine site rehabilitation, and leveraging relationships with local coal-fired power station. This paper discusses using alkaline mine and coal-fired power station waste (fly ash, red mud, and ultramafic mine tailings, i.e., nickel, diamond, PGE (platinum group elements), and legacy asbestos mine tailings) as the feedstock for CCUS to produce environmentally benign materials, which can be used in mine reclamation. Geographical proximity of mining operations, mining waste storage facilities and coal-fired power stations in Australia are identified; and possible synergies between them are discussed. This paper demonstrates that large-scale alkaline waste production and mine site reclamation can become integrated to mechanise CCUS. Furthermore, financial liabilities associated with such waste management and site reclamation could overcome many of the current economic setbacks of retrofitting CCUS in the mining industry. An improved approach to commercially viable climate change mitigation strategies available to the mining industry is reviewed in this paper.

Behaviour and fate of vanadium during the aerobic neutralisation of hyperalkaline slag leachate

Vanadium is a toxic metal present in alkaline leachates produced during the weathering of steel slags. Slag leaching can therefore have deleterious effects on local watercourses due to metal toxicity, the effects of the high pH (9-12.5) and rapid carbonation (leading to smothering of benthic communities). We studied the fate and behaviour of V in slag leachate both through field observations of a heavily affected stream (Howden Burn, Consett UK) and in controlled laboratory experiments where slag leachates were neutralised by CO₂ ingassing from air. V was found to be removed from leachates downstream from the Howden Burn source contemporaneously with a fall in pH, Ca, Al and Fe concentrations. In the neutralisation experiments pH reduced from 12 → 8, and limited quantities of V were incorporated into precipitated CaCO₃. The presence of kaolinite clay (i.e. SiOH and AlOH surfaces) during neutralisation experiments had no measureable effect on V uptake in the alkaline to circumneutral pH range. XANES analysis showed that V was present in precipitates recovered from experiments as adsorbed or incorporated V^(V) indicating its likely presence in leachates as the vanadate oxyanion (HVO₄^2-). Nano-scale particles of 2-line ferrihydrite also formed in the neutralised leachates potentially providing an additional sorption surface for V uptake. Indeed, removal of V from leachates was significantly enhanced by the addition of goethite (i.e. FeOOH surfaces) to experiments. EXAFS analysis of recovered goethite samples showed HVO₄^2- was adsorbed by the formation of strong inner-sphere complexes, facilitating V removal from solution at pH < 10. Results show that carbonate formation leads to V removal from leachates during leachate neutralisation, and the presence of both naturally occurring and neoformed Fe (oxy)hydroxides provide a potent sink for V in slag leachates, preventing the spread of V in the environment.

Leaching behaviour of co-disposed steel making wastes: Effects of aeration on leachate chemistry and vanadium mobilisation

Steelmaking wastes stored in landfill, such as slag and spent refractory liners, are often enriched in toxic trace metals (including V). These may become mobile in highly alkaline leachate generated during weathering. Fresh steelmaking waste was characterised using XRD, XRF, and SEM-EDX. Batch leaching tests were performed under aerated, air-excluded and acidified conditions to determine the impact of atmospheric CO₂ and acid addition on leachate chemistry. Phases commonly associated with slag including dicalcium silicate, dicalcium aluminoferrite, a wüstite-like solid solution and free lime were identified, as well as a second group of phases including periclase, corundum and graphite which are representative of refractory liners. During air-excluded leaching, dissolution of free lime and dicalcium silicate results in a high pH, high Ca leachate in which the V concentration is low due to the constraint imposed by Ca₃(VO₄)₂ solubility limits. Under aerated conditions, carbonation lowers the leachate pH and provides a sink for aqueous Ca, allowing higher concentrations of V to accumulate. Below pH 10, leachate is dominated by periclase dissolution and secondary phases including monohydrocalcite and dolomite are precipitated. Storage of waste under saturated conditions that exclude atmospheric CO₂ would therefore provide the optimal environment to minimise V leaching during weathering.

Hydration of dicalcium silicate and diffusion through neo-formed calcium-silicate-hydrates at weathered surfaces control the long-term leaching behaviour of basic oxygen furnace (BOF) steelmaking slag

Alkalinity generation and toxic trace metal (such as vanadium) leaching from basic oxygen furnace (BOF) steel slag particles must be properly understood and managed by pre-conditioning if beneficial reuse of slag is to be maximised. Water leaching under aerated conditions was investigated using fresh BOF slag at three different particle sizes (0.5-1.0, 2-5 and 10 × 10 × 20 mm blocks) and a 6-month pre-weathered block. There were several distinct leaching stages observed over time associated with different phases controlling the solution chemistry: (1) free-lime (CaO) dissolution (days 0-2); (2) dicalcium silicate (Ca₂SiO₄) dissolution (days 2-14) and (3) Ca-Si-H and CaCO₃ formation and subsequent dissolution (days 14-73). Experiments with the smallest size fraction resulted in the highest Ca, Si and V concentrations, highlighting the role of surface area in controlling initial leaching. After ~2 weeks, the solution Ca/Si ratio (0.7-0.9) evolved to equal those found within a Ca-Si-H phase that replaced dicalcium silicate and free-lime phases in a 30- to 150-μm altered surface region. V release was a two-stage process; initially, V was released by dicalcium silicate dissolution, but V also isomorphically substituted for Si into the neo-formed Ca-Si-H in the alteration zone. Therefore, on longer timescales, the release of V to solution was primarily controlled by considerably slower Ca-Si-H dissolution rates, which decreased the rate of V release by an order of magnitude. Overall, the results indicate that the BOF slag leaching mechanism evolves from a situation initially dominated by rapid hydration and dissolution of primary dicalcium silicate/free-lime phases, to a slow diffusion limited process controlled by the solubility of secondary Ca-Si-H and CaCO₃ phases that replace and cover more reactive primary slag phases at particle surfaces.

Dual slag filters for enhanced phosphorus removal from domestic waste water: performance and mechanisms

The phosphorus (P) removal of five combinations of dual filters consisting of blast furnace slag (BFS), argon oxygen decarburisation slag (AOD) and electric arc furnace slag (EAF) was evaluated in column experiments with domestic waste water. The columns were fed with waste water for 24 days. The column with only EAF had the best P removal performance (above 93% throughout the experiment). The speciation of the bound P was evaluated by P K-edge X-ray absorption near-edge structure (XANES) spectroscopy. In all five columns, the main P species of the slag packed in the outlet chamber was amorphous calcium phosphate (ACP). In samples from the inlet chambers, the contributions from crystalline Ca phosphates, P adsorbed on gibbsite and P adsorbed on ferrihydrite were usually much greater, suggesting a shift of P removal mechanism as the waste water travelled from the inlet to the outlet. The results provide strong evidence that P was predominantly removed by the slags through the formation of ACP. However, as the pH decreased with time due to the progressively lower dissolution of alkaline silicate minerals from the slag, the ACP was rendered unstable and hence redissolved, changing the P speciation. It is suggested that this process strongly affected the lifespan of the slag filters. Of the slags examined, EAF slag had the best P removal characteristics and BFS the worst, which probably reflected different dissolution rates of alkaline silicates in the slags.

A risk-based approach for assessing the recycling potential of an alkaline waste material as road sub-base filler material

In this work we present an integrated risk-based approach that can be used to evaluate the recycling potential of an alkaline waste material such as incineration bottom ash (BA) as unbound material for road sub-base construction. This approach, which is aimed at assessing potential risks to the groundwater resource (in terms of drinking water quality) and human health associated to the leaching of contaminants from the BA, couples the results of leaching tests for the estimation of source concentrations with the fate and transport models usually adopted in risk assessment procedures. The effects of weathering and of the type of leaching test employed to evaluate eluate concentrations were assessed by carrying out different simulations using the results of laboratory leaching tests. Specifically, pH-dependence and column percolation leaching tests were performed on freshly collected and 1-year naturally weathered BA samples produced from a grate-fired incineration plant treating Refuse Derived Fuel (RDF). To evaluate a broad span of possible scenario conditions, a Monte Carlo analysis was performed running 5000 simulations, randomly varying the input parameters within the ranges expected in the field. In nearly all the simulated conditions, the concentrations of contaminants in the groundwater for the specific type of BA tested in this work were well below EU and WHO drinking water quality criteria. Nevertheless, some caution should be paid in the case of the establishment of acidic conditions in the field since in this case the concentration of some elements (i.e. Al, Pb and Zn) is expected to exceed threshold values. In terms of risks to human health, for the considered utilization scenario the probability of exceeding the acceptable reference dose for water ingestion was usually less than 1% (except for Cr and Pb for which the probability was lower than 3.5% and 7%, respectively).

Experimental study of dissolution of minerals and CO2 sequestration in steel slag

This study strives to achieve a substantial amount of steel slag carbonation without using any harmful chemicals. For this purpose, experiments were performed in an aqueous medium, in a semi-batch reactor, to investigate the effect of varying reaction conditions during the steel slag CO₂ sequestration process. Further, studying the effect of dissolution on carbonation reactions and the mineralogical changes that subsequently occur within the slag helps provide insight into the parameters that ultimately have an impact on the carbonation rate as well the magnitude of the impact.

Effects of epoxy resin on ground-granulated blast furnace slag stabilized marine sediments

In this study, an environmentally friendly epoxy resin is mixed with ground-granulated blast furnace slag (GGBS) for use as a stabilizer to enhance mechanical performance and leaching resistance properties of marine sediments.

Mineralogical determination and geo-chemical modeling of chromium release from AOD slag: Distribution and leachability aspects

AOD (argon oxygen decarburization) slag, which is the by-product of the stainless steel refining process, is a recyclable slag because of its high content of calcium and silicon. The leaching toxicity cannot be ignored in the recycling process because the slag contains a certain amount of Cr. In this study, the mineral analysis, batch leaching tests and thermodynamic and kinetic modeling by PHREEQC combined with FactSage software were performed to explore the influence of the dissolution of primary minerals and the precipitation of secondary minerals on the elution of Cr from AOD slag. The results indicated that the main minerals in the original AOD slag are larnite, merwinite, pyroxene and periclase. Cr was dispersed in the mineral phases mentioned above. The simulation of Cr leaching controlled by Cr(III)-hydroxide corresponded better to the batch leaching tests, while the Cr leaching controlled by chromite or double control was underestimated. Increasing the L/S ratio enhances the pH of the leachate and restrains the elution of Cr from the AOD slag.

Study of the leaching behaviour of ladle slags by means of leaching tests combined with geochemical modelling and mineralogical investigations

In this study, the leachability of freshly produced ladle slag derived from both austenitic and ferritic stainless steel production, and from electrical and structural steel production, was investigated, in order to determine whether variations in the chemical and mineralogical composition of these slags affect their leaching behaviour. The effect of the method used for slag cooling was also studied. The results obtained by using the single batch test were combined with those obtained by means of more sophisticated characterisation leaching tests, which, in combination with geochemical speciation modelling, helped to better identify the release mechanisms and phases that control the release of individual elements. It was found that, although variations in the chemical composition of the slag can affect the slag's minerology, neither such variations, nor the choice of the slag cooling treatment, have a significant effect on the leachability of individual elements, since the leaching is governed by surface phenomena. In fact, the mineral transformations on the slag surface, rather than the bulk mineral composition, dictate the release of these elements from the ladle slag. The solubility-controlling phases were predicted by multi-element modelling, and verified to the extent made possible by the performed mineralogical investigations.

Impact of aging on leaching characteristics of recycled concrete aggregate

The focus of this study was to evaluate the effects of stockpiling (aging) on leaching of elements in recycled concrete aggregate (RCA) that may contribute to tufaceous constituent formation. Speciation and leaching controlling mechanisms of these elements were identified via geochemical modeling. The effects of stockpiling were simulated by comparing freshly produced RCA with RCA aged as part of this study for 1 year both in the laboratory and in the field. Leachate samples were generated following batch water leach test (WLT) and US Geological Survey leach test (USGSLT) methods. USGSLTs were conducted both on the laboratory and field samples while WLT was only conducted on laboratory samples. During the laboratory aging, it is observed that the carbonate content of RCA, measured as calcite equivalent, increased 20 % (i.e., from ∼100 to 120 mg/g) within a year time frame. The leachate extracted from RCA showed minor changes in pH and more significant decreases in electrical conductivity (i.e., ∼300 to 100 μS/cm). A comparison between laboratory and field samples revealed that the RCA aged much slower in the field than in the laboratory within a year. Comparisons between two leach extraction methods on the laboratory conditions showed that the total leached concentrations (TLCs) of most of the constituents from USGSLT were appreciably lower than the ones measured via WLT method. The results of geochemical modeling analyses showed that Al, Si, Fe, Ca, Mg, and Cu exist in their oxidized forms as Al³⁺, Fe³⁺, Si⁴⁺, Ca²⁺, Mg²⁺, and Cu²⁺ and results revealed that these elements are primarily controlled by the solubility of gibbsite, hematite, silica gel, calcite, magnesite, and tenorite solid phases, respectively. One of the significant findings of the study was to identify the changes in leaching behavior of Ca, Si, Mg, Al, Fe, and Cu due to carbonation.

CO2 sequestration through aqueous accelerated carbonation of BOF slag: A factorial study of parameters effects

A factorial study was conducted on basic oxygen furnace slag from a steelmaking industry with the aim of systematically identifying the individual and joint effects of the operating parameters (total pressure, CO2 concentration in the gas phase and temperature) on the CO2 sequestration yield of a direct aqueous carbonation process. Each operating parameter was varied over a range of three levels according to a 3(3) factorial design, resulting in 27 carbonation experiments. The carbonation performance and the changes in particle size and mineralogical characteristics of the slag were investigated in detail. The analysis of the experimental results indicated large effects of the operating factors on CO2 uptake, which was observed to span the range 6.7-53.6 g CO2/100 g slag. The best carbonation performance achieved was particularly significant compared to previous studies, even more considering the relative mild operating conditions adopted (P = 5 bar, C = 40% vol. CO2, T = 50 °C, t = 4 h). The analysis of the solid and liquid phases at the end of the carbonation treatment evidenced significant changes in the physical, chemical and mineralogical composition of the material. In particular, evidence was gained of other elements (Mg, Fe, Mn, Zn) in addition to Ca being intensively involved in the carbonation reactions, with a variety of carbonate phases being produced in addition to calcium carbonate forms.

Leaching modelling of slurry-phase carbonated steel slag

In the present work the influence of accelerated mineral carbonation on the leaching behaviour of basic oxygen furnace steel slag was investigated. The environmental behaviour of the material as evaluated through the release of major elements and toxic metals under varying pH conditions was the main focus of the study. Geochemical modelling of the eluates was used to derive a theoretical description of the underlying leaching phenomena for the carbonated material as compared to the original slag. Among the investigated elements, Ca and Si were most appreciably affected by carbonation. A very clear effect of carbonation on leaching was observed for silicate phases, and lower-Ca/Si-ratio minerals were found to control leaching in carbonated slag eluates as compared to the corresponding untreated slag sample as a result of Ca depletion from the residual slag particles. Clear evidence was also gained of solubility control for Ca, Mg and Mn by a number of carbonate minerals, indicating a significant involvement of the original slag constituents in the carbonation process. The release of toxic metals (Zn, V, Cr, Mo) was found to be variously affected by carbonation, owing to different mechanisms including pH changes, dissolution/precipitation of carbonates as well as sorption onto reactive mineral surfaces. The leaching test results were used to derive further considerations on the expected metal release levels on the basis of specific assumptions on the relevant pH domains for the untreated and carbonated slag.