Energy Consumption and Net CO2 Sequestration of Aqueous Mineral Carbonation

A Review on the Carbonation of Steel Slag: Properties, Mechanism, and Application

Steel slag is a by-product of the steel industry and usually contains a high amount of f-CaO and f-MgO, which will result in serious soundness problems once used as a binding material and/or aggregates. To relieve this negative effect, carbonation treatment was believed to be one of the available and reliable methods. By carbonation treatment of steel slag, the phases of f-CaO and f-MgO can be effectively transformed into CaCO3 and MgCO3, respectively. This will not only reduce the expansive risk of steel slag to improve the utilization of steel slag further but also capture and store CO2 due to the mineralization process to reduce carbon emissions. In this study, based on the physical and chemical properties of steel slag, the carbonation mechanism, factors affecting the carbonation process, and the application of carbonated steel slag were reviewed. Eventually, the research challenge was also discussed.

Aqueous carbonation of peridotites for carbon utilisation: a critical review

Peridotite and serpentinites can be used to sequester CO2 emissions through mineral carbonation. Olivine dissolution rate is directly proportional with temperature, presence of CO2, surface area of mineral particles and presence of ligands and is inversely proportional to pH. Olivine dissolution is better under air flow and increases seven times when rock-inhibiting fungus (Knufia petricola) is used. Olivine dissolution retards as silica layers form during reaction. Sonication, acoustic and concurrent grinding using various grinding medias have been used to artificially break these silica layers and achieve high magnesium extraction. Wet grinding using 50 wt.% ethanol enhanced CO2 uptake of dunite 6.9 times and CO2 uptake of harzburgite by 4.5 times. The best economical process is single-stage concurrent grinding at 130 bar, 185 °C, 15 wt.% solids and 50 wt.% grinding media (zirconia) using 0.64 M NaHCO3. Ratio of grinding media to feed should not be less than 3:1. Yield increases with temperature, pressure, time of reaction, pH and rpm and using additives and grinding media and reducing particle size. This review aims to investigate the progress from 1970s to 2021 on aqueous mineral carbonation of olivine and its naturally available rocks (harzburgite and dunite). This paper comprehensively reviews all aspects of olivine carbonation including olivine dissolution kinetics, effects of grinding and concurrent grinding, thermal activation of olivine feedstock (dunites and harzburgites) as well as chemistry of olivine mineral carbonation. The effects of different reaction parameters on the carbonation yield, role of mineral carbonation accelerators and costs of mineral carbonation process are discussed.

An Industrial Demonstration Study on CO2 Mineralization Curing for Concrete

A 10,000 ton-CO₂/y mineralization curing (CMC) process was demonstrated in Jiaozuo city, China by retrofitting a traditional autoclaved curing plant. An industrial concrete formula with synergistic effects of aggregate gradation, early hydration, and alkali excitation was developed using local solid wastes resources. Approximately 90% of the raw materials, including fly ash, furnace blaster slag, steel slag, and carbide slag, came from coal-based industries. An extraordinary phenomenon of high-temperature accumulation from room temperature to 140°C was first observed in an industrial scale because of the rapid and strong exothermic carbonation reaction. A step pressure-equalizing procedure was developed to achieve a rapid carbonation rate, a high CO₂ conversion ratio of >98%, and efficient carbonation exotherm recycling. The global warming potential life cycle analysis revealed that compared with autoclaved curing, CMC showed significantly decreased the emission of 182 kg CO₂-Eq/m³-product, with direct CO₂ sequestration accounting for ∼65% of the reduction.

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A full-scale 10,000 ton/y CO₂ mineralization curing project

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The CO₂ conversion rate is >98% with step pressure-equalizing process

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High-temperature accumulation in industrial CMC process is first reported

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The economic benefit of CMC technology is approximately 35 USD/t-CO₂

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.

A review on ex situ mineral carbonation

The increased CO₂ quantities in the environment have led to many harmful effects. Therefore, it is very important to decrease the CO₂ levels in the environment. CO₂ capture along with safe and permanent storage using mineral CO₂ sequestration method can play an important role to reduce carbon emissions into the environment. Mineral sequestration is a stable storage method that provides long-term storage and an appropriate substitute for the more popular geological storage method. The process is most suited for places where there is a lack of underground cavities for underground geological storage. Minerals rich in Ca and Mg are used predominantly in carbonation reactions. In addition, those alkaline wastes that are rich in Mg and Ca such as cement waste, steel slag and many process ashes can also be employed in CO₂ sequestration. Mineral carbonation could be used for the sequestration of billions of tonnes of CO₂ every year. However, various drawbacks related to mineral carbonation still need to be addressed, such as resolving the slow rate of reactions, necessity of large amounts of feedstock, decreasing the high overall cost of CO₂ sequestration and reducing the huge energy requirements to accelerate the carbonation reaction. This study explores a number of carbonation methods, parameters that control the process and future potential applications of carbonated products.

A review on steel slag valorisation via mineral carbonation

Alkaline slags, a waste product of steel industry, provide an opportunity for carbon sequestration and creation of value at the same time. This requires an understanding of the mechanisms of leaching and carbonation.

Surface Properties of Cement Kiln Dust with Water Treatment for Selective Extraction of Calcium and Potassium

Water and hydrochloric acid were employed as solvents to extract K and Ca from K- and Ca- rich cement kiln dust (CKD). It has been shown that hydrochloric acid effectively extracts Ca and K from CKD with efficiencies of more than 85 and 99%, respectively. On the other hand, water, as a solvent, selectively extracts K and Cl with an efficiency of 99%. The selectivity of Ca extracted using hydrochloric acid from treated CKD increased from 37 to 87%. Scanning electron microscopy and energy-dispersive X-ray spectroscopy revealed that K and Cl were dominant on the surface of fresh CKD. After extraction with water, the portion of Ca increased more than twice, and Ca species became dominant. Thus, extraction of CKD with water is capable of selectively removing KCl, leaving Ca on the surface; hence, treated Ca-rich CKD can serve as a suitable raw material for mineral carbonation.

Proposed Methodology to Evaluate CO2 Capture Using Construction and Demolition Waste

Since the Industrial Revolution, levels of CO2 in the atmosphere have been constantly growing, producing an increase in the average global temperature. One of the options for Carbon Capture and Storage is mineral carbonation. The results of this process of fixing are the safest in the long term, but the main obstacle for mineral carbonation is the ability to do it economically in terms of both money and energy cost. The present study outlines a methodological sequence to evaluate the possibility for the carbonation of ceramic construction waste (brick, concrete, tiles) under surface conditions for a short period of time. The proposed methodology includes a pre-selection of samples using the characterization of chemical and mineralogical conditions and in situ carbonation. The second part of the methodology is the carbonation tests in samples selected at 10 and 1 bar of pressure. The relative humidity during the reaction was 20 wt %, and the reaction time ranged from 24 h to 30 days. To show the effectiveness of the proposed methodology, Ca-rich bricks were used, which are rich in silicates of calcium or magnesium. The results of this study showed that calcite formation is associated with the partial destruction of Ca silicates, and that carbonation was proportional to reaction time. The calculated capture efficiency was proportional to the reaction time, whereas carbonation did not seem to significantly depend on particle size in the studied conditions. The studies obtained at a low pressure for the total sample were very similar to those obtained for finer fractions at 10 bars. Presented results highlight the utility of the proposed methodology.

Carbon Mineralization by Reaction with Steel-Making Waste: A Review

Carbon capture and sequestration (CCS) is taking the lead as a means for mitigating climate change. It is considered a crucial bridging technology, enabling carbon dioxide (CO2) emissions from fossil fuels to be reduced while the energy transition to renewable sources is taking place. CCS includes a portfolio of technologies that can possibly capture vast amounts of CO2 per year. Mineral carbonation is evolving as a possible candidate to sequester CO2 from medium-sized emissions point sources. It is the only recognized form of permanent CO2 storage with no concerns regarding CO2 leakage. It is based on the principles of natural rock weathering, where the CO2 dissolved in rainwater reacts with alkaline rocks to form carbonate minerals. The active alkaline elements (Ca/Mg) are the fundamental reactants for mineral carbonation reaction. Although the reaction is thermodynamically favored, it takes place over a large time scale. The challenge of mineral carbonation is to offset this limitation by accelerating the carbonation reaction with minimal energy and feedstock consumption. Calcium and magnesium silicates are generally selected for carbonation due to their abundance in nature. Industrial waste residues emerge as an alternative source of carbonation minerals that have higher reactivity than natural minerals; they are also inexpensive and readily available in proximity to CO2 emitters. In addition, the environmental stability of the industrial waste is often enhanced as they undergo carbonation. Recently, direct mineral carbonation has been investigated significantly due to its applicability to CO2 capture and storage. This review outlines the main research work carried out over the last few years on direct mineral carbonation process utilizing steel-making waste, with emphasis on recent research achievements and potentials for future research.

Factors Influencing CO2 and Energy Penalties of CO2 Mineralization Processes

Carbon mineralization is one of the carbon capture utilization, and storage (CCUS) technologies that can be used to capture large quantities of CO₂ and convert it into stable carbonate products that can be stored easily. Several CO₂ mineralization processes have been proposed; however, there are no commercial-scale projects because there are still significant issues that need to be improved before commercialization can take place. In this work, we evaluate the CO₂ and energy penalties related to the most well-known types of mineralization processes developed to date, in which the mineralization reaction takes place directly under aqueous conditions, high pressures and temperatures, and compared these with newer T-P swing processes and ball-mill reactor processes, which are under development. The data used in the evaluation are taken from published literature. By comparing the three processes, we identify important variables that contribute to high CO₂ and energy penalties so that future research can focus on optimization of these variables. It is observed that slurry concentration (heating) and particle size (grinding) are critical factors, with mineral calcination and operating pressure constituting other important factors.

Carbon dioxide mineralization process design and evaluation: concepts, case studies, and considerations

Numerous carbon dioxide mineralization (CM) processes have been proposed to overcome the slow rate of natural weathering of silicate minerals. Ten of these proposals are mentioned in this article. The proposals are described in terms of the four major areas relating to CM process design: pre-treatment, purification, carbonation, and reagent recycling operations. Any known specifics based on probable or representative operating and reaction conditions are listed, and basic analysis of the strengths and shortcomings associated with the individual process designs are given in this article. The processes typically employ physical or chemical pseudo-catalytic methods to enhance the rate of carbon dioxide mineralization; however, both methods have its own associated advantages and problems. To examine the feasibility of a CM process, three key aspects should be included in the evaluation criteria: energy use, operational considerations as well as product value and economics. Recommendations regarding the optimal level of emphasis and implementation of measures to control these aspects are given, and these will depend very much on the desired process objectives. Ultimately, a mix-and-match approach to process design might be required to provide viable and economic proposals for CM processes.

Direct mineral carbonation of steelmaking slag for CO2 sequestration at room temperature

Rapid increase of CO2 concentration in the atmosphere has forced the international community towards adopting actions to restrain from the impacts of climate change. Moreover, in India, the dependence on fossil fuels is projected to increase in the future, implying the necessity of capturing CO2 in a safe manner. Alkaline solid wastes can be utilized for CO2 sequestration by which its disposal issues in the country could also be met. The present work focuses to study direct mineral carbonation of steelmaking slag (SS) at room temperature and low-pressure conditions (<10 bar). Direct mineral carbonation of SS was carried out in a batch reactor with pure CO2 gas. The process parameters that may influence the carbonation of SS, namely, CO2 gas pressure, liquid to solid ratio (L/S) and reaction time were also studied. The results showed that maximum sequestration of SS was attained in the aqueous route with a capacity of 82 g of CO2/kg (6 bar, L/S ratio of 10 and 3 h). In the gas-solid route, maximum sequestration capacity of about 11.1 g of CO2/kg of SS (3 bar and 3 h) was achieved indicating that aqueous route is the better one under the conditions studied. These findings demonstrate that SS is a promising resource and this approach could be further developed and used for CO2 sequestration in the country. The carbonation process was evidenced using FT-IR, XRD, SEM and TG analysis.

Optimized carbonation of magnesium silicate mineral for CO2 storage

The global ambition of reducing the carbon dioxide emission makes sequestration reactions attractive as an option of storing CO2. One promising environmentally benign technology is based on forming thermodynamically stable carbonated minerals, with the drawback that these reactions usually have low conversion rates. In this work, the carbonation reaction of Mg rich olivine, Mg2SiO4, under supercritical conditions has been studied. The reaction produces MgCO3 at elevated temperature and pressure, with the addition of NaHCO3 and NaCl to improve the reaction rates. A sequestration rate of 70% was achieved within 2 h, using olivine particles of sub-10 μm, whereas 100% conversion was achieved in 4 h. This is one of the fastest complete conversions for this reaction reported to date. The CO2 sequestration rate is found to be highly dependent on the applied temperature and pressure, as well as the addition of NaHCO3. In contrast, adding NaCl was found to have limited effect on the reaction rate. The roles of NaHCO3 and NaCl as catalysts are discussed and especially how their effect changes with increased olivine particle size. The products have been characterized by Rietveld refinement of powder X-ray diffraction, scanning electron microscopy (SEM), and energy-dispersive X-ray (EDX) spectroscopy revealing the formation of amorphous silica and micrometer-sized magnesium carbonate crystals.

Reaction mechanism for the aqueous-phase mineral carbonation of heat-activated serpentine at low temperatures and pressures in flue gas conditions

Mineral carbonation is known as one of the safest ways to sequester CO2. Nevertheless, the slow kinetics and low carbonation rates constitute a major barrier for any possible industrial application. To date, no studies have focused on reacting serpentinite with a relatively low partial pressure of CO2 (pCO2) close to flue gas conditions. In this work, finely ground and heat-treated serpentinite [Mg3Si2O5(OH)4] extracted from mining residues was reacted with a 18.2 vol % CO2 gas stream at moderate global pressures to investigate the effect on CO2 solubility and Mg leaching. Serpentinite dissolution rates were also measured to define the rate-limiting step. Successive batches of gas were contacted with the same serpentinite to identify surface-limiting factors using scanning electron microscopy (SEM) analysis. Investigation of the serpentinite carbonation reaction mechanisms under conditions close to a direct flue gas treatment showed that increased dissolution rates could be achieved relative to prior work, with an average Mg dissolution rate of 3.55 × 10(-11) mol cm(-2) s(-1). This study provides another perspective of the feasibility of applying a mineral carbonation process to reduce industrial greenhouse gas (GHG) emissions from large emission sources.

A review of mineral carbonation technologies to sequester CO2

Mineral carbonation is a promising and at the same time challenging option for the sequestration of anthropogenic CO₂.

Direct gas-solid carbonation kinetics of steel slag and the contribution to in situ sequestration of flue gas CO(2) in steel-making plants

Direct gas-solid carbonation of steel slag under various operational conditions was investigated to determine the sequestration of the flue gas CO2 . X-ray diffraction analysis of steel slag revealed the existence of portlandite, which provided a maximum theoretical CO2 sequestration potential of 159.4 kg CO 2 tslag (-1) as calculated by the reference intensity ratio method. The carbonation reaction occurred through a fast kinetically controlled stage with an activation energy of 21.29 kJ mol(-1) , followed by 10(3) orders of magnitude slower diffusion-controlled stage with an activation energy of 49.54 kJ mol(-1) , which could be represented by a first-order reaction kinetic equation and the Ginstling equation, respectively. Temperature, CO2 concentration, and the presence of SO2 impacted on the carbonation conversion of steel slag through their direct and definite influence on the rate constants. Temperature was the most important factor influencing the direct gas-solid carbonation of steel slag in terms of both the carbonation conversion and reaction rate. CO2 concentration had a definite influence on the carbonation rate during the kinetically controlled stage, and the presence of SO2 at typical flue gas concentrations enhanced the direct gas-solid carbonation of steel slag. Carbonation conversions between 49.5 % and 55.5 % were achieved in a typical flue gas at 600 °C, with the maximum CO2 sequestration amount generating 88.5 kg CO 2 tslag (-1) . Direct gas-solid carbonation of steel slag showed a rapid CO2 sequestration rate, high CO2 sequestration amounts, low raw-material costs, and a large potential for waste heat utilization, which is promising for in situ carbon capture and sequestration in the steel industry.

Systematic approach to determination of maximum achievable capture capacity via leaching and carbonation processes for alkaline steelmaking wastes in a rotating packed bed

Accelerated carbonation of basic oxygen furnace slag (BOFS) coupled with cold-rolling wastewater (CRW) was performed in a rotating packed bed (RPB) as a promising process for both CO2 fixation and wastewater treatment. The maximum achievable capture capacity (MACC) via leaching and carbonation processes for BOFS in an RPB was systematically determined throughout this study. The leaching behavior of various metal ions from the BOFS into the CRW was investigated by a kinetic model. In addition, quantitative X-ray diffraction (QXRD) using the Rietveld method was carried out to determine the process chemistry of carbonation of BOFS with CRW in an RPB. According to the QXRD results, the major mineral phases reacting with CO2 in BOFS were Ca(OH)2, Ca2(HSiO4)(OH), CaSiO3, and Ca2Fe1.04Al0.986O5. Meanwhile, the carbonation product was identified as calcite according to the observations of SEM, XEDS, and mappings. Furthermore, the MACC of the lab-scale RPB process was determined by balancing the carbonation conversion and energy consumption. In that case, the overall energy consumption, including grinding, pumping, stirring, and rotating processes, was estimated to be 707 kWh/t-CO2. It was thus concluded that CO2 capture by accelerated carbonation of BOFS could be effectively and efficiently performed by coutilizing with CRW in an RPB.

CO2 mitigation potential of mineral carbonation with industrial alkalinity sources in the United States

The availability of industrial alkalinity sources is investigated to determine their potential for the simultaneous capture and sequestration of CO2 from point-source emissions in the United States. Industrial alkalinity sources investigated include fly ash, cement kiln dust, and iron and steel slag. Their feasibility for mineral carbonation is determined by their relative abundance for CO2 reactivity and their proximity to point-source CO2 emissions. In addition, the available aggregate markets are investigated as possible sinks for mineral carbonation products. We show that in the U.S., industrial alkaline byproducts have the potential to mitigate approximately 7.6 Mt CO2/yr, of which 7.0 Mt CO2/yr are CO2 captured through mineral carbonation and 0.6 Mt CO2/yr are CO2 emissions avoided through reuse as synthetic aggregate (replacing sand and gravel). The emission reductions represent a small share (i.e., 0.1%) of total U.S. CO2 emissions; however, industrial byproducts may represent comparatively low-cost methods for the advancement of mineral carbonation technologies, which may be extended to more abundant yet expensive natural alkalinity sources.

Mineralogical characterization of municipal solid waste incineration bottom ash with an emphasis on heavy metal-bearing phases

Municipal solid waste incineration (MSWI) bottom ash contains a considerable amount of heavy metals. The occurrence and uneven distribution of these heavy metals in bottom ash can increase the complexity of such residues in terms of long-term behavior upon landfilling or recycling. Bottom ashes sampled from three stoker-type incinerators in Japan were analyzed in this paper. This study presents detailed information on the mineralogical characterization of bottom ash constituents and the weathering behavior of these constituents by means of optical microscopy and scanning electron microscopy. It was revealed that bottom ash mainly consists of assorted silicate-based glass phases (48-54 wt% of ash) and mineral phases including melilites, pseudowollastonite, spinels, and metallic inclusions (Fe-P, Fe-S, Fe-Cu, Cu-Sn, Cu-Zn, Cu-S, and Cu-Pb dominated phases), as melt products formed during the incineration process. The compounds embedded in the glass matrix, e.g. spinels and metallic inclusions, played the most important role in concentration of heavy metals (Pb, Zn, Cu, Cr, Mn, Ni, etc.). Other phases such as refractory minerals and ceramics, frequently found in ash, were of less significance in terms of their influence on the involvement of heavy metals. Analysis of lab-scale artificially weathered and 10-year landfilled bottom ash samples revealed that secondary mineralization/alteration of the bottom ash constituents principally carbonation and glass evolution substantially decreased the potential risk of the heavy metals to the surrounding environment.

Reactivity of alkaline lignite fly ashes towards CO2 in water

The reaction kinetics between alkaline lignite fly ashes and CO2 (pCO2 = 0.01--0.03 MPa)were studied in a laboratory CO2 flow-through reactor at 25--75 degrees C. The reaction is characterized by three phases that can be separated according to the predominating buffering systems and the rates of CO2 uptake. Phase I (pH > 12, < 30 min) is characterized by the dissolution of lime, the onset of calcite precipitation and a maximum uptake, the rate of which seems to be limited by dissolution of CO2. Phase II (pH < 10.5, 10--60 min) is dominated by the carbonation reaction. CO2 uptake in phase III (pH < 8.3) is controlled by the dissolution of periclase (MgO) leading to the formation of dissolved magnesium-bicarbonate. Phase I could be significantly extended by increasing the solid-liquid ratios and temperature, respectively. At 75 degrees C the rate of calcite precipitation was doubled leading to the neutralization of approximately 0.23 kg CO2 per kg fly ash within 4.5 h, which corresponds to nearly 90% of the total acid neutralizing capacity.