Clinkering-free cementation by fly ash carbonation

Investigation of Carbonation Kinetics in Carbonated Cementitious Materials by Reactive Molecular Dynamics Simulations

Calcium carbonate (CaCO3) precipitation plays a significant role during the carbon capture process; however, the mechanism is still only partially understood. Understanding the atomic-level carbonation mechanism of cementitious materials can promote the mineralization capture, immobilization, and utilization of carbon dioxide, as well as the improvement of carbonated cementitious materials' performance. Therefore, based on molecular dynamics simulations, this paper investigates the effect of Si/Al concentrations in cementitious materials on carbonation kinetics. We first verify the force field used in this paper. Then, we analyze the network connectivity evolution, the number and size of the carbonate cluster during gelation, the polymerization rate, and the activation energy. Finally, in order to reveal the reasons that caused the evolution of polymerization rate and activation energy, we analyze the local stress and charge of atoms. Results show that the Ca-Oc bond number and carbonate cluster size increase with the decrease of the Si/Al concentration and the increase of temperature, leading to the higher amorphous calcium carbonate gel polymerization degree. The local stress of each atom in the system is the driving force of the gelation transition. The presence of Si and Al components increases the atom's local stress and average charge, thus causing the increase of the energy barrier of CaCO3 polymerization and the activation energy of carbonation.

Carbonation and Leaching Behaviors of Cement-Free Monoliths Based on High-Sulfur Fly Ashes with the Incorporation of Amorphous Calcium Aluminate

The high sulfate content in various alkaline wastes, including those from fossil fuel and biomass combustion, and other industrial processes, necessitates careful management when used in cementitious systems to prevent potential deterioration of construction materials and environmental safety concerns. This study explores the under-researched area of high-sulfur fly ash (HSFA) utilization in the production of cement-free monoliths through accelerated carbonation and further examines the effect of niobium slag (NS)-a calcium aluminate-containing slag-as an additive on the strength development and the mobility of SO42-. The methodology involves mineralogical and microstructural analyses of monoliths before and after carbonation, accounting for the effects of accelerated carbonation treatment and NS addition. The findings suggest that accelerated carbonation significantly improves the initial compressive strength of the HSFA monoliths and generally immobilizes heavy metals, while the effect on sulfate immobilization can vary depending on the ash composition. Moreover, the addition of NS further enhances strength without substantially hindering CO2 uptake, while reducing the leaching values, particularly of sulfates and heavy metals. These findings suggest that it is feasible to use calcium aluminate-containing NS in HSFA-based carbonated monoliths to immobilize sulfates without compromising the strength development derived from carbonation. This research contributes to the understanding of how accelerated carbonation and NS addition can enhance the performance of HSFA-based materials, providing valuable insights for the development of sustainable construction materials.

The Influence of Mg-Impurities in Raw Materials on the Synthesis of Rankinite Clinker and the Strength of Mortar Hardening in CO2 Environment

The idea of this work is to reduce the negative effect of ordinary Portland cement (OPC) manufacture on the environment by decreasing clinker production temperature and developing an alternative rankinite binder that hardens in the CO₂ atmosphere. The common OPC raw materials, limestone and mica clay, if they contain a higher MgO content, have been found to be unsuitable for the synthesis of CO₂-curing low-lime binders. X-ray diffraction analysis (ex-situ and in-situ in the temperature range of 25-1150 °C) showed that akermanite Ca₂Mg(Si₂O₇) begins to form at a temperature of 900 °C. According to Rietveld refinement, the interlayer distances of the resulting curve are more accurately described by the compound, which contains intercalated Fe²⁺ and Al³⁺ ions and has the chemical formula Ca₂(MgO_0.495·FeO_0.202·AlO_0.303)·(FeO_0.248·AlO·Si_1.536·O₇). Stoichiometric calculations showed that FeO and Al₂O₃ have replaced about half of the MgO content in the akermanite structure. All this means that only ~4 wt% MgO content in the raw materials determines that ~60 wt% calcium magnesium silicates are formed in the synthesis product. Moreover, it was found that the formed akermanite practically does not react with CO₂. Within 24 h of interaction with 99.9 wt% of CO₂ gas (15 bar), the intensity of the akermanite peaks does not practically change at 25 °C; no changes are observed at 45 °C, either, which means that the chemical reaction does not take place. As a result, the compressive strength of the samples compressed from the synthesized product and CEN Standard sand EN 196-1 (1:3), and hardened at 15 bar CO₂, 45 °C for 24 h, was only 14.45 MPa, while the analogous samples made from OPC clinker obtained from the same raw materials yielded 67.5 MPa.

The Effect of Seawater on Mortar Matrix Coated with Hybrid Nano-Silica-Modified Surface Protection Materials

Surface treatment technology is an effective method to reinforce the durability of concrete. In this study, cement-based materials containing industrial solid wastes were modified by hybrid nano-silica (HN), then applied as a novel surface protection material (SPM-HN). The effect of SPM-HN on surface hardness of mortar matrix exposed to seawater was investigated. Further, the microstructure was characterized by X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), and mercury intrusion porosimetry (MIP). The results show SPM-HN could significantly enhance the surface hardness of matrix in seawater curing, and the rebound number is increased by 94%.The microstructure analysis demonstrates that the incorporation of HN inhibits the formation of ettringite, thaumasite, and Friedel’s salt. In addition, thermodynamic modeling shows the incorporation of hybrid nano-silica could generate more C-S-H, and decrease the maximum volume of Friedel’s salt when SPM is exposed to seawater. This research indicates SPM-HN can be applied as a concrete protective layer in the marine environment.

Investigation on the Air Permeability and Pore Structure of Concrete Subjected to Carbonation under Compressive Stress

Concrete structures have to withstand the combined effects of external load and environmental factors. Therefore, it is meaningful to study the durability of concrete under compression and carbonation. The air permeability coefficient (kAu) and pore structure of concrete under uniaxial compression and carbonation were measured by the Autoclam method and mercury intrusion porosimetry (MIP). The Autoclam test results showed that the concrete kAu changed in a concave parabolic manner with the compressive stress level, and the inflection point of the stress level was 45%. The MIP results showed that the characteristic pore structural parameters (porosity, average pore diameter, median pore diameter by area, and median pore diameter by volume) first decreased and then increased with the stress level change. The change in concrete microstructure was a result of the combined effect of pore filling, decalcification, and densification, as well as the split effect. The key pore structural parameters affecting kAu were confirmed using gray relational analysis (GRA). The top three parameters with the highest correlation with the carbonated concrete kAu were porosity (gray relational grade γi = 0.789), median pore diameter by volume (γi = 0.763), and proportion of transition pore volume (γi = 0.827). Furthermore, the regression analysis showed a good linear relation between kAu and the important pore structural parameters.

The Global Carbon Footprint and How New Carbon Mineralization Technologies Can Be Used to Reduce CO2 Emissions

Carbon dioxide is a byproduct of our industrial society. It is released into the atmosphere, which has an adverse effect on the environment. Carbon dioxide management is necessary to limit the global average temperature increase to 1.5 degrees Celsius and mitigate the effects of climate change, as outlined in the Paris Agreement. To accomplish this objective realistically, the emissions gap must be closed by 2030. Additionally, 10–20 Gt of CO2 per year must be removed from the atmosphere within the next century, necessitating large-scale carbon management strategies. The present procedures and technologies for CO2 carbonation, including direct and indirect carbonation and certain industrial instances, have been explored in length. This paper highlights novel technologies to capture CO2, convert it to other valuable products, and permanently remove it from the atmosphere. Additionally, the constraints and difficulties associated with carbon mineralization have been discussed. These techniques may permanently remove the CO2 emitted due to industrial society, which has an unfavorable influence on the environment, from the atmosphere. These technologies create solutions for both climate change and economic development.

CO2 Curing of Ca-Rich Fly Ashes to Produce Cement-Free Building Materials

In this study, fly ash (FA) compacts were prepared by accelerated carbonation as a potential sustainable building material application with the locally available ashes (oil shale ash (OSA), wood ash (WA) and land filled oil shale ash (LFA)) of Estonia. The carbonation behaviour of FAs and the performance of 100% FA based compacts were evaluated based on the obtained values of CO2 uptake and compressive strength. The influence of different variables (compaction pressure, curing temperature, CO2 concentration, and pressure) on the CO2 uptake and strength development of FA compacts were investigated and the reaction kinetics of the carbonation process were tested by different reaction-order models. A reasonable relation was noted between the CO2 uptake and compressive strength of the compacts. The porous surface structure of the hydrated OSA and WA compacts was changed after carbonation due to the calcite formations (being the primary carbonation product), especially on portlandite crystals. The increase of temperature, gas pressure, and CO2 concentration improved the CO2 uptake levels of compacts. However, the positive effect of increasing compaction pressure was more apparent on the final strength of the compacts. The obtained compressive strength and CO2 uptake values of FA compacts were between 10 and 36 MPa and 11 and 13 wt%, respectively, under various operation conditions. Moreover, compacts with mixed design (OSA/LFA and WA/LFA) resulted in low-strength and density compared to the single behaviour of OSA and WA compacts, yet a higher CO2 uptake was achieved (approximately 15% mass) with mixed design. The conformity of Jander equation (3D-diffusion-limited reaction model) was higher compared to other tested reaction order models for the representation of the carbonation reaction mechanism of OSA and WA. The activation energy for OSA compact was calculated as 3.55 kJ/mol and for WA as 17.06 kJ/mol.

Selective sulfur removal from semi-dry flue gas desulfurization coal fly ash for concrete and carbon dioxide capture applications

High-sulfur mixed fly ash residues from semi-dry flue gas desulfurization units in coal-fired power plants are unsuitable for use as supplementary cementitious material (SCM) for concrete production or carbon dioxide utilization. In this work, we explore the potential for upcycling a representative spray dry absorber ash (10.44 wt% SO₃) into concrete-SCM by selective sulfur removal via weak acid dissolution while simultaneously exploring the possibility for CO₂ capture. Towards this effort, parametric studies varying liquid-to-solid ratio, acidity, and CO₂ pressure were conducted in a batch reactor to establish the sulfur removal characteristics in de-ionized water, nitric acid, and carbonic acid, respectively. The dissolution studies show that the leaching of sulfur from calcium sulfite hemihydrate, which is the predominant S phase, is rapid and achieves a concentration plateau within 5 min, and subsequently, appears to be controlled by the primary mineral solubility. Preferential S removal was sufficient to meet SCM standards (e.g., 5.0 wt% as per ASTM C618) using all three washing solutions with 0.62-0.72 selectivity (S^), defined as the molar ratio of S to Ca in the leachate, for a raw fly ash with bulk S^ = 0.3. Acid dissolution with 1.43 meq/g of ash or under 5 atm CO₂ retained > 18 wt% CaO and other Si-, Al-rich phases in the fly ash. Based on the experimental findings, two sulfur removal schemes were suggested for either integration with CO₂ capture and utilization processes using flue gas or to produce fly ash for use as a SCM.

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.

The role of gas flow distributions on CO2 mineralization within monolithic cemented composites: coupled CFD-factorial design approach

Optimizing the spatial distribution of contacting gas and the gas processing conditions enhances CO₂ mineralization reactions and material properties of carbonate-cementitious monoliths.

Mechanistic insight into mineral carbonation and utilization in cement-based materials at solid-liquid interfaces

In order to ensure the viability of CO₂ mineralization and utilization using alkaline solid waste, a mechanistic understanding of reactions at mineral–water interfaces was required to control the reaction pathways and kinetics. In this study, we provided new information for understanding the reactions of CO₂ mineralization and utilization at mineral–water interfaces. Here we have carried out high-energy synchrotron X-ray analyses to characterize the changes of mineral phases in petroleum coke fly ash during CO₂ mineralization and their subsequent utilization as supplementary cementitious materials in cement mortars. The 2-D synchrotron patterns were converted to 1-D diffraction patterns and the results were then interpreted via the Rietveld refinement. The results indicated that there was a continuous source of calcium ions mainly due to the dissolution of CaO and Ca(OH)₂ in fly ash. This would actually enhance the driving force of saturation index at the solid–fluid interfacial layer, and then could eventually result in the nucleation and growth of calcium carbonate (calcite) at the interface. A small quantity of CaSO₄ (anhydrite) in fly ash was also dissolved and simultaneously converted into calcite. In addition, the calcium sulfate in fly ash would effectively prevent the early hydration of tricalcium aluminate in blended cement, and thus could avoid the negative impact on its strength development. The proposed reaction mechanisms were also qualitatively verified by X-ray fluorescence mapping and electron microscopy. These results would help to design efficient reactors and cost-effective processes for CO₂ mineralization and utilization in the future.

Synchrotron-based X-ray analyses for understanding the reactions at mineral–water interfaces for CO₂ mineralization and utilization using petroleum coke fly ash.