Flue gas carbonation of cement-based building products

Novel accelerated carbonation methods based on deep breathing analogous and prediction model for pressurized carbonation of concrete

This research proposes a novel deep breathing analogy (DBA) accelerated carbonation process. Inspired by the breathing mechanism of human lungs, the DBA method involves injecting pure CO2 into a reaction chamber at a specific pressure (inspiration) and subsequently evacuating the gas from the chamber to a negative pressure (exhalation). This process is repeated to remove excess water from the chamber and restore optimal carbonation conditions, which further enhances the efficiency of carbonation for the sample. The effectiveness of this method is evaluated based on weight gain, proportion of captured CO2 and carbonation depth. Results show that the DBA method significantly reduces the inhibition of carbonation. Based on the test results, a correlation between the proportion of captured CO2 and carbonation depth is established. Additionally, a more accurate prediction model for pressurized carbonation is proposed and the economic potential of concrete carbonation is studied.

Effects of Curing Regimes on Calcium Oxide-Belite-Calcium Sulfoaluminate-Based Aerated Concrete

This study delves into the effects of carbonation curing and autoclave-carbonation curing on the properties of calcium oxide-belite-calcium sulfoaluminate (CBSAC) cementitious material aerated concrete. The objective is to produce aerated concrete that adheres to the strength index in the Chinese standard GB/T 11968 while simultaneously mitigating CO2 emissions from cement factories. Results show that the compressive strength of CBSAC aerated concrete with different curing regimes (autoclave curing, carbonation curing, and autoclave-carbonation curing) can reach 4.3, 0.8, and 4.1 MPa, respectively. In autoclave-carbonation curing, delaying CO2 injection allows for better CO2 diffusion and reaction within the pores, increases the carbonation degree from 19.1% to 55.1%, and the bulk density from 603.7 kg/m3 to 640.2 kg/m3. Additionally, microstructural analysis reveals that delaying the injection of CO2 minimally disrupts internal hydrothermal synthesis, along with the formation of calcium carbonate clusters and needle-like silica gels, leading to a higher pore wall density. The industrial implementation of autoclavecarbonation curing results in CBSAC aerated concrete with a CO2 sequestration capacity ranging from 40 to 60 kg/m3 and a compressive strength spanning from 3.6 to 4.2 MPa. This innovative approach effectively mitigates the carbon emission pressures faced by CBSAC manufacturers.

An efficient molten steel slag gas quenching process: Integrating carbon solidification and waste heat recovery

The iron and steel-making industries have garnered significant attention in research related to low-carbon transitions and the reuse of steel slag. This industry is known for its high carbon emissions and the substantial amount of steel slag it generates. To address these challenges, a waste heat recovery process route has been developed for molten steel slag, which integrates CO2 capture and fixation as well as efficient utilization of steel slag. This process involves the use of lime kiln flue gas from the steel plant as the gas quenching agent, thereby mitigating carbon emissions and facilitating carbonation conversion of steel slag while simultaneously recovering waste heat. The established carbonation model of steel slag reveals that the insufficient diffusion of CO2 gas molecules within the product layer is the underlying mechanism hindering the carbonation performance of steel slag. This finding forms the basis for enhancing the carbonation performance of steel slag. The results of Aspen Plus simulation indicate that 1 t of steel slag (with a carbonation conversion rate of 15.169 %) can fix 55.19 kg of CO2, process 6.08 kmol of flue gas (with a carbon capture rate of 92.733 %), and recover 2.04 GJ of heat, 0.43 GJ of exergy, and 0.68 MWh of operating cost. These findings contribute to the development of sustainable and efficient solutions for steel slag management, with potential applications in the steel production industry and other relevant fields.

Prolonging the Durability of Maritime Constructions through a Sustainable and Salt-Resistant Cement Composite

This research investigates the long-term resilience of an environmentally friendly cement blend comprising Egyptian Ordinary Portland Cement OPC and Ground-Granulated Blast Furnace Slag GGBFS when exposed to a corrosive seawater environment. This scientific investigation explores the effects of exposure to seawater on various properties of cement pastes, encompassing parameters such as free lime content (FLC), chemically combined water content (CWC), bulk density (BD), total porosity (ϕ), total sulfate content, total chloride content, and compressive strength (CS). By contrast, Differential Thermal Analysis (DTA), FT-IR spectroscopy, and X-ray diffraction (XRD) analysis can be utilized to investigate the influence of exposure to seawater on the hydration products of GGBFS cement pastes over a period of up to one year. This analytical approach offers valuable insights into the alterations that occur in hydration products and their resilience when subjected to seawater conditions. The results obtained from this investigation reveal that all cement pastes incorporating GGBFS exhibit heightened resistance to deterioration in seawater, with slag cement containing 60 wt. % GGBFS and achieving a notable compressive strength of 85.7 Mpa after one year of immersion in seawater. These findings underscore the capacity of these cement blends to effectively withstand challenges in durability in marine environments.

Carbon Emission Evaluation of CO2 Curing in Vibro-Compacted Precast Concrete Made with Recycled Aggregates

The objective of the present study was to explore three types of vibro-compacted precast concrete mixtures replacing fine and coarse gravel with a recycled/mixed concrete aggregate (RCA or MCA). The portlandite phase found in RCA and MCA by XRD is a "potential" CO₂ sink. CO₂ curing improved the compressive strength in all the mixtures studied. One tonne of the mixtures studied could be decarbonised after only 7 days of curing 13,604, 36,077 and 24,635 m³ of air using natural aggregates, RCA or MCA, respectively. The compressive strength obtained, XRD, TGA/DTA and carbon emission evaluation showed that curing longer than 7 days in CO₂ was pointless. The total CO₂ emissions by a mixture using CO₂ curing at 7 days were 221.26, 204.38 and 210.05 kg CO₂ eq/m³ air using natural aggregates, RCA or MCA, respectively. The findings of this study provide a valuable contribution to carbon emission evaluation of CO₂ curing in vibro-compacted precast concrete with recycled/mixed concrete aggregates (RCA or MCA). The technology proposed in this research facilitates carbon capture and use and guarantees enhanced compressive strength of the concrete samples.

Stabilization of biomass ash granules using accelerated carbonation to optimize the preparation of soil improvers

After the revision of the Fertilizer Regulation (EC 2019/1009), biomass ash can be used as component material for soil improvers to be placed on the EU market. This provides opportunities for large scale recycling of biomass ash. However, this material cannot be directly applied to soil without stabilization by carbonation, which also creates an opportunity for CO₂ capture and storage. Here, accelerated carbonation in an atmospheric fixed-bed reactor (AFR) was applied to prepare ash granules (AG). Relative humidity of gas, temperature, reaction time and CO₂ concentration were optimized and further tested in a closed high-pressure reactor (HPR). Materials resulting from both reactors were compared with those obtained after 1-year of carbonation under atmospheric conditions. This study showed that AFR accelerated tests resulted in a significant reduction of the reaction time than HPR to achieve a similar pH adjustment. Also, under 100 vol.% CO₂ atmospheric conditions, pH and electrical conductivity reached target values faster than under 15 vol.% CO₂ conditions. Based on results obtained here we recommend AFR operating at 25 °C and 100 vol.% CO₂ for 20 h, as the optimal procedure for stabilization of AG. In this study we provide evidence that accelerated carbonation enables a much faster and cost-efficient preparation of potentially valuable soil additives than natural carbonation. Also, leaching tests revealed that plant nutrient availability (B, Mg, Mn, Mo and P) was increased under accelerated carbonation compared to natural carbonation. The present work paves the way towards the development of optimized protocols to effectively recycle biomass ashes for soil recovery.

Evolution of Microstructural Characteristics of Carbonated Cement Pastes Subjected to High Temperatures Evaluated by MIP and SEM

The microstructural evolutions of both uncarbonated and carbonated cement pastes subjected to various high temperatures (30 °C, 200 °C, 400 °C, 500 °C, 600 °C, 720 °C, and 950 °C) are presented in this study by the means of mercury intrusion porosimetry (MIP) and scanning electron microscopy (SEM). It was found that the thermal stabilities of uncarbonated cement pastes were significantly changed from 400 to 500 °C due to the decomposition of portlandite at this temperature range. More large pores and microcracks were generated from 600 to 720 °C, with the depolymerization of C-S-H. After carbonation, the microstructures of carbonated cement pastes remained unchanged below 500 °C and started to degrade at 600 °C, due to the decompositions of calcium carbonates and calcium modified silica gel. At 950 °C, both uncarbonated and carbonated cement pastes showed a loosely honeycombed microstructure, composed mainly of β-C₂S and lime. It can be concluded that carbonation improves the high-temperature resistance of cement pastes up to 500 °C, but this advantage is lost at temperatures over 600 °C.

CO2 Curing on the Mechanical Properties of Portland Cement Concrete

This study was to evaluate the CO2 curing on mechanical properties of Portland cement concrete. Three different specimen sizes (5 × 10 cm, 10 × 20 cm, and 15 × 30 cm cylinders), three CO2 concentrations (50%, 75%, 100%), three curing pressures (0.2, 0.4, 0.8 MPa), three curing times (1, 3, 6 h), two water cement ratios (0.41, 0.68) for normal and high-strength concretes, and two test ages (3, 28 days) were used for this investigation. Before using the CO2 curing process, the concrete samples reached the initial set at approximately 4 h, and the free water in the samples was gradually removed when dry CO2 gas was injected. The test results show that the 3-day early compressive strength of normal concrete cured by CO2 is higher than that of concrete cured by water, but the difference is not obvious for high-strength concrete cured by CO2. In addition, there is a size effect on the strength of the 5 × 10 cm and 15 × 30 cm cylinders, and the strength conversion factor ks5 value obtained for the 28-day compressive strength is greater than 1.18. Compared to conventional water-cured concrete, the elastic modulus of carbon dioxide-cured one generally increases in proportion to the square root of the 28-day compressive strength. It was observed that there are only minor differences in the four EC empirical equations obtained by CO2 curing from 5 × 10 cm and 10 × 20 cm cylinders, respectively.

CO2 Mineralization Methods in Cement and Concrete Industry

Production of Portland clinker is inherently associated with CO2 emissions originating from limestone decomposition, the irreplaceable large-scale source of calcium oxide needed. Besides carbon capture and storage, CO2 mineralization is the only lever left to reduce these process emissions. CO2 mineralization is a reversal reaction to clinker production—CO2 is bound into stable carbonates in an exothermic process. It can be applied in several environmentally and economically favorable ways at different stages of clinker, cement and concrete life cycle. These possibilities are assessed and discussed in this contribution. The results demonstrate that when combined with concrete recycling, the complete circularity of all its constituents, including the process CO2 emissions from the clinker, can be achieved and the overall related CO2 intensity significantly reduced.

Dimensional stability of cement paste and concrete subject to early-age carbonation curing

Early-age carbonation curing of concrete is receiving more interest in terms of performance improvement and emission reduction. However, the volume change of cement-based products subject to carbonation curing may become a concern because of the potential carbonation shrinkage and its related shrinkage cracking. The purpose of this study was to investigate the dimensional stability of cement paste and concrete subject to the early-age carbonation curing. It was found that the carbonation curing introduced first an initial shrinkage due to water evaporation upon gas injection and then generated an expansion due to CO₂ uptake and carbonate precipitation. As carbonation proceeded, the deformation was switched to a secondary shrinkage after expansion. The residual deformation due to carbonation curing was shrinkage in cement paste samples and expansion in concrete samples. This was because the relative expansion due to carbonate precipitation in paste was not large enough to compensate for the shrinkage caused by water loss. However, for concrete samples, the introduction of aggregates reduced the pore spaces in concrete, leading to an expansion owing to the limited precipitation. The results of carbon dioxide uptake, XRD, and SEM analysis confirmed that calcium carbonate formation played a critical role in the relative expansion. The study also showed that cement-based products were more resistant to weathering carbonation after the early-age carbonation curing. After 61-day weathering carbonation exposure, both paste and concrete samples exhibited carbonation shrinkage as a result of carbonation of hydration products. However, the magnitude of shrinkage was much smaller in carbonation curing than in weathering carbonation because of the short period of exposure. Both carbonations did not significantly affect the compressive strength of carbonated products. Carbonation curing likely makes concrete products more dimensionally stable in the long-term service.

Market Stakeholder Analysis of the Practical Implementation of Carbonation Curing on Steel Slag for Urban Sustainable Governance

Carbonation curing on steel slag is one of the most promising technologies for the iron and steel industry to manage its solid waste and carbon emissions. However, the technology is still in its demonstration stage. This paper investigates the market stakeholders of carbonation curing on steel slag for construction materials for its effective application by taking China as a case study. A holistic analysis of the competition, market size, and stakeholders of carbonation curing on steel slag was carried out through a literature review, a survey, a questionnaire, and interviews. The results showed that carbonation curing on steel slag had the advantages of high quality, high efficiency, low cost, and carbon reduction compared with other technologies. Shandong province was the most suitable province for the large-scale primary application of the technology. Stakeholder involvement to establish information platforms, enhance economic incentives, and promote adequate R&D activities would promote carbonation curing of steel slag into practice. This paper provides a reference for the commercialization of carbonation curing on similar calcium- and magnesium-based solid waste materials.

Macroscopic and Microscopic Properties of Cement Paste with Carbon Dioxide Curing

Carbon dioxide is the main component of greenhouse gases, which are responsible for an increase in global temperature. The utilization of carbon dioxide in cement-based materials is an effective way to capture this gas. In this paper, the influence of carbon dioxide curing on the setting time, the electrical resistivity, dry shrinkage ratio, water absorption by unit area and mechanical strengths (flexural and compressive strengths) were determined. The scanning electron microscope, X-ray diffraction and thermogravimetric analysis were obtained to investigate the mechanism of carbonation reaction of cement paste. Water-cement ratios of cement paste were selected to be 0.3, 0.4 and 0.5. Results showed that carbon dioxide curing could accelerate the setting of cement paste. The electrical resistivity decreased with the increasing water-cement ratio and increased with the carbon dioxide curing. Moreover, the evaluation function for the curing age and dry shrinkage rate or the mechanical strengths fit well with the positive correlation quadratic function. The water absorption by unit area increased linearly with the testing time. The carbon dioxide curing led to increasing the mechanical strengths and the dry shrinkage ratio. Meanwhile, the carbon dioxide curing demonstrated a decreasing effect on the water absorption by unit area. The mechanical strengths were improved by the carbon dioxide curing and increased in the form of quadratic function with the curing age. As obtained from the microscopic findings, that the carbon dioxide curing could accelerate the reaction of cement and improve the compactness of cement paste.

Orthogonal Test Design for the Optimization of Preparation of Steel Slag-Based Carbonated Building Materials with Ultramafic Tailings as Fine Aggregates

The high carbonation potential makes ultramafic tailings ideal aggregates for carbonated building materials. This paper investigates the preparation condition of ultramafic tailings and steel slag through orthogonal experiments. The results show that compressive strength has a positive exponential correlation with the CO2 uptake of the carbonated compacts. The optimized conditions include a slag-tailings ratio of 5:5, a carbonation time of 12 h, a grinding time of 0 min, and a water-solid ratio of 2.5:10, when the compressive strength of the carbonated compacts reaches 29 MPa and the CO2 uptake reaches 66.5 mg CO2/g. The effects on the compressive strength ordered from high to low impact are the slag/tailings ratio, carbonation time, grinding time of steel slag, and water–solid ratio. The effects on the CO2 uptake ordered from high to low impact are the slag–tailings ratio, water–solid ratio, carbonation time, and grinding time of steel slag. A high water–solid ratio hinders the early carbonation reactions, but promotes the long-term carbonation reaction. Steel slag is the main material being carbonated and contributes to the hardening of the compacts through carbonation curing at room temperature. Ultramafic tailings assist steel slag in hardening through minor carbonation and provide fibrous contents. The obtained results lay a solid foundation for the development of tailings-steel slag carbonated materials.

Carbon dioxide utilization in concrete curing or mixing might not produce a net climate benefit

Carbon capture and utilization for concrete production (CCU concrete) is estimated to sequester 0.1 to 1.4 gigatons of carbon dioxide (CO2) by 2050. However, existing estimates do not account for the CO2 impact from the capture, transport and utilization of CO2, change in compressive strength in CCU concrete and uncertainty and variability in CCU concrete production processes. By accounting for these factors, we determine the net CO2 benefit when CCU concrete produced from CO2 curing and mixing substitutes for conventional concrete. The results demonstrate a higher likelihood of the net CO2 benefit of CCU concrete being negative i.e. there is a net increase in CO2 in 56 to 68 of 99 published experimental datasets depending on the CO2 source. Ensuring an increase in compressive strength from CO2 curing and mixing and decreasing the electricity used in CO2 curing are promising strategies to increase the net CO2 benefit from CCU concrete.