A critical review to bridge the gaps between carbon capture, storage and use of CaCO3

Multiscale Process Intensification of Waste Valorization Reactions

ConspectusThe central theme of this Account is the development of intensified and sustainable chemical processes for the sequestration of CO2 in synergism with the utilization of wastes of industrial, urban, and agricultural origins. A challenge when working with solid waste-fluid reactions is that mass transfer limitations across solid-liquid, solid-gas, and gas-liquid interfaces and unfavorable thermodynamics lead to slow reaction rates, incomplete reaction conversions, high energy expenditure and processing costs, and inadequate product properties. The traditional macroscale approaches to overcoming slurry reaction limitations can be effective; however, they come at a cost to the environment. In the treatment or valorization of low-grade and waste resources, such conventional approaches are often unfeasible on an industrial scale. Sustainable solutions are thus needed.In the last six years, we have been exploring and developing approaches to overcoming reaction rate limitations of slurry reactions of environmental relevance by concurrently applying process intensification strategies and multiscale engineering approaches. The scientific approach has relied on laboratory-scale experiments to test and refine the devised multiscale process intensification strategies, with thermodynamic and computational modeling work supporting the experimental work and with advanced characterization techniques being used to elucidate reaction and transport mechanisms and aid the development of nanoscale reaction models and micro- and macroscale process models. The research streams, associated with the four key references, discussed next are (a) brine carbonation; (b) mineral carbonation and enhanced weathering; (c) process intensification and integration; and (d) characterization techniques.Within the four research streams, a number of mineral carbonation processes have been investigated and can be classified as (i) ambient weathering and carbonation; (ii) gas-(wet) solid accelerated carbonation; (iii) aqueous accelerated carbonation; (iv) supercritical accelerated carbonation; and (v) CO2 mineralization from brine. In some cases, the research was aimed at producing valuable products with reduced environmental risk or a reduced carbon footprint, such as an organomineral fertilizer and zeolites. In other cases, the aim was to assess the reactivity of minerals to match the right feedstock with the right carbonation process, in view of maximizing net carbon sequestration. There were also cases where the carbonation process was reimagined by the use of innovative reaction conditions, reactors, and reagents. The experience with accelerated weathering and carbonation in engineered processes has been translated into the field of enhanced rock weathering (ERW) in agriculture, where the multidisciplinary approach used has served to advance ERW science and technology in ways that have had a resounding effect on recent commercial deployment.The completed research serves to encourage the adoption of process intensification technologies in place of conventional processes, in industry and among the research community, and to catalyze the development of the types of sustainable processes required by the chemical, metallurgical, and minerals industries (which are critical to the green transition) to reduce their environmental impact and carbon emissions. Moreover, the multiscale process intensification approaches developed may also be extended to other industrial, urban, and agricultural processes where the reduction of energy intensity, carbon intensity, and environmental footprint could be achieved.

Continuous carbon capture in an electrochemical solid-electrolyte reactor

Electrochemical carbon-capture technologies, with renewable electricity as the energy input, are promising for carbon management but still suffer from low capture rates, oxygen sensitivity or system complexity^1-6. Here we demonstrate a continuous electrochemical carbon-capture design by coupling oxygen/water (O₂/H₂O) redox couple with a modular solid-electrolyte reactor⁷. By performing oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) redox electrolysis, our device can efficiently absorb dilute carbon dioxide (CO₂) molecules at the high-alkaline cathode-membrane interface to form carbonate ions, followed by a neutralization process through the proton flux from the anode to continuously output a high-purity (>99%) CO₂ stream from the middle solid-electrolyte layer. No chemical inputs were needed nor side products generated during the whole carbon absorption/release process. High carbon-capture rates (440 mA cm^-2, 0.137 mmol_CO2 min^-1 cm^-2 or 86.7 kg_CO2 day^-1 m^-2), high Faradaic efficiencies (>90% based on carbonate), high carbon-removal efficiency (>98%) in simulated flue gas and low energy consumption (starting from about 150 kJ per mol_CO2) were demonstrated in our carbon-capture solid-electrolyte reactor, suggesting promising practical applications.

A green and multi-win strategy for coal fly ash disposal by CO2 fixation and mesoporous silica synthesis

Coal combustion provides plenty of energy, along with enormous coal fly ash (CFA) and CO₂ emission. CFA could be recycled for mesoporous silica synthesis, but expensive templates are usually needed. In this work, we proposed a multi-win strategy using CO₂ as the precipitator and template. Mesoporous silica powders, with a maximum specific surface area of 355.45 m²/g, a pore volume of 0.73 cm³/g, and an average pore size of around 7.67 nm, were synthesized. The influences of silicon concentration, CO₂ flow rate, and ultrasound were investigated. In addition, the Na₂CO₃ by-product was produced with a purity of over 92 %. By averagely calculating, 1 ton CFA could generate 285 kg mesoporous silica and 1.02 t crude Na₂CO₃. Around 433 kg of CO₂ could be absorbed. Therefore, multi-goals of CFA disposal, CO₂ storage, and valuable silica materials production were realized, and the study could pave the way for large-scale industrial applications.

Carboxymethyl cellulose/sodium alginate beads incorporated with calcium carbonate nanoparticles and bentonite for phosphate recovery

Although anionic polyelectrolyte hydrogel beads offer attractive adsorption of cationic dyes, phosphate adsorption is limited by electrostatic interactions. In this work, carboxymethyl cellulose (CMC)/sodium alginate (SA) hydrogel beads were modified with calcium carbonate (CaCO₃) and/or bentonite (Be). The compatibility between CaCO₃ and Be was proven by the homogeneous surface, as shown in the scanning electron microscopic images. Fourier-transform infrared and X-ray diffraction spectra further confirmed the existence of inorganic filler in the hydrogel beads. Although CMC/SA/Be/CaCO₃ hydrogel beads attained the highest methylene blue and phosphate adsorption capacities (142.15 MB mg/g, 90.31 P mg/g), phosphate adsorption was significantly improved once CaCO₃ nanoparticles were incorporated into CMC/SA/CaCO₃ hydrogel beads. The kinetics of MB adsorption by CMC/SA hydrogel beads with or without inorganic fillers could be described by the pseudo-second-order model under chemical interactions. The phosphate adsorption by CMC/SA/Be/CaCO₃ hydrogel beads could be explained by the Elovich model due to heterogeneous properties. The incorporation of Be and CaCO₃ also improved the phosphate adsorption through chemical interaction since Langmuir isotherm fitted the phosphate adsorption by CMC/SA/Be/CaCO₃ hydrogel beads. Unlike MB adsorption, the reusability of these hydrogel beads in phosphate adsorption reduced slightly after 5 cycles.

3D Printed Gas Distributor for Enhanced Production of CaCO3 via Bubbling Carbonation

Bubbling carbonation is the most widely used method for production of CaCO₃. A structure-controllable preparation of calcium carbonate with homogeneous crystallinity and narrow particle size distribution is generally required. In this work, a gas distributor is designed and fabricated by light-curing three-dimensional (3D) printing technology to optimize the pore size and distribution of the distributor. The printed gas distributor is combined with a home-made glass vessel to form a simple carbonation reactor without the need for stirring. With the optimized gas flow rate and concentration of Ca(OH)₂, this reactor produces small-sized bubbles continuously and uniformly. A homogeneous bubble flow regime can be thus easily formed with the printed distributor, which leads to an enhanced production of calcium carbonate at room temperature with a uniform morphology and narrow particle size distribution. The time required for carbonization is significantly reduced as well. The present study extends the 3D printing to the construction of bubbling reactors with broad applications beyond production of CaCO₃.

Calcium carbonate: controlled synthesis, surface functionalization, and nanostructured materials

Calcium carbonate (CaCO₃) is an important inorganic mineral in biological and geological systems. Traditionally, it is widely used in plastics, papermaking, ink, building materials, textiles, cosmetics, and food. Over the last decade, there has been rapid development in the controlled synthesis and surface modification of CaCO₃, the stabilization of amorphous CaCO₃ (ACC), and CaCO₃-based nanostructured materials. In this review, the controlled synthesis of CaCO₃ is first examined, including Ca²⁺-CO₃^2- systems, solid-liquid-gas carbonation, water-in-oil reverse emulsions, and biomineralization. Advancing insights into the nucleation and crystallization of CaCO₃ have led to the development of efficient routes towards the controlled synthesis of CaCO₃ with specific sizes, morphologies, and polymorphs. Recently-developed surface modification methods of CaCO₃ include organic and inorganic modifications, as well as intensified surface reactions. The resultant CaCO₃ can then be further engineered via template-induced biomineralization and layer-by-layer assembly into porous, hollow, or core-shell organic-inorganic nanocomposites. The introduction of CaCO₃ into nanostructured materials has led to a significant improvement in the mechanical, optical, magnetic, and catalytic properties of such materials, with the resultant CaCO₃-based nanostructured materials showing great potential for use in biomaterials and biomedicine, environmental remediation, and energy production and storage. The influences that the preparation conditions and additives have on ACC preparation and stabilization are also discussed. Studies indicate that ACC can be used to construct environmentally-friendly hybrid films, supramolecular hydrogels, and drug vehicles. Finally, the existing challenges and future directions of the controlled synthesis and functionalization of CaCO₃ and its expanding applications are highlighted.

Valorization of high-salinity effluents for CO2 fixation and hypochlorite generation

In this work, it is evaluated the fixation of carbon dioxide using the alkali generated in the chloralkaline process, as a new way to face the treatment of highly saline wastewater, in which it is aimed not to separate the wastewater into concentrated and diluted streams but to recover value-added products (VAPs) while contributing to minimize the carbon fingerprint of other processes. The electrolytic process is combined with a reactive absorption and with a crystallization, demonstrating the formation of pure nahcolite, hypochlorite (or chlorine) and hydrogen from the waste. Carbon dioxide is captured with a current efficiency over 90% and the energy required is around 0.65 kWh kg^-1, which is very promising from the view point of sustainability, considering that the system can be easily powered with green energies.

Assessment of Cubic Equations of State: Machine Learning for Rich Carbon-Dioxide Systems

Carbon capture and storage (CCS) has attracted renewed interest in the re-evaluation of the equations of state (EoS) for the prediction of thermodynamic properties. This study also evaluates EoS for Peng–Robinson (PR) and Soave–Redlich–Kwong (SRK) and their capability to predict the thermodynamic properties of CO2-rich mixtures. The investigation was carried out using machine learning such as an artificial neural network (ANN) and a classified learner. A lower average absolute relative deviation (AARD) of 7.46% was obtained for the PR in comparison with SRK (AARD = 15.0%) for three components system of CO2 with N2 and CH4. Moreover, it was found to be 13.5% for PR and 19.50% for SRK in the five components’ (CO2 with N2, CH4, Ar, and O2) case. In addition, applying machine learning provided promise and valuable insight to deal with engineering problems. The implementation of machine learning in conjunction with EoS led to getting lower predictive AARD in contrast to EoS. An of AARD 2.81% was achieved for the three components and 12.2% for the respective five components mixture.