Recycling of waste autoclaved aerated concrete powder in Portland cement by accelerated 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.

Effects of temperature and CO2 concentration on the early stage nucleation of calcium carbonate by reactive molecular dynamics simulations

It is significant to investigate the calcium carbonate (CaCO3) precipitation mechanism during the carbon capture process; nevertheless, CaCO3 precipitation is not clearly understood yet. Understanding the carbonation mechanism at the atomic level can contribute to the mineralization capture and utilization of carbon dioxide, as well as the development of new cementitious materials with high-performance. There are many factors, such as temperature and CO2 concentration, that can influence the carbonation reaction. In order to achieve better carbonation efficiency, the reaction conditions of carbonation should be fully verified. Therefore, based on molecular dynamics simulations, this paper investigates the atomic-scale mechanism of carbonation. We investigate the effect of carbonation factors, including temperature and concentration, on the kinetics of carbonation (polymerization rate and activation energy), the early nucleation of calcium carbonate, etc. Then, we analyze the local stresses of atoms to reveal the driving force of early stage carbonate nucleation and the reasons for the evolution of polymerization rate and activation energy. Results show that the higher the calcium concentration or temperature, the higher the polymerization rate of calcium carbonate. In addition, the activation energies of the carbonation reaction increase with the decrease in calcium concentrations.

Utilization Potential of Aerated Concrete Block Powder and Coffee Grounds Ash in Green-Growing Concrete

The purpose of this research is to investigate the utilization potential of recycled powder made from spent coffee grounds (SCGs) and aerated concrete blocks (ACBs) in green-growing concrete. The green-growing concrete is prepared using ACB powder and SCG ash as raw materials instead of 5%, 15%, and 25% and 5%, 10%, and 15% cement, respectively. Then, the two raw materials are compounded with the optimal content. The compressive strength and alkalinity of green-growing concrete at 7d and 28d and the frost resistance after 25 freeze-thaw cycles at 28d are studied. The results showed that the optimum content of ACB powder and SCG ash was 5%. Replacing 5% cement with recycled powder could improve the strength of concrete. The alkalinity of concrete containing ACB powder gradually increased, while the alkalinity of concrete containing SCG ash gradually decreased. The alkalinity of ACB-SCG powder was lower than that of ACB powder but slightly higher than that of SCG ash. The frost resistance of concrete containing ACB powder decreased gradually, and the frost resistance of concrete containing SCG ash increased first and then decreased greatly. The frost resistance of ACB-SCG powder could neutralize that of ACB powder and SCG ash.

A comparative life cycle assessment of recycling waste concrete powder into CO2-Capture products

Waste concrete powder (WCP), a byproduct of construction and demolition (C&D), currently has a low degree of recycling despite its potential for environmentally friendly applications. WCP can serve as a valuable substitute for cement, offering advantages for resource conservation and carbon sequestration. However, there are very few studies that quantitatively assess the environmental impact of incorporating WCP into the circular economy as a secondary material instead of disposing of it. The energy-intensive processing of WCP raises questions about the optimal carbonation time using available equipment. This study aims to fill this knowledge gap by employing carbon footprint and life cycle assessments (LCA) to optimize WCP recycling. Three recycling WCP scenarios are analyzed. The first scenario involved the conversion of WCP into compacts that absorb CO2 during the carbonation process. The results of the first scenario revealed that the optimal carbonation time for WCP compacts was 8 h, during which 42.7 kg CO2-e per tonne of WCP compacts was sequestered. The total global warming potential (GWP) was -4.22 kgCO2-e, indicating a carbon-negative recycling process. In the second and third scenarios, LCA was conducted to compare the use of carbonated and uncarbonated WCP as a partial replacement for cement in concrete. In these scenarios, it was found that uncarbonated WCP is a more effective solution for reducing the carbon footprint of traditional concrete mixes, achieving a significant 16% reduction of GWP when 20% of cement is replaced. Conversely, using carbonated WCP as a partial cement replacement in concrete mixtures shows limited potential for CO2 uptake. The sensitivity analysis reveals that the carbon footprint of the WCP compacts production process is strongly influenced by the electricity supplier used.

Possibility of Using Waste Materials as Substitutes for Gravel or Water in Concrete Mix

Analyzing the global waste management sector, we can see that some waste, due to its specificity, is a major challenge when it comes to its management. This group includes rubber waste and sewage sludge. Both items pose a major threat to the environment and human health. The remedy for this problem may be the solidification process, in which the presented wastes are used as substrates in the production of concrete. The aim of this work was to determine the effect of waste addition to cement in the form of an active additive (sewage sludge) and a passive additive (rubber granulate). An unusual approach to sewage sludge was used, which was introduced as a substitute for water, and not, as in most works, sewage sludge ash. In the case of the second waste, commonly used tire granules were replaced with rubber particles resulting from the fragmentation of conveyor belts. A wide range of the share of additives in the cement mortar was analyzed. The results for the rubber granulate were consistent with numerous publications. For the addition in the form of hydrated sewage sludge, the deterioration of the mechanical properties of concrete was demonstrated. It was found that the flexural strength of the concrete in which water was replaced with hydrated sewage sludge was lower than that of the sample without the addition of sludge. The compressive strength of concrete with the addition of rubber granules was higher than the control sample and did not significantly depend on the amount of granulate used.

New insights into the early stage nucleation of calcium carbonate gels by reactive molecular dynamics simulations

The precipitation of calcium carbonate (CaCO₃) is a key mechanism in carbon capture applications relying on mineralization. In that regard, Ca-rich cementitious binders offer a unique opportunity to act as a large-scale carbon sink by immobilizing CO₂ as calcium carbonate by mineralization. However, the atomistic mechanism of calcium carbonate formation is still not fully understood. Here, we study the atomic scale nucleation mechanism of an early stage amorphous CaCO₃ gel based on reactive molecular dynamics (MD) simulations. We observe that reactive MD offers a notably improved description of this reaction as compared to classical MD, which allows us to reveal new insights into the structure of amorphous calcium carbonate gels and formation kinetics thereof.

Optimisation of self-healing of bio-foamed concrete bricks pores using Bacillus tequilensis under different temperature and CO2 curing conditions

The self-healing of bio-concrete cracks and pores have been utilised worldwide to improve the properties of bio-concrete using different types of bacteria. Meanwhile, no published research was conducted to heal bio-foamed concrete bricks (B-FCB) pores using Bacillus tequilensis. Previous studies focused on the concentration of bacteria and neglect other factors that could affect the healing process. This research aimed to optimise the healing ratio of B-FCB pores using four factors: B. tequilensis concentration, concrete density, temperature and CO₂ concentration. Initial water absorption (IWA) and water absorption (WA) were used as responses in statistical methods, namely, factorial and response surface methodology (RSM). B. tequilensis species was isolated from cement kiln dust, produced in a powder form, then subjected to simulate test using a special medium consisting of foamed concrete materials to check the survival ability in B-FCB. SEM, EDX, and XRD were used to investigate the healing process of B-FCB pores. The results revealed that the decrement ratios of IWA and WA of B-FCB were 52.8% and 29.1% compared to FCB, respectively. SEM results reflect the healing that occurred in B-FCB pores, mostly healed via precipitation of CaCO₃ as demonstrated on the XRD results.

Early-Age Performance of Graphene-Nanoplatelet-Modified High-Strength Concrete Cured by Electric Thermal Curing in Severe Cold Regions

Concrete structure construction with a high strength grade in cold regions is a significant problem that has elicited considerable research attention. In this work, we firstly prepared steel-fiber-reinforced high-strength concrete (HSC) at −20 °C for winter concrete construction in a cold region. Specifically, the combination of graphene nanoplatelet (GNP) incorporation and electric thermal (ET) curing could effectively improve the performance when preparing high-strength concrete (GNP-HSC) at −20 °C. The optimal amount of steel fiber added in this work was determined numerically and experimentally to be 2.5 vol%. The temperature development regularity of the ET-cured sample was also recorded during the whole curing process. Mechanical property results indicated that the combination of GNP incorporation and ET curing could effectively stimulate the strength formation of HSC samples to 91.2 MPa at early age, which is remarkable for concrete construction at −20 °C. Moreover, microstructural analyses (including XRD, TG and SEM analyses) were further conducted to verify the advantages of GNP incorporation and ET curing on the hydration products, hydration degree and microstructure of HSC samples. This work provides new insights into the application of GNP as a nanoscale material to improve the performance of HSC structures at extremely low temperatures.

Factors Affecting Carbonation Depth in Foamed Concrete Bricks for Accelerate CO2 Sequestration

Foamed concrete bricks (FCB) have high levels of porosity to sequestrate atmospheric CO2 in the form of calcium carbonate CaCO3 via acceleration of carbonation depth. The effect of density and curing conditions on CO2 sequestration in FCB was investigated in this research to optimize carbonation depth. Statistical analysis using 2k factorial and response surface methodology (RSM) comprising 11 runs and eight additional runs was used to optimize the carbonation depth of FCB for 28 days (d). The main factors selected for the carbonation studies include density, temperature and CO2 concentration. The curing of the FCB was performed in the chamber. The results indicated that all factors significantly affected the carbonation depth of FCB. The optimum carbonation depth was 9.7 mm, which was determined at conditions; 1300 kg/m3, 40 °C, and 20% of CO2 concentration after 28 d. Analysis of variance (ANOVA) and residual plots demonstrated the accuracy of the regression equation with a predicted R2 of 89.43%, which confirms the reliability of the predicted model.

Investigation of Mineral Carbonation with Direct Bubbling into Concrete Sludge

Mineral carbonation, which is CO₂ fixation through a carbonation reaction using alkaline earth metals, is being investigated as a carbon capture and utilization method to reduce CO₂ atmospheric emissions. Concrete sludge is an alkali waste material from the concrete industry and contains abundant calcium components. We investigated the applicability of concrete sludge for mineral carbonation. In this study, gas containing CO₂ was bubbled through the model concrete sludge solution and the effects of the solid-liquid ratio, bubbling time, gas flow rate, and the partial pressure of CO₂ on the CO₂ fixation ratio and fixation rate were investigated. The CO₂ fixation ratio decreased with increasing CO₂ bubbling time, CO₂ flow rate, and CO₂ partial pressure. The CO₂ fixation rate increased with increasing CO₂ flow rate and CO₂ partial pressure. The formation of calcite, a form of calcium carbonate, was confirmed.

Assessment of the Permeability to Aggressive Agents of Concrete with Recycled Cement and Mixed Recycled Aggregate

Acceptance by the construction industry of recycled concrete as a sustainable alternative material is contingent upon a reliable assessment of its permeability to corrosive agents. This study analyses the transport mechanisms associated with chloride (Cl−), oxygen (O2) and carbon dioxide (CO2) ions in concrete with cement made with 10% or 25% ground recycled concrete (GRC) separately or in combination with 50% mixed recycled aggregate (MRA). The findings show that, irrespective of aggregate type, concrete with GRC exhibited lower resistance to ingress than conventional concrete due to its greater porosity. Nonetheless, O2 permeability was consistently below 4.5 × 10−17 m2 and CO2 penetration, under 4 mm/year0.5, indicative of concrete with high quality. Resistance to CO2 and Cl− penetration in the materials with 10% GRC was similar to the values observed in conventional concrete. On the other hand, the incorporation of 25% GRC increased the penetration of CO2 and Cl- by 106% and 38%, respectively. Further to those findings in normal carbonation environments, reinforcement passivity would be guaranteed in such recycled materials over a 100 year service life.

Recycling drinking water treatment sludge into eco-concrete blocks with CO2 curing: Durability and leachability

Drinking water treatment sludge (DWTS) can be recycled into low-strength concrete blocks for construction use. The sodium sulfate resistance and leaching behaviours of the DWTS-derived blocks are investigated in this study. The experimental results show that the addition of DWTS degrades the sodium sulfate resistance of the concrete blocks, however CO₂ curing compensates for such property, especially in the case of blocks incorporating 30% DWTS. The improvement can be attributed to the formation of crystalline CaCO₃ during CO₂ curing for microstructure refinement evidenced by X-ray Computed Tomography and Scanning Electron Microscopy. Leaching analyses show that Cu and Al concentrations increased with increasing DWTS content, and CO₂ curing adversely increased the leachability of metals due to the decrease of pH, especially at early leaching stage. Nevertheless, the total leaching concentrations of Cu and Al after 60-day test is far below the prescribed limitations, regardless of samples subject to air curing or CO₂ curing. In summary, sludge-derived blocks exposed to CO₂ curing are safe and behave well in aggressive environments. Therefore, this study showcases a green technology that successfully recycling DWTS into value-added and durable concrete blocks with low environmental impacts.

Influences of coal fly ash containing ammonium salts on properties of cement paste

This paper aims to investigate the influence of coal fly ash containing ammonium salts on properties of cement paste. Fly ash was incorporated at percentage of 20% by weight of the total binder to replace Portland cement. Ammonium hydrogen sulfate (NH₃HSO₄) or ammonium sulfate ((NH₃)₂SO₄) were introduced at percentages of 3.0%-6.0% or 1.5%-3.0% by fly ash weight. Compressive strength, setting time and hydration heat were evaluated on variable blend mixtures. Adsorption behaviors of polycarboxylate-based superplasticizer and air entraining agent on fly ash particles were also evaluated using total organic carbon (TOC) method. Semi-adiabatic calorimetry, X-ray diffraction, Fourier transform infrared spectroscopy, thermogravimetry-differential thermal analysis, mercury intrusion porosity and scanning electron microscope measurements were carried out on typical samples. Experimental results showed that the chemical admixtures adsorbed by coal fly ash were increased by the introduction of NH₃HSO₄ or (NH₃)₂SO₄. The addition of 3.0%-6.0% NH₃HSO₄ and 1.5%-3.0% (NH₃)₂SO₄ decreased the 28d compressive strength of fly ash-cement pastes by 4.3%-10.4% and 6.3%-8.9%, respectively. The initial and final setting times were delayed and the early age hydration of Portland cement was also retarded. Moreover, the pore structure was coarsened and porosity was increased for the hardened cement specimens due to the release of ammonia and lower hydration degree. Therefore, more attention should be paid to the application of denitration fly ash to the cement and concrete industry.