Environmental Benefit Assessment for the Carbonation Process of Petroleum Coke Fly Ash in a Rotating Packed Bed

A high-gravity carbonation process was deployed at a petrochemical plant using petroleum coke fly ash and blowdown wastewater to simultaneously mineralized CO₂ and remove nitrogen oxides and particulate matters from the flue gas. With a high-gravity carbonation process, the CO₂ removal efficiency was found to be 95.6%, corresponding to a capture capacity of 600 kg CO₂ per day, at a gas flow rate of 1.47 m³/min under ambient temperature and pressure. Moreover, the removal efficiency of nitrogen oxides and particulate matters was 99.1% and 83.2%, respectively. After carbonation, the reacted fly ash was further utilized as supplementary cementitious materials in the blended cement mortar. The results indicated that cement with carbonated fly ash exhibited superior compressive strength (38.1 ± 2.5 MPa at 28 days in 5% substitution ratio) compared to the cement with fresh fly ash. Furthermore, the environmental benefits for the high-gravity carbonation process using fly ash were critically assessed. The energy consumption of the entire high-gravity carbonation ranged from 80 to 169 kWh/t-CO₂ (0.29-0.61 GJ/t-CO₂). Compared with the scenarios of business-as-usual and conventional carbon capture and storage plant, the economic benefit from the high-gravity carbonation process was approximately 90 and 74 USD per ton of CO₂ fixation, respectively.