Preparation of High-Purity Calcium Carbonate by Mineral Carbonation Using Concrete Sludge

A new type of mineral carbonation process for concrete sludge, a waste of fresh concrete under hydration, was developed, and the carbonation performances of the process were examined by laboratory-scale experiments. The process is composed of two steps; filtration of concrete sludge and bubbling of CO₂ into the filtrate to form calcium carbonate. Model concrete sludge, a mixture of cement and water, was filtered through a cellulose filter after hydration for 24 h to obtain a solution containing dissolved calcium ions. Then, the model flue gas containing CO₂ (10%) was bubbled through the filtrate solution, and calcium carbonate was precipitated by the carbonation reaction. About 3% of calcium in the concrete sludge could be extracted into the filtrate in a single filtration step, and more than 95% of dissolved calcium was recovered as calcium carbonate by the bubbling of CO₂. The obtained calcium carbonate was calcite with a high purity (>95%) and 5-10 μm. The solid residue (concrete sludge) after filtration was mixed with fresh water and filtered through a cellulose filter. Then, the model flue gas was bubbled into the filtrate solution for carbonation. This filtration-bubbling step was repeated 5 times, and 10.8% of calcium in the feed cement was extracted into the filtrates in total. More than 95% of the extracted calcium could be recovered as calcium carbonate with high purity (>97%), and the overall conversion of calcium in the feed cement to calcium carbonate was 10.1%. The purity of calcium carbonate and the calcium conversion were much higher than those for the direct bubbling method, where the model flue gas is bubbled into concrete sludge.