Considering the dangers and risks posed by climate change, many countries and organizations have pledged to achieve “net-zero emissions” by 2050. The present work introduces a new approach that addresses the growing global carbon emissions issue by integrating CO₂ capture and sequestration through the carbonation of recycled concrete aggregates (RCAs), producing an alternative sand (AS) product. This study explores the capture of low-concentration CO₂ and its suitability for sequestration into RCA. The integration of RCA in the process allows concrete manufacturers to reduce their reliance on mined sand, thereby minimizing its impact on the environment. A techno-economic analysis (TEA) was conducted on the CO₂ absorption and mineralization process to assess its economic viability across various processing scales, from 150 kt CO₂ per year to 1 Mt CO₂ per year. Initial bench-scale experiments show that RCA samples have a carbonation capacity of 10% by mass—these experimental results were used to conduct a TEA using Aspen Plus and an Aspen Process Economic Analyzer (APEA). The TEA results reveal a cost of 11.02 USD/t AS at the smallest scale and 8.02 USD/t AS at the largest scale.

The increasing generation of incineration bottom residues poses environmental risks due to heavy metal leaching, while carbonation is one of the effective methods to immobilize heavy metals. This study introduces a novel approach to mitigate heavy metal leaching from incineration bottom ash (IBA) by accelerated carbonation with ammonium carbonate solution. The effect of ammonium carbonate concentration on carbonation efficiency and inhibition of heavy metal leaching was systematically investigated. X-ray fluorescence was used to analyze the composition of IBA, and thermogravimetric analysis (TGA) and inductively coupled plasma optical emission spectroscopy/mass spectrometry were used to determine carbonation capacity and heavy metal leaching, respectively. Results showed that maximum carbonation capacity was achieved at 8 wt% ammonium carbonate concentration at a solid/liquid ratio of 1:5 for 1 h, but the increase in carbonation efficiency slowed down when the concentration exceeded 4 wt%. Ammonium carbonate accelerated carbonation effectively inhibited heavy metal leaching, particularly copper, with an 89% inhibition rate at 10 wt% ammonium carbonate, while diminished effects were observed with chromiun. The effect of the ammonium carbonate concentration on heavy metal inhibition became less significant above 4 wt%, revealing a nuanced relationship between carbonation and heavy metal leaching inhibition. TGA and X-ray diffraction analyses confirmed the formation of insoluble CaCO3 during carbonation, elucidating neomineralization processes that immobilize trace heavy metals. In addition, the study explored the impact of carbonation on leachate pH, emphasizing the interplay between pH reduction and heavy metal leaching inhibition.