Mineral carbonation is a process where carbon dioxide (CO2) is converted into solid carbonates. The product of mineral carbonation is obtained when CO2 is being contacted with alkaline earth metals, such as calcium and magnesium. In this research, the team focusing on producing precipitated calcium carbonate (PCC), as a solution to manage CO2 release which comes from high CO2 content natural gas field production. To make this process economically feasible, the team has researched obtaining valuable PCC quality which is marketable in various industries. The quality mainly measured in terms of particle size, where the particle size will determine the application of the PCC. This study investigates the effect of feed solution retention in reactor towards PCC particle size, using continuous mineral carbonation system. In this system, Milk of Lime, which is Calcium Hydroxide (Ca(OH)2) solution used as feed. To produce this solution, 7 g/L Calcium Oxide (CaO) is suspended in deionized water and stirred. This solution is injected in the range of 0.8 L/min to 1.2 L/min into pressurized CO2 in the range of 10 bar to 80 bar. The retention time is varied by using mechanically modified reactor inlet cap, where the feed inlet time is delayed by elongation of feed injector inside the reactor by 15 cm (NEWCAP). Particle size of the product was analyzed by using Malvern Mastersizer 3000. Experimental data show that by shortening the feed solution retention time inside the reactor, will produce smaller particle size. Using the unmodified reactor inlet, the obtained product particle size ranging (D50) from 15 micron to 25 micron. On the other hand, using NEWCAP reactor inlet the obtained particle size ranging (D50) from 8 micron to 20 micron.

The current state of the art research, and latest engineering technology application in the synthesis of the aragonite crystalline phase of calcium carbonate is presented here. Aragonite crystalline products are highly valuable in selected industries, such as medical and personal care, and in food additives using MgCl₂ as a chemical inducer. The outcome of this literature review provides the outlook of the available research whitespace opportunity in optimizing the current process parameters and in ensuring that sustainable and economically feasible continuous production of aragonite products could be achieved. One of the major improvements proposed in this study is to investigate the methods of synthesizing aragonite crystalline particles using a continuous mineral carbonation reactor system and optimizing the operating parameters. An experimental design was established to identify all the main effects to maximize aragonite production. The three main effects investigated are the effect of feedstock or reactant concentration, the effect of reaction temperature, and the effect of reaction time towards aragonite yield in the final products synthesized. An optimized operating parameter for maximum aragonite yield at 95% purity was proposed at the reaction temperature T of 90 °C, reaction time t of 10 min, and feedstock ratio Mg-to-Ca of 0.4. Subsequently, the continuous reactor system was designed, operated, and tested for at least 50 h operation, where the lime CaO(s) feed was successfully converted into aragonite products with purity between 75 and 81%. The properties and quality of the aragonite produced were analytically characterized from the following laboratory methods which include the thermalgravimetric analysis, TGA; X-Ray Diffraction, XRD; scanning electron microscopy, SEM; and induction coupled plasma, ICP. TGA mass balance after decomposition suggests that 44% of the mass balance represents the weight of CO₂ sequestered in the aragonite crystalline carbonates. Hence, the aragonite crystalline carbonates can be labeled as a green product which sequesters 0.44 kg of CO₂ per 1 kg of precipitated aragonite products synthesized. Interestingly, SEM microscopy characterization results revealed that the aragonite precipitate has a physical morphology of needle-like shape with a good aspect ratio (length/diameter) AR of between 8.67 micron and 11.35 micron. The properties were found to be suitable for paper making fillers, medical, personal care, and food additive applications.

Conventional production methods of aragonite production utilize chemical inducers to promote the evolution of the calcite crystalline phase to the aragonite phase of calcium carbonate. The chemical inducers used require a considerable amount of magnesium chloride (MgCl₂) to induce crystallization, which is a major operational cost. Application of such materials in large amounts can be a deterrent to achieving a sustainable and economically feasible end-product derived from carbon dioxide (CO₂) molecules. A number of previous research works focused mainly on optimizing the usage of MgCl₂ or introducing alternative chemical inducers for aragonite production. In this work, we are proposing the usage of natural seawater as it is a naturally available and abundant resource to induce the synthesis and continuous production of aragonite compounds. Due to inconsistent quality and salinity of the natural seawater sampled, harvested, and dried, Red Sea Salt is utilized, blended at 33 g/L throughout the laboratory experiments for better statistical control, and is referred to as blended or artificial seawater. A methodology of utilizing seawater, which has a considerable concentration of MgCl₂ compound, can be utilized as a sustainable, natural, and economically feasible natural inducer to synthesize aragonite has been developed by utilizing artificial seawater for laboratory proof of concept. The main effects identified for the optimization of aragonite synthesis are lime (CaO) feedstock concentration in seawater, reaction temperature, and reaction duration. The experiment results indicated that only by increasing temperature and reaction duration, or both, can the aragonite yield be increased. It is suggested that the range of operation to obtain > 80% aragonite purity has been identified with the reaction temperature at 90 °C, reaction duration of 10 min, and CaO concentration in seawater at 1 g/L. The quality of the aragonite synthesized via seawater is characterized using XRD, ICP, FESEM, and TGA, and compared with aragonite particles synthesized using MgCl₂ inducers. In comparison, seawater aragonite has lower residual alkalinity compared to both calcite and aragonite via MgCl₂ and has a mixture of predominantly needle-shaped crystalline structure and remnants of cubic-shaped particles, presumably calcite, suitable for application in food, beverages, and pharmaceuticals (calcium antacids, nutritional supplements, chewable, lozenges).

The US National Academy of Sciences has reported that CO₂ mineral carbonation is among the largest, most energy-efficient CO₂ utilization technologies closest to commercial scale due to its thermodynamic favorability and end-product market size. However, the natural rate of reaction is generally slow in terms of kinetics, whereby only by dramatically increasing the CO₂ dissolution rate can a major impact on the rate of reaction for CO₂ mineral carbonation happen. Hence, despite the clear advantages of CO₂ mineral carbonation over other options in Carbon Capture and Sequestration CCS technologies, the current research gaps highlighted here should be addressed to ensure future technology deployment success. Therefore, this study investigated the feasibility of the design, operation and experimental improvement of a continuous high-pressure CO₂ reactor in producing and optimizing high-quality precipitated calcium carbonates PCC synthesized for consumer and industrial application. A novel mineral carbonation reactor is hereby proposed, in which, by incorporating the application of a high-pressure or supercritical CO₂ phase into the reactor, CO₂ diffusion can be increased into the continuously fine-sprayed aqueous reaction media within the reactor to form PCC. The effective reactor volume can be simultaneously decreased from the reduced high-pressure CO₂ volume. Next, by incorporating a backpressure regulator, a continuous flow of the liquid phase in and out of the reactor can be controlled. The initial reactor design had undergone successful start-up, but experimental improvement alone was unable to provide the anticipated particle size of the calcium carbonate precipitate PCC. Optimized design of the new reactor to limit internal dead flow zones was proven to successfully reduce the particle size of precipitated calcium carbonate PCC from an initially P50/P90 of 87/131 μm to 3.8/9.1 μm. Additionally, a continuous 100 h stable run was successfully executed to thoroughly investigate the three main factors influencing the quality of PCC synthesized, in which the reactant flow rate and feedstock concentration were found to be significant, with the exception of CO₂ gas pressure. The overall 3D surface trend of the particle size spread P50/P90 of the PCC synthesized was plotted over the experimental range and found to meet most of the industrial requirements and technical specifications, except for TiO₂ replacement which requires sub-micron quality. Instantaneous electricity power consumption was also measured at various operating points. Performance-wise, the continuous high-pressure CO₂ mineral carbonation reactor in this work was calculated to be able to process a maximum of 4200 g/h lime CaO feedstock at a lime concentration of 7 g/L and flow rate of 10 g/L, using a 40 L internal volume vessel, effectively increasing the productivity of lime CaO production by several fold from what was reported by peer studies assuming similar electricity costs were used for all productivity factors under consideration.