Towards zero-waste mineral carbon sequestration via two-way valorization of ironmaking slag

• A symbiotic process is developed to valorize blast furnace slag into two products.
• Carbonation of extracted acetic acid leachate results in the production of PCC.
• Hydrothermal conversion of the extraction residues forms various zeolitic materials.
• Leaching selectivity is a key factor in the valorization potential of both products.

A three-stage process was developed to transform blast furnace slag (BFS) into two valuable products: precipitated calcium carbonate (PCC) and zeolitic materials. The conceptualized process aims to simultaneously achieve sustainable CO2 sequestration and solid waste elimination. Calcium is first selectively extracted by leaching with an organic acid, followed by carbonation of the leachate to precipitate CaCO3. In parallel, the hydrothermal conversion of the extracted solid residues in alkali solution induces the dissolution/precipitation mechanism that leads to the formation of micro- and meso-porous zeolitic materials. Leaching selectivity was identified as a key factor in the valorization potential of both products. Acetic acid satisfactorily limited the leaching of aluminum, required for the subsequent synthesis of zeolites, and carbonation of the acetic acid leachate resulted in the production of PCC of varied mineralogy and morphology, depending on processing conditions. In the hydrothermal conversion stage, the formation of zeolitic phases was observed, and their characteristics were found to vary depending on the calcium extraction efficiency in the previous stage, and the alkali (NaOH) concentration. The zeolitic phases produced, in order of increasing valorization potential, were: tobermorite, sodalite, lazurite, and analcime.

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