METHOD AND SYSTEM FOR ELECTROLYSIS-ASSISTED MINERALIZATION OF CARBON DIOXIDE WITH INDUSTRIAL ALKALI WASTE

Description

FIELD OF TECHNOLOGY

The present disclosure relates generally to a field of carbon dioxide (CO₂) sequestration. More specifically, the present disclosure relates to a method for electrolysis-assisted mineralization of carbon dioxide with industrial alkali waste (i.e., mineral carbonation) to generate purified calcium carbonate and a system for electrolysis-assisted mineralization of carbon dioxide with industrial alkali waste to generate the purified calcium carbonate.

BACKGROUND

Climate change, driven primarily by anthropogenic carbon dioxide (CO₂) emissions, presents one of the most significant challenges of our time. As the world transitions towards more sustainable energy sources, there is an urgent need for effective CO₂ sequestration technologies to mitigate the impact of existing and future emissions. Conventional approaches to carbon dioxide (CO₂) sequestration, e.g., carbon capture, utilization, and storage (CCUS), have shown promise but face significant hurdles not only in terms of efficiency, cost-effectiveness, and scalability but also usability and sustainability.

Current direct CO₂ sequestration methods, particularly those involving subsurface storage or enhanced oil recovery (EOR), suffer from several drawbacks. Such direct CO₂ sequestration methods often require substantial energy input, potentially offsetting some of the carbon reduction benefits. In the case of CO₂ EOR, the overall carbon footprint reduction can be limited. Additionally, costs associated with capturing, storing, and injecting CO₂ are prohibitively high, making widespread adoption economically challenging. Furthermore, subsurface injection of CO₂ does not generate any marketable products, limiting the economic incentives for implementation. As a result of the aforementioned challenges, many CCUS projects have fallen behind schedule and are struggling to meet the projected CO₂ sequestration targets necessary to achieve net-zero emissions goals.

There is a growing recognition of the potential for mineral carbonation as an alternative approach to CO₂ sequestration. The process involves the reaction of CO₂ with alkaline materials to form stable carbonate minerals, effectively locking away the carbon in a solid form. Industrial alkali wastes, such as steel blast furnace slag, cement kiln dust, and fly ash, present an attractive feedstock for such processes due to their abundance and alkaline nature. However, existing mineral carbonation technologies face their own set of challenges. Conventional methods of mineralization of CO₂ have high complexity that requires multiple steps and complex equipment, not only increasing operational complexity and cost but also the time span of mineral carbonation. Typically, conventional mineral carbonation processes are very time and resource-intensive, thereby limiting throughput and scalability. The current systems, conventional reactors, and methods are inefficient due to technical challenges in balancing reaction time and resources for adequate contact between CO₂ and the alkaline materials, thereby adversely affecting overall conversion efficiency. For example, the resulting carbonated materials from conventional methods may have limited use, reducing the overall economic viability of the process, and typically, wastewater is generated in the conventional methods. Further, in conventional methods and systems, most of the chemicals introduced during the process of CO₂ mineralization are either consumed or wasted, which is not desirable from both an economic and environmental perspective. Furthermore, currently, the disposal of these spent or wasted chemicals creates additional environmental concerns and treatment requirements, making the overall process less sustainable and economically viable.

Further limitations and disadvantages of conventional and traditional approaches will become apparent to one of skill in the art through comparison of such systems with some aspects of the present disclosure as set forth in the remainder of the present application with reference to the drawings.

BRIEF SUMMARY OF THE DISCLOSURE

A method and a system for electrolysis-assisted mineralization of carbon dioxide with industrial alkali waste, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.

These and other advantages, aspects and novel features of the present disclosure, as well as details of an illustrated embodiment thereof, will be more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

FIG. 1 is a block diagram of a system for electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure;

FIG. 2 is a diagram of an electrolysis apparatus used in the electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure;

FIGS. 3A, 3B, 3C, and 3D are diagrams illustrating different views of an apparatus for electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure;

FIGS. 4A, 4B, and 4C collectively is a flowchart illustrating a method for electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure;

FIG. 5 is a diagram illustrating exemplary operations for electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure;

FIG. 6 is a block diagram of a system for electrolysis-assisted mineralization of carbon dioxide, in accordance with another embodiment of the present disclosure; and

FIGS. 7A, 7B, and 7C collectively, is a flowchart illustrating another method for electrolysis-assisted mineralization of carbon dioxide, in accordance with another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

Certain embodiments of the disclosure may be found in a method and system for electrolysis-assisted mineralization of carbon dioxide with industrial alkali waste. The disclosed method and system uniquely combine in-situ electrolysis operations with operations executed in a specially designed and modified hydrocyclone reactor to achieve rapid, high-purity calcium carbonate production while enabling continuous amine-based solvent regeneration. The disclosed technology provides a significantly improved solution for both carbon dioxide sequestration and valuable material production through an energy-efficient, environmentally sustainable process.

Unlike conventional mineralization approaches that typically require hours or days of processing time to generate calcium carbonate, the present disclosure achieves remarkable improvements in both processing speed and product quality as compared to conventional methods and systems. The entire mineralization process, from initial electrolysis to final calcium carbonate formation, is completed in under 5 minutes while maintaining product purity levels exceeding 95%. The system achieves this through a synergistic combination of electrolysis-assisted pH control and optimized hydrocyclone reactor design and operation, enabling carbonation rates of 90-99.99% within this drastically reduced timeframe.

Furthermore, the disclosed system demonstrates superior efficiency in amine-based solvent utilization and recycling through its innovative hydrocyclone design that enables simultaneous reaction and separation. The system achieves continuous regeneration and recycling of the electrolyzed-alkaline water solvent blend, with separation occurring between the overflow and underflow sections of the modified hydrocyclone. This design enables efficient solvent recovery while maintaining high product purity, creating a more sustainable and economically viable process compared to conventional approaches.

The method provides precise control over reaction conditions through its electrolysis-assisted pH manipulation capabilities. The system first generates hydroxide ions through electrolysis to achieve a first pH range, followed by controlled blending with an amine-based solvent to reach a second, higher pH range. This two-stage pH control enables optimal conditions for both calcium oxide extraction from industrial alkali waste and subsequent carbonation reactions, resulting in superior product quality and conversion efficiency. In an implementation, before the electrolysis operation, a pre-processing operation may be executed, where an industrial alkali waste material is mixed with ammonium chloride or hydrogen chloride in an extraction reactor to extract calcium and magnesium from the industrial alkali waste material as metal chlorides and form a first mixture and the first mixture is passed to an in-line electrolysis apparatus. Such implementation further improves the carbonation rate and generation of calcium carbonate with high purity (e.g., 98-99.99%) where the entire process cycle in a run takes less than 2-3 minutes (mostly 1 minute).

In the following description, reference is made to the accompanying drawings, which form a part hereof, and in which are shown, by way of illustration, various embodiments of the present disclosure.

FIG. 1 is a block diagram of a system for electrolysis-assisted mineralization of carbon dioxide (CO₂), in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown a block diagram of a system 100. The system 100 includes a modified hydrocyclone 104 and a filtration reactor 106 operatively and fluidly coupled to the modified hydrocyclone 104. In some implementations, the system 100 further includes a heating chamber 102 positioned between the modified hydrocyclone 104 and the filtration reactor 106 and also operatively and fluidly coupled to each of the modified hydrocyclone 104 and the filtration reactor 106. The system 100 further includes a defined CO₂ source 108 fluidly connected at an outlet of the filtration reactor 106 and an inlet of the heating chamber 102. The filtration reactor 106 is operatively and fluidly coupled to an amine reactor 110 (including an amine-based solvent), an industrial alkali waste material source 112, and a metal catalyst source 114. The system 100 further includes an in-line electrolysis apparatus 118 operatively and fluidly coupled to the amine reactor 110.

In some implementation, the system 100 may further include a first flow indicator positioned at an outlet of the defined CO₂ source 108. The first flow indicator may be configured to measure and control a flow of CO₂ into the heating chamber 102. Similarly, the system 100 may further include a second flow indicator positioned at an outlet of the amine reactor 110. The second flow indicator is configured to measure and control the flow of the amine-based solvent into the filtration reactor 106.

The system 100 may further include one or more controllers 116 communicatively coupled to the system 100 and its components. The system 100 may further include a separator 122 fluidly coupled to the modified hydrocyclone 104. Further, the system 100 includes one or more dryers 124 operably coupled to the separator 122. Furthermore, the system 100 may include a final product packaging unit 126 operably coupled to the one or more dryers 124.

In an implementation, the present disclosure provides the system 100 for electrolysis-assisted mineralization of CO₂, where water undergoes electrolysis in the in-line electrolysis apparatus 118 to produce an alkaline water stream including hydroxide ions within a first pH range (typically pH 9-10). The alkaline water stream is then blended with the amine-based solvent (such as MEA or MDEA) received from the amine reactor 110 to obtain an electrolyzed-alkaline water solvent blend having a second, higher pH range (typically pH 12-14). The electrolyzed-alkaline water solvent blend is mixed with industrial alkali waste material (received from the industrial alkali waste material source 112) in the filtration reactor 106, enabling efficient extraction of the metal oxide and formation of metal hydroxides. The process simultaneously separates silica byproducts 106A at a first end of the filtration reactor 106 while producing a fluidic filtrate comprising the metal hydroxide at a second end. CO₂ from the defined CO₂ source 108 (either pure CO₂ or flue gas containing CO₂) is then injected into the fluidic filtrate to obtain a first mixture including the metal carbonate, achieving a first carbonation rate of 10-30%. The resulting mixture is directed through the heating chamber 102 maintained at 25-120° C. (preferably 80° C.), achieving a carbonation rate of 31-50%. The heated mixture then enters the modified hydrocyclone 104 configured as a carbon dioxide mineralization reactor, where final carbonation occurs, achieving a second carbonation rate of 51-99.99%. In some implementation, the second carbonation rate is in range of 90-99.99% and the integrated process produces high-purity calcium carbonate (95-99.999% pure) while simultaneously regenerating the electrolyzed-alkaline water solvent blend for reuse. For example, processing 1 ton of CO₂ requires approximately 2.5-3.5 tons of industrial alkali waste (depending on calcium oxide content), 1-2 tons of amine solvent, and 8 tons of water, yielding approximately 2 tons of high-purity calcium carbonate. The entire conversion process is completed in under 5 minutes (typically 1-2 minutes with catalyst addition), representing a significant improvement over conventional methods. The resulting calcium carbonate product finds immediate application in construction materials, polymer and paint manufacturing, paper production, and various industrial applications.

The heating chamber 102 refers to a mixing and reaction vessel where an initial interaction between the fluidic filtrate produced by the filtration reactor 106 and the CO₂ from the defined CO₂ source 108 occurs. The heating chamber 102 serves as a pre-processing stage before the first mixture enters the modified hydrocyclone 104. In some embodiments, the heating chamber 102 has an inlet 102A for heat intake from a heat source and an outlet 102B for heat exit back to the heat source. The heating chamber 102 is configured to control the temperature of a mixture, which may significantly influence the reaction kinetics.

The heating chamber 102 may include a loop pathway or a predefined movement pattern to facilitate thorough mixing of the components. The loop pathway or the predefined movement pattern ensures that the CO₂ is well-dispersed in the fluidic filtrate, promoting efficient surface contact between the reactants. A retention time of the first mixture in the heating chamber 102 is controlled to optimize an initial reaction and mixing process. It is to be understood that the retention time may vary based on the length of the loop pathway in an example.

In some embodiments, the heating chamber 102 may be configured with different geometries or internal structures to enhance mixing. Some other examples of the heating chamber 102 may include, but are not limited to, baffles, static mixers, or agitation mechanisms without limiting the scope of the disclosure.

The heating chamber 102 is configured to handle various types of industrial alkali waste materials, including but not limited to steel slag (either crushed or granulated), cement kiln dust, and fly ash. In some cases, the heating chamber 102 may also accommodate pure calcium oxide as an alkali source. In some embodiments, the heating chamber 102 may also be equipped with sensors and monitoring devices to track parameters such as temperature, pH, and composition of the first mixture. Tracking of the parameters and associated measurements measured from the sensors and the monitoring devices may be used by the controller 116 to adjust process conditions in real-time for optimal performance. In some embodiments, the heating chamber 102 may be pressurized to enhance the dissolution of CO₂ in the carbon dioxide-dissolving solvent and to promote the initial stages of a mineral carbonation process.

Throughout the present disclosure, the term “mineral carbonation process” refers to a process in which carbon dioxide (CO₂) is transformed into solid carbonate minerals through a chemical reaction with metal-containing minerals. In the mineral carbonation process, CO₂ reacts with naturally occurring or synthetic minerals containing alkaline earth metals to form stable carbonate compounds. The mineral carbonation process is employed for the permanent sequestration of CO₂, converting the carbon dioxide from a gas into a stable solid form that may be safely stored or utilized.

The modified hydrocyclone 104 refers to a special-purpose reactor designed and configured for a mineral carbonation process. In an embodiment, the modified hydrocyclone 104 is configured as the carbon dioxide mineralization reactor. The modified hydrocyclone 104 is configured to facilitate rapid mineral carbonation of the industrial alkali waste material while simultaneously separating the products and regenerating the electrolyzed-alkaline water solvent blend for reuse. The modified hydrocyclone 104 includes one or more sections including an overflow section, an underflow section, a vortex-creating component positioned within the overflow section, and a conical section. The modified hydrocyclone 104 further includes an inlet connected to the overflow section, configured to receive the first mixture from the heating chamber 102. In some implementations, a slurry pump 120 is configured to feed the first mixture into the inlet of the modified hydrocyclone 104 from the heating chamber 102. In some implementations, dimensions and dimension ratios of the one or more sections may be optimized for the mineral carbonation process, as per application requirements. The one or more sections work together to create controlled fluid dynamics essential for the mineral carbonation process and associated chemical reactions.

The filtration reactor 106 refers to a specialized vessel configured to mix the electrolyzed-alkaline water solvent blend with the industrial alkali waste material to achieve efficient separation of the silica byproducts 106A and the fluidic filtrate including the metal hydroxides. In some implementations, the filtration reactor 106 includes a dual-output design with distinct separation zones i.e., the first end configured to collect the silica byproducts 106A and the second end configured to output the fluidic filtrate including calcium hydroxide. The filtration reactor 106 operates under controlled mixing conditions to ensure contact between the electrolyzed-alkaline water solvent blend (pH 12-14) and the industrial alkali waste material. The filtration reactor 106 may incorporate advanced monitoring systems that continuously measure and maintain optimal mixing parameters. In some implementations, the filtration reactor 106 includes automated feed systems for precise dosing of the metal catalyst in the range of 10-500 parts per million (ppm) of the electrolyzed-alkaline water solvent blend. Temperature control mechanisms may be integrated to maintain conditions between 25-40° C. during the initial mixing phase. The filtration reactor 106 is designed to handle industrial alkali waste material feed rates proportional to the electrolyzed-alkaline water solvent blend flow, typically maintaining a ratio where processing one ton of CO₂ requires approximately 2.5-3.5 tons of industrial alkali waste material (depending on metal oxide content). Additionally, the filtration reactor 106 may incorporate real-time monitoring systems to ensure separation of the silica byproduct stream from the metal hydroxide-rich filtrate stream.

The defined CO₂ source 108 refers to any suitable source of carbon dioxide that may supply CO₂ to the system 100 for mineralization of CO₂. In this case, the defined CO₂ source 108 may be an industrial flue gas comprising CO₂ or a purified CO₂ stream. In a case where the defined CO₂ source 108 is the industrial flue gas, additional gases other than the CO₂ may be vented out from a gas vent (not shown) after the CO₂ is dissolved in the fluidic filtrate to obtain the first mixture. It is to be understood by a person of ordinary skill in the art (POSITA) that different carbon capture methods and systems may be used without limiting the scope of the disclosure. For example, when the defined CO₂ source 108 is the industrial flue gas, the system 100 may incorporate pre-treatment units such as desulfurization or dehumidification to ensure the CO₂ stream's quality. As long as CO₂ is present in sufficient quantity in the defined CO₂ source 108, any carbon capture methods may be used. A flow rate of CO₂ released from the defined CO₂ source 108 may be regulated to match capacity and a predefined carbonation rate of the system 100.

Throughout the present disclosure, the term “carbonation rate” refers to a rate at which carbon dioxide reacts with a substance, typically an alkaline material, to form stable carbonates. The carbonation rate is influenced by factors such as the concentration of CO₂, temperature, pressure, pH, and availability of reactive materials in the system 100. The carbonation rate determines how quickly and efficiently CO₂ may be mineralized or converted into solid carbonates.

Concentration of CO₂ in a supply of CO₂ from the defined CO₂ source 108 may vary between 1 to 100%. In some examples, a preferred range of the CO₂ concentration from the defined CO₂ source 108 may be between 10% and 100%. In other examples, a range of the CO₂ concentration from the defined CO₂ source 108 may be between 25% and 100%. Additionally, another range may be between 30% and 100%. In other examples, a more preferred range of the CO₂ concentration from the defined CO₂ source 108 may be between 50% and 100%. In some other examples, most preferably, the CO₂ concentration from the defined CO₂ source 108 may be 100% or near 100% (pure CO₂).

The amine reactor 110 may be a blender and refers to a specialized vessel configured to mix the alkaline water stream 128B with a solvent (i.e., an amine-based solvent). The amine reactor 110 may include temperature-controlled storage vessels, precision metering pumps, and automated dispensing systems to maintain consistent solvent quality and delivery. In an exemplary implementation, the amine reactor 110 incorporates monitoring systems to track solvent concentration and maintain optimal blending ratios with the electrolyzed water stream.

The amine reactor 110 provides the solvent that are CO₂ soluble and are compatible with the electrolysis-assisted mineralization process. In some implementations, the solvent is an amine-based solvent. The amine-based solvent may include, but are not limited to, primary amines (such as monoethanolamine, i.e., MEA), secondary amines (such as diethanolamine (DEA)), tertiary amines (such as methyldiethanolamine (MDEA)), and quaternary amines. The amine-based solvent concentration in the electrolyzed water blend is maintained between 1% to 30% by volume. In some examples, the concentration of the amine-based solvent in the electrolyzed water blend is in the range between 10% to 20% by volume. In some other examples, the concentration of the amine-based solvent in the electrolyzed water blend is in the range between 20% to 30%. The blend ratio is used for achieving the desired pH range for calcium oxide extraction and subsequent carbonation reactions. The amine reactor 110 maintains precise control over the solvent-to-water ratio. In an example, the process of the electrolysis-assisted mineralization of carbon dioxide may utilize a blend of 1-2 tons of amine solvent with 8 tons of water per ton of CO₂ processed.

The industrial alkali waste material source 112 refers to a supply of reactive materials for electrolysis-assisted CO₂ mineralization. The industrial alkali waste material source 112 may supply various materials including, but not limited to, steel slag (crushed or granulated), cement kiln dust, fly ash, or pure calcium oxide. In some embodiments, the industrial alkali waste material source 112 may include pre-treatment capabilities such as grinding, sieving, or chemical activation to prepare the industrial alkali waste material for the mineral carbonation process. The particle size distribution of the industrial alkali waste material may be controlled to optimize reactivity. In some examples, the particle size distribution of the industrial alkali waste material may range from 1 micrometer (μm) to 1000 μm. In some other examples, the particle size distribution of the industrial alkali waste material may have a preferred range of 10 μm to 500 μm.

The metal catalyst source 114 refers to a supply of catalysts used to enhance the electrolysis-assisted mineral carbonation process. The metal catalyst source 114 may include, but is not limited to, nanoparticles of metals such as nickel, cobalt, or platinum. In some implementations, the metal catalyst source 114 may further include precision dosing systems, dispersion mechanisms, and safeguards to handle potentially reactive materials. In some embodiments, the metal catalyst may be supported on carrier materials to enhance distribution and recovery. In some implementations, metal catalyst may not be used depending on the cycle time of the mineral carbonation process to be achieved. For example, when used metal catalysts may further reduce the cycle time of the mineral carbonation process to less than 1 minute.

The one or more controllers 116 may be configured to manage the overall operation of the mineral carbonation process, i.e., manages the overall operation of the system 100. The one or more controllers 116 may control flow rates, mixing ratios, reaction conditions, and monitor various parameters throughout the process. The one or more controller 116 may be communicatively coupled to one or more sensors, including but not limited to pH meters, temperature probes, pressure sensors, and composition analyzers at various locations in the system 100. In some implementations, the one or more controllers 116 may use advanced control operations, potentially including machine learning or artificial intelligence, to optimize the mineral carbonation process in real-time. The one or more controllers 116 may adjust operational parameters such as feed rates, temperatures, and pressures to maintain performance of the system 100 under varying input conditions. In some examples, the one or more controllers 116 may further manage safety protocols, system start-up and shut-down procedures, and provide data logging and reporting capabilities.

The in-line electrolysis apparatus 118 refers to a specialized vessel configured to perform controlled electrolysis of water to generate hydroxide ions and achieve the first pH range (typically pH 9-10). In some implementations, the in-line electrolysis apparatus 118 includes a cathode chamber and an anode chamber separated by an ion-selective membrane, with electrodes fabricated from materials such as platinum, titanium, or carbon-based composites. The in-line electrolysis apparatus 118 operates under controlled current densities ranging from 50 to 500 mA/cm², with voltage potentials typically maintained between 2-5V DC. In some implementations, the in-line electrolysis apparatus 118 includes advanced pH monitoring systems that continuously measure and adjust hydroxide ion generation to maintain the desired first pH range. Temperature control mechanisms are integrated to maintain optimal electrolysis conditions between 20-40° C. In some implementations, the in-line electrolysis apparatus 118 is configured to process water flow rates proportional to the overall system capacity. For example, for processing of 1 ton of CO₂, electrolysis of approximately 8 tons of water is required. Additionally, the in-line electrolysis apparatus 118 may incorporate automated cleaning systems to prevent electrode fouling and maintain consistent performance over extended operation periods.

The in-line electrolysis apparatus 118 is configured to maximize hydroxide ion generation while minimizing energy consumption. In some examples, the in-line electrolysis apparatus 118 incorporates flow distribution systems that ensure uniform electrolyte circulation and prevent concentration gradients. In some examples, the in-line electrolysis apparatus 118 may be equipped with automated pressure relief valves operating at 1-5 bar to manage any hydrogen gas generation during electrolysis. In some implementations, the in-line electrolysis apparatus 118 includes real-time conductivity sensors to monitor electrolyte concentration and ion generation rates, ensuring consistent hydroxide ion production for pH control in subsequent process steps.

The separator 122 refers to a device configured to separate a solid carbonated product from any remaining liquid after the chemical reaction in the modified hydrocyclone 104. In some embodiments, the separator 122 may include, but not limited to, a centrifuge, filter, or another type of solid-liquid separation equipment. In an example, the separator 122 may be used to recover the solid carbonated minerals produced in the chemical reaction in the modified hydrocyclone 104.

The one or more dryers 124 are configured to remove residual moisture from the separated solid carbonated product. In some embodiments, the one or more dryers 124 may include, but not limited to, a fluidized bed dryer, rotary dryer, or another type of drying equipment. The purpose of the one or more dryers 124 is to produce a dry, final carbonated mineral product suitable for storage or further use.

The final product packaging unit 126 refers to equipment configured to package the dried, carbonated mineral product for storage, transport, or distribution. The final product packaging unit 126 may include bagging machinery, bulk packaging systems, or other appropriate packaging systems suitable for handling and preserving the properties of the carbonated mineral product. The final product packaging unit 126 may also be referred to as calcium carbonate packaging station, which ensures that end product of the electrolysis-assisted CO₂ mineralization process is properly contained and ready for its intended use or further processing.

In operation, the in-line electrolysis apparatus 118 is configured to perform controlled electrolysis of an input water stream 128A to generate the alkaline water stream 128B including hydroxide ions within the first pH range. Further, the one or more controllers 116 are configured to control the in-line electrolysis apparatus 118 to produce the alkaline water stream 128B comprising hydroxide ions within the first pH range through electrolysis of the input water stream 128A. Specifically, the in-line electrolysis apparatus 118 functions through a precisely controlled sequence of steps to generate and collect hydroxide ions. The in-line electrolysis apparatus 118 first receives the input water stream 128A into its dual-chamber configuration. Upon initiation of the electrolysis process, the in-line electrolysis apparatus 118 may perform controlled electrolysis by applying predefined current densities and predefined voltage potentials across the electrodes. The controlled electrolysis generates hydroxide ions (OH−) at the cathode while simultaneously maintaining the first pH range (typically pH 9-10) in the resulting alkaline water stream 128B. Through its specialized membrane separation system, the in-line electrolysis apparatus 118 effectively separates and collects the alkaline water stream 128B containing the generated hydroxide ions from the cathode chamber, while simultaneously diverting the acidic stream produced at the anode chamber through a separate pathway. Throughout the operation, the in-line electrolysis apparatus 118 continuously monitors and adjusts critical operating parameters, including current density, voltage potential, temperature (maintained between 20-40° C.), and pH levels, through integrated sensor systems to maintain optimal hydroxide ion generation rates necessary for subsequent mineralization processes.

The one or more controllers 116 are further configured to control blending of the alkaline water stream comprising the hydroxide ions with the solvent to obtain the electrolyzed-alkaline water solvent blend having the second pH range greater than the first pH range. The one or more controllers 116 maintain specific solvent-to-water blend ratios ranging from 1%/99% to 30%/70% by volume. In some examples, the one or more controllers 116 maintain solvent-to-water blend ratios of 20%/80%. In some other examples, the one or more controllers 116 maintain solvent-to-water blend ratios of 30%/70%. Through the controlled blending process, the system 100 achieves the second pH range (typically pH 12-14) for the metal oxide extraction from the industrial alkali waste material.

In some implementations, the one or more controllers 116 are further configured to control the electrolysis of the input water stream 128A and the blending of the alkaline water stream 128B including the hydroxide ions with the solvent to control and change the second pH range of the electrolyzed-alkaline water solvent blend. In such implementations, the one or more controllers 116 continuously monitor and adjust blending parameters through integrated sensor systems to maintain the desired pH levels, while simultaneously managing the flow rates of both the alkaline water stream 128B and the amine-based solvent (such as monoethanolamine (MEA), diethanolamine (DEA), or methyldiethanolamine (MDEA)). The control over the blending process ensures consistent pH levels necessary for subsequent calcium hydroxide formation and carbonation reactions.

In some implementations, the first pH range of the alkaline water stream may vary between 9 and 10. In some examples, the second pH range of the electrolyzed-alkaline water solvent blend may fall within a range of 10 to 14. In other examples the second pH range of the electrolyzed-alkaline water solvent blend may vary between 11 to 12. In some cases, the second pH range of the electrolyzed-alkaline water solvent blend may vary between 12 and 14.

The one or more controllers 116 are further configured to control mixing of the electrolyzed-alkaline water solvent blend with the industrial alkali waste material in the filtration reactor 106 to obtain the silica byproduct 106A at a first end of the filtration reactor 106 and the fluidic filtrate including calcium hydroxide at a second end of the filtration reactor 106. The one or more controllers 116 monitor and adjust multiple process parameters to achieve a predefined separation of the silica byproduct 106A and metal hydroxide-rich filtrate. As mentioned above, upon blending with the amine-based solvent, the one or more controllers 116 regulate the mixing ratio to achieve the second pH range of 12 to 14, preferably 12 to 13, which enables efficient calcium oxide extraction. The one or more controllers 116 regulate the feed rate of industrial alkali waste material to maintain a predefined ratio of the industrial alkali waste material to the electrolyzed water-amine blend. Through continuous monitoring and adjustment of the parameters, the controllers 116 ensure the silica byproduct 106A, containing primarily aluminum calcium silicates, is effectively separated at the first end while the calcium hydroxide-rich filtrate is collected at the second end of filtration reactor 106, achieving a calcium hydroxide extraction efficiency exceeding 95%, for example, 99%.

In an implementations, prior to feeding the electrolyzed-alkaline water solvent blend and the industrial alkali waste material into the filtration reactor 106, the metal catalyst from the metal catalyst source 114 may be added to further reduce the cycle time of the electrolysis-assisted mineral carbonation process. In some embodiments, the one or more controllers 116 are further configured to control introduction of the metal catalyst in the filtration reactor 106 in a range of 10-500 parts per million (ppm) of the electrolyzed-alkaline water solvent blend for the mixing of the electrolyzed-alkaline water solvent blend with the industrial alkali waste material in presence of the metal catalyst. As mentioned above, the concentration of the metal catalyst fed into the filtration reactor 106 may range from 10 parts per million (ppm) to 500 ppm of the electrolyzed-alkaline water solvent blend for the mixing of the electrolyzed-alkaline water solvent blend with the industrial alkali waste material in presence of the metal catalyst. In some examples, the concentration of the metal catalyst may range from 10 ppm to 200 ppm of the electrolyzed-alkaline water solvent blend. In other examples, the concentration of the metal catalyst may vary between 10 ppm to 150 ppm of the electrolyzed-alkaline water solvent blend. In some other examples, the concentration of the metal catalyst fed into the heating chamber 102 may vary between 30 ppm to 100 ppm of the electrolyzed-alkaline water solvent blend. In another example, the concentration of the metal catalyst fed into the heating chamber 102 may vary between 50 ppm to 100 ppm of the electrolyzed-alkaline water solvent blend. Alternatively, in other implementations, the metal catalyst may not be required to be added to the mixture of the solvent blend and the industrial alkali waste material.

The one or more controllers 116 are further configured to control injection of carbon dioxide in a gaseous form captured from the defined carbon dioxide source 108 into the fluidic filtrate to obtain the first mixture including calcium carbonate with the first carbonation rate. Carbon dioxide is injected from the carbon dioxide source 108 by precisely controlling the injection parameters to achieve the first carbonation rate ranging from 10% to 90%. Specifically, the controller 116 monitors and adjusts the CO₂ injection where the gaseous CO₂ stream intersects with the flowing fluidic filtrate containing metal hydroxide. The controller 116 regulates the CO₂ flow rate through proportional control valves to maintain a predefined gas-to-liquid ratios, while simultaneously monitoring pressure sensors at the injection point to ensure stable CO₂ dissolution conditions. The controller 116 utilizes feedback from inline pH sensors and flow meters to dynamically adjust the CO₂ injection rate, maintaining optimal carbonation conditions as the CO₂ dissolves and reacts with the calcium hydroxide in the fluidic filtrate to form calcium carbonate. This controlled injection process ensures consistent the first carbonation rates within the target range of 10-30%, preparing the mixture for subsequent processing stages.

In some implementations, the one or more controllers 116 are further configured to control feeding of the first mixture with injected carbon dioxide in the heating chamber 102. As the first mixture enters the heating chamber 102, the fluidic filtrate including the industrial alkali waste material interacts with the CO₂, which is introduced simultaneously or sequentially. In an implementations, a feed rate of the fluidic filtrate including the industrial alkali waste material may be adjusted according to CO₂ input and predefined stoichiometric ratios.

In some implementations, the one or more controllers 116 are further configured to control the heating chamber 102 to cause the first mixture with injected carbon dioxide to move along a loop pathway configured in the heating chamber 102 while controlling temperature in the heating chamber 102 in a range of 25 degree Celsius to 120 degree Celsius followed by the control of the flow of the first mixture to the inlet of the modified hydrocyclone 104. Specifically, in such implementation, the heating chamber 102 is configured to mix the fluidic filtrate including the industrial alkali waste material with the injected carbon dioxide to obtain the first mixture. The mixing action ensures uniform distribution of the dissolved CO₂ throughout the industrial alkali waste material, initiating early stages of the carbonation process. In the mixing operation, a homogeneous slurry is formed where particles of the industrial alkali waste material are surrounded and encounters the electrolyzed-alkaline water solvent blend and the injected CO₂. This maximizes the surface area available for reaction, promoting efficient mass transfer between the liquid and solid phases. Additionally, the mixing action helps to break down any agglomerates in the industrial alkali waste material, further increasing the reactive surface area. Alternatively stated, by initial mixing in the heating chamber 102, the reactants of the first mixture are preconditioned before the first mixture enters the modified hydrocyclone 104. By ensuring contact between the electrolyzed-alkaline water solvent blend, the industrial alkali waste material, and the injected CO₂, the heating chamber 102 initiates the mineral carbonation process, potentially reducing the overall reaction time in the subsequent stages. The preconditioning of the reactants may lead to higher conversion rates and more efficient use of the CO₂ in the system 100, ultimately improving the overall performance and efficiency of the electrolysis assisted mineral carbonization process.

The one or more controllers 116 are further configured to control a flow of the first mixture to an inlet of the modified hydrocyclone configured as the carbon dioxide mineralization reactor. An example of the modified hydrocyclone 104 configured as electrolysis-assisted carbon dioxide mineralization reactor has been described in detail, for example, in FIGS. 3A to 3D. Specifically, the modified hydrocyclone 104 is configured to receive the first mixture via the inlet of the modified hydrocyclone 104. In an exemplary implementation, the modified hydrocyclone 104 is specifically configured for tangential introduction. The introduction of the first mixture via the inlet of the modified hydrocyclone 104 may initiate the controlled fluid dynamics for the electrolysis-assisted mineral carbonation process immediately upon entry. Optimized dimensions and orientation of the inlet of the modified hydrocyclone 104 maintain velocity and consistency of the first mixture, ensuring a smooth transition from the heating chamber 102 and inducing a spiral flow pattern. The tangential introduction converts linear momentum of the first mixture into rotational momentum, generating centrifugal forces central to the function of the modified hydrocyclone 104. By receiving the preconditioned mixture in such manner, the modified hydrocyclone 104 seamlessly integrates the mixing process from the heating chamber 102 with its more intensive reaction environment. The controlled introduction of the first mixture via the optimized inlet prevents clogging, ensures a consistent feed rate, and maintains the reactivity of components of the first mixture. Consequently, such configuration contributes to faster reaction kinetics, higher conversion rates, and overall improved efficiency and stability of the electrolysis assisted mineral carbonation process.

The one or more controllers are configured to control a movement of the first mixture in the modified hydrocyclone to obtain carbonate slurry with the second carbonation rate. Specifically, the modified hydrocyclone 104 includes a plurality of different sections that causes the first mixture to move within the modified hydrocyclone 104 and creates the controlled fluid dynamics that facilitate and accelerate the electrolysis-assisted mineral carbonation process. As the first mixture, including the electrolyzed-alkaline water solvent blend (i.e., blended with the amine-based solvent), the industrial alkali waste material, and the injected CO₂, enters tangentially into the overflow section, the modified hydrocyclone 104 generates a high-speed rotational flow. The high-speed rotational flow creates strong centrifugal forces in the cylindrical and conical sections, driving denser particles of the industrial alkali waste material towards walls of the modified hydrocyclone 104. Concurrently, the geometry of the modified hydrocyclone 104 establishes radial and axial pressure gradients. The vortex finder in the overflow section induces a central vortex, drawing the regenerated electrolyzed-alkaline water solvent blend devoid of carbon dioxide towards a center of the modified hydrocyclone 104 and upwards. In the conical section, decreasing diameter intensifies the rotational velocity and shear forces, enhancing interactions between the electrolyzed-alkaline water solvent blend and the industrial alkali waste material. The combination of centrifugal force, centripetal force, and gravitational force creates zones of intense turbulence and micro-mixing, particularly near the walls of the modified hydrocyclone 104 and in the transition between the cylindrical section and the conical section. By creating the zones of intense turbulence and micro-mixing, frequent and high-energy collisions occur between the components of the first mixture. In some implementations, the metal catalyst dispersed throughout the first mixture further accelerates the reaction involved in the mineral carbonation process at the zones in the modified hydrocyclone 104. The first mixture within the overflow section of the modified hydrocyclone 104 follows a controller flow pattern ensuring that fresh reactant surfaces are continuously exposed, maintaining a high carbonation rate throughout the mineral carbonation process. Further, by optimizing retention time of the first mixture in the modified hydrocyclone 104 and reaction conditions within the modified hydrocyclone 104, the modified hydrocyclone 104 form the carbonate slurry in a predefined time with the second carbonation rate greater than the first carbonation rate. In an implementation, beneficially, certain dimensional alterations of different sections of a hydrocyclone may be performed to be used as the modified hydrocyclone 104. Advantageously, the structural modifications to the modified hydrocyclone 104 transforms the modified hydrocyclone 104 into a highly efficient electrolysis assisted carbon dioxide mineralization reactor. The modifications, such as precise dimensional alterations, carefully calibrated and interrelated, create a synergistic effect that optimizes the fluid dynamics within the modified hydrocyclone 104 in a manner specifically tailored for electrolysis-assisted carbon dioxide mineralization. In an example, the details of the modification of the modified hydrocyclone 104, has been explained in detail, for example, in the FIGS. 3A to 3D.

The one or more controllers 116 are configured to control release of the carbonate slurry comprising calcium carbonate in a defined purity parameter range from the underflow section of the modified hydrocyclone 104 while concurrently regenerating and releasing the electrolyzed-alkaline water solvent blend devoid of carbon dioxide for reuse from the overflow section of the modified hydrocyclone 104. Specifically, the modified hydrocyclone 104 is configured to simultaneously achieve product separation and solvent regeneration. The simultaneous operation is accomplished through the overflow section and the underflow section, which leverage density differences created during the carbonation process. As the mixture moves through the modified hydrocyclone 104, the calcium carbonate particles, being denser, are directed towards the walls and down to the underflow section by the centrifugal forces. Thus, the calcium carbonate suspension is efficiently separated and released for further processing. Concurrently, the electrolyzed-alkaline water solvent blend devoid of carbon dioxide, being lighter, is drawn towards the center by the pressure gradient and upwards through the vortex finder to the overflow section. In some implementations, the one or more controllers 116 are further configured to control pushing of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide from the overflow section of the modified hydrocyclone 104 back to the filtration reactor 106 for further reuse in the filtration reactor 106. The regenerated solvent blend is released back to the filtration reactor 106, as shown by flow 130A. This continuous, simultaneous separation process ensures uninterrupted mineralization, maximizing efficiency. The regenerated electrolyzed-alkaline water solvent blend is immediately available for reuse, reducing fresh solvent requirements and minimizing waste. This approach not only streamlines the overall process but also contributes to economic viability and environmental sustainability by optimizing resource utilization and maintaining closed-loop operation.

In an implementation, the industrial alkali waste material may be a porous media where the electrolyzed-alkaline water solvent blend impregnates into the porous media under the influence of the centrifugal force generated by the modified hydrocyclone 104. The centrifugal force drives the electrolyzed-alkaline water solvent blend deep into pores of the industrial alkali waste material, significantly increasing the effective reaction surface area for calcium oxide extraction.

In an implementation, the predefined threshold time for the formation of the calcium carbonate slurry is in a range of 1-15 minutes. In some implementations, the controlled fluid dynamics enables the electrolysis-assisted mineral carbonation process to occur in less than 5 minutes. In other implementations, the electrolysis-assisted mineral carbonation process may occur in less than 2 minutes. In some implementations, the electrolysis-assisted mineral carbonation process may be completed in less than 1 minute. Such a rapid and efficient electrolysis-assisted mineral carbonation process not only increases the overall CO₂ sequestration capacity of the system 100 but also improves the quality and consistency of the carbonate slurry, potentially enhancing its value for subsequent applications.

In some implementations, the process of extracting calcium oxide from industrial alkali waste material and subsequent carbonation involves multiple chemical reaction steps. The electrolyzed-alkaline water solvent blend, having hydroxide ions (OH−) from the electrolysis process, facilitates the extraction of calcium ions (Ca²+) from the industrial alkali waste material. The calcium ions react with the hydroxide ions according to the following reaction:

The formed calcium hydroxide (Ca(OH)₂) then reacts with the injected carbon dioxide (CO₂) in the modified hydrocyclone to form calcium carbonate (CaCO₃) according to the following reaction:

In some implementations, when the industrial alkali waste material contains magnesium-based compounds, similar reactions occur simultaneously. Magnesium ions (Mg²+) extracted from the industrial alkali waste material react with hydroxide ions to form magnesium hydroxide:

The formed magnesium hydroxide (Mg(OH)₂) subsequently reacts with carbon dioxide to form magnesium carbonate (MgCO₃) according to the following reaction:

The reactions proceed in a controlled manner within the system 100, with initial hydroxide formation occurring in the filtration reactor 106, followed by carbonation reactions primarily taking place in the modified hydrocyclone 104. The modified hydrocyclone 104 provides conditions for the reactions while simultaneously facilitating the separation of the formed carbonate products from the regenerated solvent blend. The carbonation reactions achieve conversion rates of 10-30% upon initial CO₂ injection, 31-50% in the heating chamber 102, and 51-99.99% in the modified hydrocyclone 104, resulting in high-purity calcium carbonate and/or magnesium carbonate products.

The pH of the reaction medium impacts a leaching process and the composition of the final product. The leaching process refers to the dissolution of components, such as CaO and MgO, into the reaction medium under controlled pH conditions. In some implementations, at the first pH range of 9 to 11, the leaching of CaO and MgO progresses at a slower rate, necessitating an extended extraction time. During the process, additional components, including calcium aluminum silicates and other silicates, hydrolyze and leach into the CaO/MgO and water/amine solution. Upon the introduction of CO₂, the formation of CaCO₃ and MgCO₃ occurs alongside impurities, such as aluminum and iron, in the final product. These impurities may account for up to 5%, resulting in a product purity of at least 95%.

In some other implementations, at the second pH range of 11 to 13, the leaching of CaO and MgO occurs more rapidly, requiring a shorter extraction time. The reduced extraction time limits the introduction of silicate impurities into the CaO/MgO extracted into the amine/water solution. Consequently, the final product exhibits impurities of up to 1%, achieving a purity of at least 99%.

In some implementations, the one or more controllers 116 are configured to control a purity parameter of the calcium carbonate in the defined purity parameter range during the release of the carbonate slurry from the underflow section of the modified hydrocyclone 104 based on the control and change in the second pH range of the electrolyzed-alkaline water solvent blend. In such implementations, the one or more controllers 116 are configured to regulate the purity parameter of the calcium carbonate by coordinating the electrolysis process and pH management. Specifically, the one or more controllers 116 maintain the purity parameter by monitoring and regulating the electrolysis current to sustain the first pH range of the alkaline water stream (i.e., approximately 9-10). Additionally, the one or more controllers 116 control the blending ratio of the alkaline water stream with the amine-based solvent to achieve the second pH range (i.e., 13-14) in the electrolyzed-alkaline water solvent blend. Inline pH sensors positioned at the underflow section of the modified hydrocyclone 104 continuously measure pH levels, enabling the implementation of feedback control loops to dynamically adjust the electrolysis current based on pH measurements, the solvent-to-water ratio, and the residence time within the modified hydrocyclone 104 through flow rate regulation.

In the event of deviations from target pH range, the one or more controllers 116 adjust the electrolysis current to modify hydroxide ion concentration, fine-tune the solvent blend ratio to restore pH conditions, and modify flow parameters of the modified hydrocyclone 104 to ensure effective separation. The precise and coordinated regulation of the electrolysis process and the pH management ensures that the carbonate slurry discharged from the underflow section of the modified hydrocyclone achieves the purity parameter in the range of 95-99.999%.

The separator 122 is configured to further process the carbonate slurry through forced centrifugation to segregate additional portions of the electrolyzed-alkaline water solvent blend for reuse. Specifically, as the carbonate slurry passes through the separator 122, intense centrifugal forces act to separate any remaining solvent from the calcium carbonate output, enhancing product purity. The separated electrolyzed-alkaline water solvent blend is recirculated back to the filtration reactor 106, as shown by flow 130B, maximizing solvent recovery and process efficiency while minimizing waste generation.

The one or more dryers 124 are configured to produce the final high-purity calcium carbonate product through carefully controlled drying stages. The drying process removes residual moisture while preserving product quality. The staged drying approach allows precise control over final moisture content and physical properties, ensuring the final product of dry calcium carbonate meets the defined purity parameter range of 95-99.999%. The resulting dry calcium carbonate exhibits enhanced stability, uniformity, and suitability for various high-value applications in construction materials, polymers, paints, and other industrial uses.

In some implementations, the process demonstrates remarkable flexibility in solvent composition, accommodating a solvent concentration range of 0% to 50% in the electrolyzed water. The electrolyzed water, containing hydroxide ions (OH−) generated through electrolysis, provides a baseline alkaline environment with elevated pH suitable for the mineralization process. While the process can operate effectively with electrolyzed water alone (0% solvent), the addition of amine-based solvents or other suitable solvents in concentrations up to 50% typically enhances process efficiency and yield. For example, when using amine-based solvents such as monoethanolamine (MEA) or methyldiethanolamine (MDEA), optimal performance is often achieved in the range of 20-30% solvent concentration, though lower concentrations of 1-20% or higher concentrations of 30-50% may be preferred for specific applications or feed materials. The flexibility in solvent concentration allows for process optimization based on factors such as industrial alkali waste composition, desired reaction rates, and economic considerations, while maintaining the core functionality of CO₂ mineralization even in cases where minimal or no additional solvent is used.

The high-purity calcium carbonate (CaCO₃) produced through this electrolysis-assisted mineral carbonation process has diverse applications across multiple industries. The product, having the defined purity parameter range of 95-99.999%, can be utilized in building and construction sectors, incorporated into polymer formulations and paints to enhance their properties, and employed in various oil and gas industry applications. The process achieves carbonation rates of 10-30% upon initial CO₂ injection, 31-50% in the heating chamber, and 51-99.99% in the modified hydrocyclone 104, resulting in consistently high-purity calcium carbonate suitable for commercial applications.

In some implementations, the system 100 for electrolysis-assisted mineralization of carbon dioxide may be configured in a multi-stage arrangement to enhance the overall efficiency and conversion rate of the CO₂ mineralization process. Such multi-stage configuration builds upon the single-stage process while incorporating multiple modified hydrocyclones arranged in series.

In the multi-stage configuration, the system 100 may include multiple reactor stages, where each stage comprises a modified hydrocyclone configured as a carbon dioxide mineralization reactor. The first reactor stage receives the initial mixture comprising the electrolyzed-alkaline water solvent blend, industrial alkali waste material, and injected CO₂ via a first slurry pump. After processing in the first modified hydrocyclone, a first carbonated output is collected in a first slurry tank before being pumped to the subsequent stage. The first slurry tank enables potential adjustments to composition and conditions before the material enters the second reactor stage.

The second reactor stage processes the carbonated output received from the first reactor stage, further advancing the carbonation reaction. The output from the second stage is collected in a second slurry tank and subsequently pumped to the next stage. Between reactor stages, slurry pumps facilitate material transfer, ensuring consistent flow through the system. Such inter-stage transfers also provide opportunities for sampling, analysis, or additional input if required.

In the multi-stage configuration, each reactor stage may release a portion of the electrolyzed-alkaline water solvent blend devoid of CO₂ from the overflow outlet of their respective modified hydrocyclones. The regenerated solvent blend from earlier stages can be fed into subsequent stages, optimizing solvent utilization throughout the process. The final stage produces a highly carbonated output that proceeds to separation and post-processing steps, including filtration, centrifugation, washing, and drying.

The multi-stage system may further include a fine particle filter operably coupled with the overflow outlet of the final modified hydrocyclone. The fine particle filter purifies the regenerated solvent blend by removing suspended fine solid particles, which may include remnants of carbonated material, unreacted industrial alkali waste, or other process-introduced impurities. This filtration step is essential for maintaining system efficiency by preventing potential clogging or fouling of equipment in subsequent cycles.

The multi-stage configuration allows for progressive carbonation, potentially increasing the overall conversion rate and efficiency of the CO₂ mineralization process. Additionally, it offers flexibility in optimizing conditions at each stage to accommodate varying feedstock qualities or to target specific product characteristics. The number of stages can be adjusted based on application requirements to achieve desired carbonation rates and product purity levels.

FIG. 2 is a diagram of an electrolysis apparatus to be used in electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure. FIG. 2 is described in conjunction with elements from FIG. 1. With reference to FIG. 2, there is shown the in-line electrolysis apparatus 118. The in-line electrolysis apparatus 118 may include one or more electrolytic cells configured to generate hydroxide ions (OH−) through electrolysis of the input water stream 128A. In the illustrated embodiment of FIG. 2, the in-line electrolysis apparatus 118 includes an anode 202 and a cathode 204 powered by a power source 206. The electrolytic cell is filled with an electrolyte 208, which may comprise water with sufficient conductivity for efficient electrolysis, in some example, having a salinity ranging from that of distilled water up to 5000 PPM, preferably using standard tap water with 150-200 PPM salinity.

In operation, the power source 206 may apply an electrical potential between the anode 202 and the cathode 204, causing water molecules in the electrolyte 208 to dissociate. At the cathode 204, water molecules are reduced to form hydroxide ions (OH−) and hydrogen gas (H₂), while at the anode 202, water molecules are oxidized to form oxygen gas (O₂) and hydrogen ions (H+). The hydroxide ions generated at the cathode 204 create the alkaline water stream 128B with the first pH range of 8 to 11, preferably 9 to 10.

In some implementations, the in-line electrolysis apparatus 118 may include multiple electrolytic cells arranged in series or parallel to increase hydroxide ion production capacity. The electrolytic cells may be equipped with ion-selective membranes to separate the alkaline catholyte from the acidic anolyte, ensuring efficient collection of the hydroxide-rich alkaline water stream. The power source 206 may include control circuitry to adjust current density and voltage based on desired hydroxide ion production rates and pH levels.

The in-line electrolysis apparatus 118 is designed to maintain a predefined electrode spacing and electrolyte circulation to ensure uniform hydroxide ion generation and efficient mass transfer. The generated alkaline water stream 128B is subsequently blended with an amine-based solvent to achieve the second pH range of 12 to 14, preferably 12 to 13, which is useful for efficient calcium oxide extraction from industrial alkali waste materials.

FIGS. 3A, 3B, 3C, and 3D are diagrams illustrating different views of a modified hydrocyclone for electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure. FIGS. 3A-3D are described in conjunction with elements from FIG. 1. With reference to FIG. 3A, there is shown a perspective view of the modified hydrocyclone 104 for electrolysis-assisted mineralization of carbon dioxide. With reference to FIG. 3B, there is shown a view of the modified hydrocyclone 104 with different sections. With reference to FIG. 3C, there is shown a top view of the modified hydrocyclone 104 with an inlet 314. With reference to FIG. 3D, there is shown a view of a flow pattern of fluids in the modified hydrocyclone 104.

Referring to the FIGS. 3A-3D, the modified hydrocyclone 104 includes a plurality of different sections that include an overflow section 302, an underflow section 304, a vortex finder 306 positioned within the overflow section 302, and a cone section 308. Specifically, the overflow section 302 is disposed at the top portion of the modified hydrocyclone 104, comprising the vortex finder 306. The overflow section 302 corresponds to the cylindrical body, which then transitions into the cone section 308. The conical shape of the modified hydrocyclone 104 narrows towards the bottom of the modified hydrocyclone 104, terminating in the underflow section 304 with a spigot. Further, the overflow section 302 includes an overflow outlet 310 and the underflow section 304 includes an underflow outlet 312. The modified hydrocyclone 104 further includes an inlet 314 connected to the overflow section 302.

Advantageously, the structural modifications to the modified hydrocyclone 104 may transform the modified hydrocyclone 104 into a highly efficient electrolysis-assisted carbon dioxide mineralization reactor. These precise dimensional alterations, carefully calibrated and interrelated, create a synergistic effect that optimizes the fluid dynamics within the modified hydrocyclone 104 in a manner specifically tailored for electrolysis-assisted carbon dioxide mineralization. Thus, the modified hydrocyclone 104 may be referred to as the modified hydrocyclone 104 configured as the electrolysis-assisted carbon dioxide mineralization reactor. The modified hydrocyclone 104 is modified in terms of configuration (based on experimentation), comprising specific ratios between the different sections of the modified hydrocyclone 104, which engenders a controlled turbulent environment. This environment may be precisely engineered to maximize the interfacial area between the industrial alkali waste particles and the carbon dioxide-laden solvent blend. The result is a significant improvement in the kinetics of the carbonation reaction, leading to markedly improved efficiency and effectiveness in the mineralization process (i.e., the mineral carbonation process). The dimensions of each section of the modified hydrocyclone 104 and ratio of each section with respect to a diameter Dc of the overflow section 302 are precisely calibrated to improve the electrolysis-assisted mineralization process (i.e., the electrolysis-assisted mineral carbonation process). Various examples of the modification and calibrations (configurations) are given below, in an example.

In some implementations, the overflow section 302 of the modified hydrocyclone 104 configured as the carbon dioxide mineralization reactor has a diameter Dc in a range of 0.08 meter to 1.2 meter. In some examples, the diameter Dc of the overflow section 302 may be in a preferred range of 0.1 meter to 1 meter. Adjusting the diameter Dc directly impacts the controlled fluid dynamics within the modified hydrocyclone 104, particularly influencing both the capacity and flow rate of the first mixture. The adjustments to the diameter Dc optimize the surface interactions between particles of the industrial alkali waste material and the electrolyzed-alkaline water solvent blend, thereby enhancing the efficiency of the electrolysis-assisted mineral carbonation process.

In some implementations, a diameter Jc of the underflow outlet 312 of the underflow section 304 of the modified hydrocyclone 104 is in a range of one-third to one-fifth of the diameter Dc of the overflow section 302. In some examples, the diameter Jc of the underflow outlet 312 is in a preferred range of one-quarter to one-fifth of the diameter Dc of the overflow section 302. In some other examples, most preferably, the diameter Jc of the underflow outlet 312 is one-quarter of the diameter Dc of the overflow section 302. The diameter Jc of the underflow outlet 312 controls the release of the carbonate slurry. Specifically, adjusting the diameter Jc directly impacts the amount and quality of the calcium carbonate slurry. By adjusting the diameter Jc of the underflow outlet 312 smaller, pressure at the base of the modified hydrocyclone 104 is increased, ensuring that only well-reacted, dense particles of the calcium carbonate slurry are discharged.

In some implementations, a diameter De of the vortex finder 306 or the overflow outlet 310 of the modified hydrocyclone 104 is in a range of one-half to one-quarter of the diameter Dc of the overflow section 302. In some examples, the diameter De is in a preferred range of one-half to one-third of the diameter Dc of the overflow section 302. In some other examples, most preferably, the diameter De is one-half of the diameter Dc of the overflow section 302. In such implementations, the diameter De of the vortex finder 306 or the overflow outlet 310 of the modified hydrocyclone 104 controls the amount of the electrolyzed-alkaline water solvent blend released through the overflow outlet 310 of the overflow section 302 of the modified hydrocyclone 104. Specifically, the rate at which the amount of the electrolyzed-alkaline water solvent blend released in a given time, which is part of the controlled fluid dynamics of the modified hydrocyclone 104, is influenced by adjusting the diameter De.

In some implementations, a spigot diameter Sc of the modified hydrocyclone 104 is in a range of one-sixth to one-tenth of the diameter Dc of the overflow section 302. In some examples, the spigot diameter Sc of the modified hydrocyclone 104 is in a preferred range of one-eighth to one-tenth of the diameter Dc of the overflow section 302. In some other examples, most preferably, the spigot diameter Sc of the modified hydrocyclone 104 is one-eight of the diameter Dc of the overflow section 302. In some examples, adjusting the spigot diameter Sc increases velocity of the first mixture, potentially enhancing the centrifugal force applied to the first mixture.

In some implementations, a length Lc of the overflow section 302 representing a cylindrical body of the modified hydrocyclone 104 is one of: either equal to the diameter Dc of the overflow section 302 or twice the diameter Dc of the overflow section 302. In some examples, the length Lc of the overflow section 302 is twice the diameter Dc of the overflow section 302. In some other examples, most preferably, the length Lc of the overflow section 302 is equivalent to the diameter Dc of the overflow section 302. The length Lc of the overflow section 302 directly impacts the residence time of the first mixture within the modified hydrocyclone 104. Thus, the residence time of the first mixture within the modified hydrocyclone 104 is controlled by adjusting the length Lc of the overflow section 302.

In some implementations, a length Zc of the cone section 308 of the modified hydrocyclone 104 is in a range of three times to five times of the diameter Dc of the overflow section 302. In some examples, most preferably, the length Zc of the cone section 308 is three times the diameter Dc of the overflow section 302. The length Zc is adjusted to directly influence the residence time of the first mixture within the cone section 308, with a longer cone providing increased residence time. This extended duration allows for more complete interaction between the electrolyzed-alkaline water solvent blend, the industrial alkali waste material and the injected CO₂, thereby optimizing the electrolysis-assisted mineral carbonation reaction.

In some implementations, the inlet 314 of the modified hydrocyclone 104 has a width Bc in a range of one-third to one-sixth of the diameter Dc of the overflow section 302. In some examples, the width Bc of the inlet 314 is in a preferred range of one-quarter to one-sixth of the diameter Dc of the overflow section 302. In some other examples, most preferably, the width Bc of the inlet 314 is one-quarter of the diameter Dc of the overflow section 302. Adjusting the width Bc directly impacts the controlled fluid dynamics within the modified hydrocyclone 104, particularly influencing the velocity of the first mixture entering the modified hydrocyclone 104 (i.e., the modified hydrocyclone). Moreover, adjusting the width Bc enhances the interaction between the porous media of the industrial alkali waste material and the electrolyzed-alkaline water solvent blend including the dissolved carbon dioxide, thereby promoting the electrolysis-assisted mineral carbonation reaction.

In some implementations, the length Hc of the inlet 314 of the modified hydrocyclone 104 is in a range of one-half to one-quarter of the diameter Dc of the overflow section 302. In some examples, the length Hc of the inlet 314 is in a preferred range of one-half to one-third of the diameter Dc of the overflow section 302. In some other examples, most preferably, the length Hc of the inlet 314 is one-half of the diameter Dc of the overflow section 302. The length Hc defines a distance over which the first mixture enters the modified hydrocyclone 104, directly affecting an initial flow rate and velocity of the first mixture as it begins its movement through the modified hydrocyclone 104, thereby impacting the efficiency of subsequent mixing and reactions.

Thus, it is observed that such structural modification yields multiple tangible benefits that directly address the technical challenges in carbon dioxide mineralization. In first example, the modified fluid dynamics substantially reduce the time required for carbonation, achieving the formation of carbonate slurry in less than a predefined threshold time of 1-15 minutes, mostly less than 5 minutes, which is about 97% reduction than conventional time of about 8 hours. In a second example, the optimized particle-solvent interactions result in the second carbonation rate that exceeds the first carbonation rate, surpassing the capabilities of conventional systems. In a third example, the modified structure of the modified hydrocyclone 104 enables simultaneous calcium carbonate slurry formation and the electrolyzed-alkaline water solvent blend regeneration, streamlining the overall process and improving resource efficiency. In a fourth example, the precisely defined dimensional relationships allow for scaling of the modified hydrocyclone 104 while maintaining optimal performance across various operational capacities.

Referring to FIG. 3D, the modified hydrocyclone 104 includes the inlet 314 through which the first mixture may enter tangentially, as indicated by a solid arrow 316. As the first mixture enters through the inlet 314, the first mixture may begin a spiraling motion, represented by curved lines within the modified hydrocyclone 104. The spiraling motion of the first mixture forms a spiral flow pattern for the electrolysis assisted mineral carbonation process. The spiral flow pattern includes a primary vortex 318, closer to the walls of the modified hydrocyclone 104, representing a flow of denser particles, forming calcium carbonate slurry. The calcium carbonate slurry are driven outward by centrifugal force as the calcium carbonate slurry moves downward through the cone section 308, as indicated by a solid arrow 320.

The spiral flow pattern further includes a second vortex 322, closer to the center of the modified hydrocyclone 104, representing the upward flow of the regenerated electrolyzed-alkaline water solvent blend devoid of carbon dioxide, as indicated by the solid arrow 324. The upward flow is facilitated by the vortex finder 306, which creates a low-pressure zone at the center of the modified hydrocyclone 104. The spigot at the bottom of the underflow section 304 allows for the controlled release of the formed solid calcium carbonate, while the vortex finder 306 in the overflow section 302 enables the collection of the regenerated electrolyzed-alkaline water solvent blend. The modified hydrocyclone 104 enables simultaneous reaction, separation, and product collection, making the modified hydrocyclone 104 highly efficient for the electrolysis assisted mineral carbonation process. The controlled fluid dynamics created within the modified hydrocyclone 104 contribute to the rapid reaction times and high carbonation rates achieved in the electrolysis-assisted CO₂ mineralization process.

FIGS. 4A, 4B, and 4C collectively is a flowchart of a method for electrolysis assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure. FIGS. 4A, 4B, and 4C are described in conjunction with the elements from FIGS. 1, 2, and 3A to 3D. With reference to FIGS. 4A, 4B, and 4C, there is shown a flowchart of a method 400 for electrolysis-assisted mineralization of carbon dioxide. In an implementation, the method 400 is executed in the system 100. The method 400 may include steps 402 to 428.

At 402, the alkaline water stream 128B including hydroxide ions within the first pH range is produced through electrolysis of the input water stream 128A. The electrolysis process ensures a controlled and consistent generation of hydroxide ions, enabling precise regulation of the alkaline water's pH, which is critical for downstream reactions.

At 404, the alkaline water stream 128B including the hydroxide ions is blended with the solvent to obtain the electrolyzed-alkaline water solvent blend having the second pH range greater than the first pH range. Blending the alkaline water stream 128B with the solvent achieves a higher pH range, optimizing the solvent's reactivity and improving the overall efficiency of subsequent chemical interactions.

At 406, the electrolysis of the input water stream 128A and the blending of the alkaline water stream 128B including the hydroxide ions with the solvent is controlled to control and change the second pH range of the electrolyzed-alkaline water solvent blend. This step enables dynamic adjustment of the pH range to suit varying process requirements, ensuring consistency and adaptability in the production process.

At 408, the metal catalyst in the filtration reactor 106 in a range of 10-500 parts per million (ppm) of the electrolyzed-alkaline water solvent blend is introduced for the mixing of the electrolyzed-alkaline water solvent blend with the industrial alkali waste material in presence of the metal catalyst. Introducing the metal catalyst enhances reaction kinetics, ensuring effective interaction between the electrolyzed-alkaline water solvent blend and industrial alkali waste material for optimal product formation.

At 410, the electrolyzed-alkaline water solvent blend with the industrial alkali waste material in the filtration reactor 106 is mixed to obtain the silica byproduct 106A at the first end of the filtration reactor 106 and the fluidic filtrate comprising calcium hydroxide at the second end of the filtration reactor 106. The controlled mixing and separation in the filtration reactor 106 enable efficient recovery of valuable byproducts, such as silica, while simultaneously isolating the fluidic filtrate for further processing.

At 412, carbon dioxide in the gaseous form captured from the defined carbon dioxide source 108 is injected into the fluidic filtrate to obtain the first mixture comprising calcium carbonate with the first carbonation rate. The controlled injection of carbon dioxide allows precise regulation of the carbonation process, leading to improved calcium carbonate formation and enhanced product quality.

At 414, the first mixture is directed to the inlet of the modified hydrocyclone 104 configured as a carbon dioxide mineralization reactor. Utilizing the modified hydrocyclone 104 as the mineralization reactor ensures efficient processing and promotes the controlled transformation of the first mixture into the carbonate slurry.

At 416, the first mixture in the modified hydrocyclone 104 is moved to obtain carbonate slurry with the second carbonation rate. The step achieves enhanced carbonation efficiency, facilitating the production of high-purity carbonate slurry with improved process control.

At 418, a purity parameter of the calcium carbonate in the defined purity parameter range is controlled during the release of the carbonate slurry from the underflow section 304 of the modified hydrocyclone 104 based on the control and change in the second pH range of the electrolyzed-alkaline water solvent blend. Real-time control of the purity parameter ensures the consistent quality of the calcium carbonate product, meeting stringent purity standards.

At 420, the carbonate slurry comprising calcium carbonate in the defined purity parameter range is released from the underflow section 304 of the modified hydrocyclone 104 while concurrently regenerating and releasing the electrolyzed-alkaline water solvent blend devoid of carbon dioxide for reuse from the overflow section 302 of the modified hydrocyclone 104. The concurrent regeneration process promotes resource efficiency by recovering and reusing the solvent blend, reducing waste and operational costs.

At 422, the electrolyzed-alkaline water solvent blend devoid of carbon dioxide is pushed from the overflow section 302 of the modified hydrocyclone 104 back to the filtration reactor 106 for further reuse in the filtration reactor 106. Recycling the solvent blend minimizes the consumption of raw materials and enhances the sustainability of the process.

At 424, the calcium carbonate slurry from the underflow section 304 of the modified hydrocyclone 104 is passed through a forced centrifuge to further segregate at least a portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide from the calcium carbonate slurry for further reuse in the filtration reactor 106. The forced centrifuge enables precise separation of the solvent blend, ensuring its effective reuse and improving the efficiency of calcium carbonate recovery.

At 426, the portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide is passed back to the filtration reactor 106 for further reuse in the filtration reactor 106. Continuous reuse of the solvent blend reduces waste and lowers operational costs, contributing to an environmentally sustainable process.

At 428, the calcium carbonate output from the forced centrifuge to pass through the one or more subsequent drying stages to obtain the final product of dry calcium carbonate within the defined purity parameter range. The drying stages ensure the production of high-quality dry calcium carbonate with the desired purity, suitable for industrial applications.

The described method 400, encompassing steps 402 to 428, synergistically integrates electrolysis, precise pH control, catalytic enhancement, and efficient material separation and recycling processes to achieve multiple objectives in a streamlined and sustainable manner. By producing and manipulating the electrolyzed-alkaline water solvent blend, the method 400 optimizes chemical reactions, ensures high-purity outputs such as silica and calcium carbonate, and minimizes resource consumption through effective reuse of materials.

The comprehensive approach not only maximizes the yield and quality of the final products but also reduces waste and operational costs, significantly improving environmental sustainability. The controlled injection of carbon dioxide and the advanced separation techniques ensure precise carbonation and high process efficiency, making the method 400 a robust solution for industrial applications requiring effective waste material utilization and byproduct recovery. The integrated design of the method 400 promotes resource efficiency, scalability, and adaptability, providing a cost-effective and environmentally friendly solution for industrial chemical processes.

FIG. 5 is a diagram illustrating exemplary operations for electrolysis-assisted mineralization of carbon dioxide, in accordance with an embodiment of the present disclosure. FIG. 5 is described in conjunction with elements from FIGS. 1, 2, 3A-3D, and 4A-4C. With reference to FIG. 5, there is shown a flowchart 500 illustrating exemplary operations 502 to 518 for electrolysis-assisted mineralization of carbon dioxide with industry alkali waste material.

At operation 502, the process includes producing an alkaline water stream comprising hydroxide ions within a first pH range through electrolysis of an input water stream. The electrolysis process generates hydroxide ions (OH−) at the cathode while separating them from the acidic stream produced at the anode, creating a highly alkaline water stream with pH ranging from 8 to 11, preferably 9 to 10.

At operation 504, the process includes blending the alkaline water stream with a solvent to obtain an electrolyzed-alkaline water solvent blend having a second pH range greater than the first pH range. The solvent, preferably an amine-based solvent such as monoethanolamine (MEA) or methyldiethanolamine (MDEA), is blended in a ratio of up to 30% solvent in electrolyzed water to achieve a pH range of 12 to 14.

At operation 506, the process includes mixing the electrolyzed-alkaline water solvent blend with an industrial alkali waste material in a reactor. The industrial alkali waste material may include steel slag, cement kiln dust, or fly ash. Additionally, a metal catalyst, such as nickel nanoparticles, cobalt metal, or platinum metal catalyst, is added in a concentration range of 10-500 ppm, preferably 30-100 ppm.

At operation 508, the process includes obtaining a silica byproduct at a first end of the reactor and a fluidic filtrate comprising calcium hydroxide at a second end of the reactor. The silica byproduct is separated and can be used as a silica source material for silica filler applications.

At operation 510, the process includes injecting carbon dioxide into gaseous form into the fluidic filtrate to obtain the first mixture comprising calcium carbonate with a first carbonation rate of 10-30%. After that, at operation 512, the process includes directing the first mixture to the heating chamber 102 and controlling the temperature to 80° C., achieving a carbonation rate of 31-50%.

At operation 514, the process includes directing the heated mixture to the modified hydrocyclone 104 configured as a carbon dioxide mineralization reactor, where the second carbonation rate increases to 51-99.99%. At operation 516, the process includes separating the calcium carbonate product from a regenerated solvent blend in the modified hydrocyclone. The modified hydrocyclone's unique design facilitates simultaneous reaction and separation, where the calcium carbonate product is collected from the underflow section 304 while the regenerated solvent blend exits through the overflow section 302.

At operation 518, the process includes recycling the regenerated solvent blend devoid of carbon dioxide back into the system for subsequent mineralization cycles. The regenerated solvent blend maintains its effectiveness through multiple cycles, contributing to the process's overall efficiency and sustainability. Prior to recycling, the regenerated solvent blend may undergo filtration to remove any suspended fine particles, ensuring optimal performance in subsequent cycles.

The sequence of operations 502-518 represents a continuous and efficient process for carbon dioxide mineralization, achieving high conversion rates and product purity. The process integrates electrolysis-based pH modification, controlled reaction conditions, and specialized reactor designs to optimize both reaction kinetics and separation efficiency. The recycling of the regenerated solvent blend significantly reduces operational costs and environmental impact.

In some implementations, the process parameters may be adjusted based on specific requirements. The specific requirements are the electrolysis current density that may be modified to achieve desired hydroxide ion concentrations, the solvent-to-water ratio that may be adjusted within the range of 1%/99% to 30%/70%, the catalyst concentration that may be varied between 30-100 ppm, the heating chamber temperature that may be controlled between 70° C. to 80° C. The adjustments enable the optimization of the process for different types of industrial alkali waste materials and desired product specifications.

The described sequence of operations results in the production of high-purity calcium carbonate (>95% purity) while simultaneously achieving efficient carbon dioxide utilization and industrial waste valorization. The process demonstrates significant advantages over conventional carbonation methods in terms of reaction rates, product quality, and process efficiency.

FIG. 6 is a block diagram of a system for electrolysis-assisted mineralization of carbon dioxide, in accordance with another embodiment of the present disclosure. FIG. 6 is described in conjunction with the elements from FIGS. 1 to 5. With reference to FIG. 6, there is shown a system 600 for electrolysis-assisted mineralization of carbon dioxide. The system 600 includes substantially similar components as the system 100 of FIG. 1, including the heating chamber 102, the modified hydrocyclone 104, the filtration reactor 106, the defined carbon dioxide source 108, the amine reactor 110, the industrial alkali waste material source 112, the metal catalyst source 114, the one or more controllers 116, the in-line electrolysis apparatus 118, the slurry pump 120, the separator 122, and the one or more dryers 124. However, in this embodiment, the system 600 further includes an extraction reactor 602 operatively and fluidly coupled to the in-line electrolysis apparatus 118.

The extraction reactor 602 refers to a specialized vessel configured to perform controlled chemical leaching of the industrial alkali waste material using chloride-based leaching agents to generate metal chloride salts. The extraction reactor 602 is placed before the in-line electrolysis apparatus 118 to execute the pre-processing step before electrolysis operations are executed in the in-line electrolysis apparatus 118. In some implementations, the extraction reactor 602 includes a multi-chamber reaction vessel with integrated mixing and temperature control systems, configured to facilitate selective extraction of metal oxides such as calcium and magnesium oxides. In some implementations, the extraction reactor 602 utilizes ammonium chloride or hydrogen chloride as the chloride-based leaching agents, with reaction temperatures maintained between 40-80° C. to optimize salt formation. In some implementations, the extraction reactor 602 may be equipped with advanced monitoring systems that continuously measure ionic concentration, pH, and reaction kinetics to ensure optimal mineral extraction efficiency. In some examples, mixing mechanisms, such as high-shear impellers or ultrasonic agitation, are integrated to enhance reaction completeness and uniformity of metal chloride salt generation. In some examples, the extraction reactor 602 is configured to process the industrial alkali waste material with varying mineral compositions, with typical processing capacities ranging from 0.5 to 10 tons of the industrial alkali waste material per hour. In some implementations, advanced filtration and separation systems are incorporated to isolate the silica byproducts 106A and ensure high-purity metal chloride salt solutions. Additionally, the extraction reactor 602 may include automated cleaning and regeneration protocols to maintain consistent performance and minimize mineral scaling or equipment degradation.

In operation, the one or more controllers 116 are configured to control mixing the industrial alkali waste material with ammonium chloride or hydrogen chloride in presence of an input water stream 604A in the extraction reactor 602 to extract calcium and magnesium from the industrial alkali waste material as metal chlorides and form a first mixture. The one or more controllers 116 regulate the flow rate of the input water stream 604A into the extraction reactor 602 and control addition of ammonium chloride or hydrogen chloride (shown by arrow 604B) based on the calcium oxide content present in the industrial alkali waste material (shown by arrow 604C). The one or more controllers 116 further regulate the introduction of predetermined amounts of the industrial alkali waste material to maintain predefined ratios with the ammonium chloride or hydrogen chloride for extraction of calcium and magnesium. In some examples, 50-100 grams of industrial alkali waste material are introduced per 1 liter of a 0.5-1.0 M ammonium chloride or hydrogen chloride solution, maintaining a weight-to-volume ratio of 1:10 to 1:20 for effective calcium and magnesium extraction. In other examples, 25-75 grams of the waste material are added to achieve a molar ratio of 1:2 to 1:4 with the chloride solution.

For the ammonium chloride, the extraction reaction controlled by the one or more controllers 116 proceeds according to the reactions: 2CaOSiO₂(a)+4NH₄Cl(aq)→2CaCl₂(aq)+4NH₃+2H₂O(l)+SiO₂(s) for calcium extraction and 2MgOSiO₂(a)+4NH₄Cl(aq)→2MgCl₂(aq)+4NH₃+2H₂O(l)+SiO₂(s) for magnesium extraction from the industrial alkali waste material. For the hydrogen chloride, the extraction reaction controlled by the one or more controllers 116 proceeds according to the reactions: 2CaOSiO₂(a)+₄HCl(aq)→2CaCl₂(aq)+2H₂O(l)+SiO₂(s) for calcium extraction and 2MgOSiO₂(a)+4HCl(aq)→2MgCl₂(aq)+2H₂O(l)+SiO₂(s) for magnesium extraction from the industrial alkali waste material. This pre-processing step before the electrolysis further improves the carbonation rate and generation of calcium carbonate with high purity (e.g., 98-99.99%) where the entire process cycle in a run takes less than 2-3 minutes (mostly 1 minute). In an example, the metal chlorides may be added in a range of 1-5% (or 5-10%), slag may be 30-70%, and rest may be water content, where make-up water may be required only as the reaction of the industrial alkali waste material (2CaOSiO₂(a)) with metal chlorides (ammonium chloride or hydrogen chloride or a combination of both ammonium chloride or hydrogen chloride) also generates water as byproduct.

In some implementations, the one or more controllers 116 are further configured to control passing the first mixture to the in-line electrolysis apparatus 118 to produce the alkaline water stream 604D including hydroxide ions within the first pH range through electrolysis of the input water stream 604A and concomitantly initiating production of metal hydroxides including calcium hydroxide to obtain a second mixture. In such implementation, during electrolysis the reactions proceed as: 2CaCl₂+4NH₃+2OH−→Ca(OH)₂+4NH₄Cl for calcium hydroxide production and 2MgCl₂+4NH₃+2OH−→Mg(OH)₂+4NH₄Cl for magnesium hydroxide production when ammonium chloride is used as the chloride-based leaching agent; and 2CaCl₂+2H₂O+2OH−→Ca(OH)₂+2HCl for calcium hydroxide production and 2MgCl₂+2H₂O+2OH−→Mg(OH)₂+2HCl for magnesium hydroxide production when hydrogen chloride is used as the chloride-based leaching agent. The electrolysis simultaneously produces the alkaline water stream 604D including hydroxide ions within the first pH range through electrolysis of the input water stream 604A while initiating production of the metal hydroxides to obtain the second mixture.

In some implementations, the one or more controllers 116 are further configured to control filtering the second mixture in the filtration reactor 106 to obtain the silica byproduct 106A at a first end 606A of the filtration reactor 106 and the fluidic filtrate including the metal hydroxides including the calcium hydroxide at a second end 606B of the filtration reactor 106. The fluidic filtrate may also include magnesium hydroxide. In this case, the concentration of the metal hydroxides including the calcium hydroxide and the magnesium hydroxide may be higher than the process described in FIG. 1-5. While silica extraction primarily occurs in the extraction reactor 602, the filtration reactor 106 may optionally be used for further silica extraction, if needed.

In certain embodiments, the one or more controllers 116 are configured to blend the second mixture comprising hydroxide ions, with the amine-based solvent to enhance the production of metal hydroxides, including calcium hydroxide, and to form the electrolyzed-alkaline water solvent blend in the second mixture, wherein the second pH range is greater than the first pH range. Specifically, the alkaline water stream 604D containing metal chloride salts, is blended with the amine-based solvent, such as monoethanolamine (MEA) or methyldiethanolamine (MDEA), received from the amine reactor 110. The blending facilitates increased production of metal hydroxides, including calcium hydroxide, while forming the electrolyzed-alkaline water solvent blend within the second mixture characterized by the second pH range exceeding the first pH range. The amine-based solvent may be blended for the first run whereas from the second run onwards, the amine-based solvent may be used in make-up amount only as 4NH₄Cl is generated in previous step along with the Ca(OH)₂.

In scenarios involving ammonium chloride, the extraction reaction inherently incorporates amine, thereby negating the need for additional amine blending. Conversely, in the case of hydrogen chloride, the requirement for amine may be addressed through the blending of the second mixture with the amine-based solvent.

In some implementations, the one or more controllers 116 are further configured to control the electrolysis of the input water stream 604A and the blending of the amine-based solvent with the second mixture to control and change the second pH range of the electrolyzed-alkaline water solvent blend. In some implementations, the one or more controllers 116 are further configured to control the purity parameter of the calcium carbonate in the defined purity parameter range during the release of the carbonate slurry from the underflow section 304 of the modified hydrocyclone 104 based on the control and change in the second pH range of the electrolyzed-alkaline water solvent blend.

In some implementations, the one or more controllers 116 are further configured to control introduction of an additional amount of the industrial alkali waste material in the filtration reactor 106 to increase concentration of the metal hydroxides including the calcium hydroxide obtained at the second end of the filtration reactor 106. In some implementations, the one or more controllers 116 are configured to control introduction of the metal catalyst in the filtration reactor 106.

In some implementations, the one or more controllers 116 are further configured to control injection of carbon dioxide in a gaseous form captured from the defined carbon dioxide source 108 into the fluidic filtrate to obtain a third mixture including calcium carbonate with the first carbonation rate. In some implementations, the one or more controllers 116 are configured to control feeding of the third mixture with injected carbon dioxide in the heating chamber 102, and control the movement of the third mixture with injected carbon dioxide along a loop pathway configured in the heating chamber 102 while controlling temperature in the heating chamber 102 in a range of 25 to 120 degree Celsius followed by directing the third mixture to the inlet of the modified hydrocyclone 104.

In some implementations, the one or more controllers 116 are further configured to control a flow of the third mixture to an inlet of the modified hydrocyclone 104 configured as a carbon dioxide mineralization reactor. In some implementations, the one or more controllers 116 are further configured to control movement of the third mixture in the modified hydrocyclone 104 to obtain carbonate slurry with the second carbonation rate. In some implementations, the one or more controllers 116 are further configured to control releasing the carbonate slurry including calcium carbonate in a defined purity parameter range from the underflow section 304 of the modified hydrocyclone 104 while concurrently regenerating and releasing the electrolyzed-alkaline water solvent blend devoid of carbon dioxide for reuse from the overflow section 302 of the modified hydrocyclone 104.

In some implementations, the one or more controllers 116 are further configured to control passing the carbonate slurry from the underflow section 304 of the modified hydrocyclone through a forced centrifuge to further segregate at least a portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide from the carbonate slurry for further reuse in one of: the extraction reactor 602 or the filtration reactor 106 or a combination of the extraction reactor 602 and the filtration reactor 106. In some implementations, the one or more controllers 116 are further configured to control passing the portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide back to one of: the extraction reactor 602 or the filtration reactor 106 or a combination of the extraction reactor 602 and the filtration reactor 106. In some implementations, the one or more controllers 116 are further configured to control passing the calcium carbonate output from the forced centrifuge through one or more subsequent drying stages to obtain the final product of dry calcium carbonate within the defined purity parameter range.

FIGS. 7A, 7B, and 7C, collectively, is a flowchart illustrating another method for electrolysis-assisted mineralization of carbon dioxide, in accordance with another embodiment of the present disclosure. FIGS. 7A, 7B, and 7C are described in conjunction with the elements from FIGS. 1 to 6. With reference to FIGS. 7A, 7B, and 7C, there is shown a flowchart of a method 700 for electrolysis-assisted mineralization of carbon dioxide. In an implementation, the method 700 is executed in the system 600. The method 700 may include steps 702 to 728.

At 702, the industrial alkali waste material is mixed with ammonium chloride or hydrogen chloride in presence of the input water stream 604A in the extraction reactor 602 to extract calcium and magnesium from the industrial alkali waste material as metal chlorides and form the first mixture. Mixing the industrial alkali waste material with ammonium chloride or hydrogen chloride in the presence of the input water stream 604A (e.g., make-up water) in the extraction reactor 602 facilitates efficient extraction of calcium and magnesium as metal chlorides. The step enables the conversion of waste material into valuable chemical precursors while minimizing waste.

At 704, the first mixture is passed to the in-line electrolysis apparatus 118 to produce the alkaline water stream 604D including hydroxide ions within the first pH range through electrolysis of the input water stream 604A and concomitantly initiating production of metal hydroxides including calcium hydroxide to obtain a second mixture. Passing the first mixture to the in-line electrolysis apparatus 118 allows the production of the alkaline water stream 604D with hydroxide ions and the simultaneous initiation of metal hydroxide formation. The dual functionality optimizes process efficiency and reduces energy consumption by combining multiple operations in a single apparatus.

At 706, the second mixture including the hydroxide ions is blended with the amine-based solvent to increase production of the metal hydroxides including the calcium hydroxide and obtain the electrolyzed-alkaline water solvent blend in the second mixture having the second pH range greater than the first pH range. Blending the second mixture, which includes hydroxide ions, with the amine-based solvent increases the production of metal hydroxides, such as calcium hydroxide, and achieves a higher pH range in the electrolyzed-alkaline water solvent blend. The step enhances the reactivity and effectiveness of the solvent for downstream processes.

At 708, an additional amount of the industrial alkali waste material is introduced in the filtration reactor 106 to increase concentration of the metal hydroxides including the calcium hydroxide obtained at the second end of the filtration reactor 106. Introducing the additional amount of industrial alkali waste material into the filtration reactor 106 increases the concentration of metal hydroxides, such as calcium hydroxide. The step improves the overall yield and maximizes resource utilization in the process.

At 710, the second mixture is filtered in the filtration reactor 106 to obtain the silica byproduct 106A at the first end of the filtration reactor 106 and the fluidic filtrate including the metal hydroxides including the calcium hydroxide at the second end of the filtration reactor 106. Filtering the second mixture in the filtration reactor 106 separates the silica byproduct 106A at one end and the fluidic filtrate containing metal hydroxides at the other. The step ensures efficient material separation, enabling the recovery of high-purity silica and metal hydroxides for subsequent use.

At 712, the metal catalyst is introduced in the filtration reactor 106. Introducing the metal catalyst into the filtration reactor 106 accelerates chemical reactions, enhancing the formation of desired products. The step reduces reaction time and energy requirements, making the process more cost-effective.

At 714, the carbon dioxide in a gaseous form captured from the defined carbon dioxide source 108 is injected into the fluidic filtrate to obtain the third mixture including calcium carbonate with the first carbonation rate. Injecting carbon dioxide from the defined CO₂ source 108 into the fluidic filtrate results in the third mixture containing calcium carbonate with the first carbonation rate. The step leverages captured carbon dioxide, contributing to carbon sequestration and the sustainable production of calcium carbonate.

At 716, the third mixture with injected carbon dioxide is fed in the heating chamber 102, and then the third mixture with injected carbon dioxide is moved along the loop pathway configured in the heating chamber 102 while controlling temperature in the heating chamber 102 in a range of 25 to 120 degree Celsius followed by directing the third mixture to the inlet of the modified hydrocyclone 104. Feeding the third mixture into the heating chamber 102 with the loop pathway and controlled temperature ensures optimal conditions for carbonation and reaction kinetics. The step improves the reaction efficiency and the quality of the final carbonate product.

At 718, the third mixture is directed to the inlet of the modified hydrocyclone 104 configured as a carbon dioxide mineralization reactor. Directing the third mixture to the modified hydrocyclone 104 configured as the carbon dioxide mineralization reactor enables efficient mineralization reactions. The step enhances the carbonation process, yielding high-purity calcium carbonate.

At 720, the third mixture is moved in the modified hydrocyclone 104 to obtain the carbonate slurry with the second carbonation rate. Moving the third mixture in the modified hydrocyclone 104 results in the formation of the carbonate slurry with an increased carbonation rate. The step improves the overall throughput of the process and enhances product quality.

At 722, the carbonate slurry from the underflow section 304 of the modified hydrocyclone 104 is passed through the forced centrifuge to further segregate at least a portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide from the carbonate slurry for further reuse. Passing the carbonate slurry through the forced centrifuge separates a portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide for reuse. The step enhances process sustainability by recycling and conserving resources.

At 724, the portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide is passed back to one of: the extraction reactor 602 or the filtration reactor 106 or a combination of the extraction reactor 602 and the filtration reactor 106. Reusing the portion of the electrolyzed-alkaline water solvent blend devoid of carbon dioxide in the extraction reactor 602 or the filtration reactor 106 ensures process continuity and minimizes the consumption of new solvents, improving overall process economics.

At 726, the carbonate slurry including calcium carbonate in the defined purity parameter range is released from the underflow section 304 of the modified hydrocyclone 104 while concurrently regenerating and releasing the electrolyzed-alkaline water solvent blend devoid of carbon dioxide for reuse from the overflow section 302 of the modified hydrocyclone 104. Releasing the carbonate slurry from the underflow section 304 of the modified hydrocyclone 104 while regenerating and recovering the electrolyzed-alkaline water solvent blend ensures the production of high-purity calcium carbonate and promotes solvent recycling, enhancing the environmental and economic viability of the process.

At 728, the calcium carbonate output from the forced centrifuge is passed through one or more subsequent drying stages to obtain a final product, i.e., dry calcium carbonate within the defined purity parameter range. Passing the calcium carbonate output through subsequent drying stages yields a final product of dry calcium carbonate with defined purity. This step ensures the production of a market-ready product, meeting industrial standards and specifications.

The method 700 of the present disclosure offers a robust and efficient approach to synthesizing calcium carbonate from industrial alkali waste material. By leveraging the in-line electrolysis and subsequent carbonation, the process ensures high resource utilization, minimal wastage, and consistent production of calcium carbonate within defined purity parameters. The method 700 is particularly advantageous due to its ability to operate with varying compositions of industrial alkali waste, ensuring adaptability and scalability across different industrial setups. The integration of electrolysis not only facilitates the generation of hydroxide ions necessary for the carbonation reaction but also maintains reaction uniformity and shortens reaction times, thereby enhancing overall process efficiency.

Additionally, the method's ability to handle varying calcium oxide (CaO) content in the industrial alkali waste material makes it versatile, ensuring reliable calcium carbonate production without requiring extensive preprocessing of the input material. This adaptability significantly reduces operational costs and complexity.

The inclusion of a pre-step involving the extraction reactor 602, where the industrial alkali waste is treated with ammonium chloride or hydrogen chloride, further elevates the efficacy of the method 700. The pre-treatment facilitates the extraction of calcium and magnesium as metal chlorides, thereby ensuring their availability for subsequent electrolysis. As a result, the carbonation reaction is accelerated, with reaction times reduced to 1-3 minutes.

Furthermore, the pre-step enhances the yield and purity of the calcium carbonate produced, reaching levels as high as 98%, while concurrently improving reaction uniformity. The improvement underscores the superiority of the method 700 with the pre-step, as it achieves better resource efficiency and higher-quality output with the same input resources. The pre-step also enables better scalability for industrial applications by optimizing the interaction of the raw materials, thereby making the method 700 a preferred choice for advanced industrial carbonation processes.

EXAMPLES OF PREPARATION

Example 1

In one exemplary embodiment, for every 1 kg of point-sourced CO₂ introduced into the system 100, 2.5 to 3.5 kg of slag, depending on its composition, was added. The slag used was an industrial alkali waste selected from a steel blast furnace slag, cement kiln dust, or fly ash. Additionally, 1 to 2 kg of amine and 8 kg of water were provided. This combination resulted in the production of 2 kg of calcium carbonate as a final product. Calcium carbonate obtained from the process can directly be blended with cement and used in paper, paint, and polymer applications.

Example 2

In another exemplary embodiment, a flue gas stream containing 10% CO₂ was utilized. To capture 1 kg of CO₂ from the flue gas, 10 kg of flue gas was processed. Additionally, 2.5 to 3.5 kg of slag, depending on its composition, 1 to 2 kg of amine, and 8 kg of water were required. The slag used was an industrial alkali waste selected from a steel blast furnace slag, cement kiln dust, or fly ash. This resulted in the production of 2 kg of calcium carbonate. The approach effectively reduced the cost of CO₂ capture by utilizing the flue gas stream, rather than directly capturing pure CO₂, for reacting with slag to form the calcium carbonate.

Example 3

In one exemplary embodiment, for the mineralization of 1 ton of point-sourced CO₂, approximately 2.5 to 3.5 tons of slag (depending on its composition) was required, along with 2 tons of amine and 8 tons of water. The slag used was an industrial alkali waste selected from a steel blast furnace slag, cement kiln dust, or fly ash. This process resulted in the production of 2 tons of calcium carbonate, which serves as the final product. The process sequestered 1 ton of CO₂ per 2 tons of calcium carbonate.

Example 4

In another exemplary embodiment, when utilizing a flue gas stream containing 10% CO₂, 1 ton of CO₂ was extracted from approximately 10 tons of flue gas. To mineralize this 1 ton of CO₂, around 2.5 to 3.5 tons of slag (depending on its composition), 2 tons of amine, and 8 tons of water were required. The slag used was an industrial alkali waste selected from a steel blast furnace slag, cement kiln dust, or fly ash. This process produced 2 tons of calcium carbonate as the final product.

Example 5

In yet another exemplary embodiment, for every 1 kg of point-sourced CO₂ introduced into the system 600, 2.5 to 3.5 kg of slag, depending on its composition, was added. The slag used was an industrial alkali waste selected from a steel blast furnace slag, cement kiln dust, or fly ash. Additionally, 2.3 to 3.8 kg of ammonium chloride, 8 Kg of water, 1 to 2 kg of amine and 8 kg of water were provided.

Example 6

In yet another exemplary embodiment, a flue gas stream containing 10% CO₂ was utilized. To capture 1 kg of CO₂ from the flue gas, 10 kg of flue gas was processed. Additionally, 2.5 to 3.5 kg of slag, depending on its composition, 2.3 to 3.8 kg of ammonium chloride, 8 kg of water, 1 to 2 kg of amine were required. The slag used was an industrial alkali waste selected from a steel blast furnace slag, cement kiln dust, or fly ash. This resulted in the production of 2 kg of calcium carbonate. The approach effectively reduced the cost of CO₂ capture by utilizing the flue gas stream, rather than directly capturing pure CO₂, for reacting with slag to form the calcium carbonate.

EXPERIMENTAL PART

Experiment 1

In an experimental setup, mono ethanol amine (MEA) was used as a solvent with varying CO₂ loadings to react with steel blast furnace slag containing different percentages of calcium oxide. Tables 1, 2, and 3 present the results for slags with 50%, 40%, and 30% calcium oxide content respectively as provided below.

TABLE 1
MEA as a solvent with different CO2 loading with a steel blast furnace slag which
has 50% calcium oxide.

			MEA							Slag
CO2	MEA	20 g	weight	Water	CO2	CO2	CaCO3	CaO	CaO	(50%	CaCO3
(moles)	(Moles)	MEA	(g)	(g)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)

0.40	1.00	0.33	20.00	80.00	0.13	5.77	100.00	56.00	7.34	14.69	13.11
0.50	1.00	0.33	20.00	80.00	0.16	7.21	100.00	56.00	9.18	18.36	16.39
0.60	1.00	0.33	20.00	80.00	0.20	8.66	100.00	56.00	11.02	22.03	19.67

TABLE 2
MEA as a solvent with different CO2 loading with a steel blast furnace slag which
has 40% calcium oxide.

			MEA							Slag
CO2	MEA	20 g	weight	Water	CO2	CO2	CaCO3	CaO	CaO	(40%	CaCO3
(moles)	(Moles)	MEA	(g)	(g)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)

0.40	1.00	0.33	20.00	80.00	0.13	5.77	100.00	56.00	7.34	18.36	13.11
0.50	1.00	0.33	20.00	80.00	0.16	7.21	100.00	56.00	9.18	22.95	16.39
0.60	1.00	0.33	20.00	80.00	0.20	8.66	100.00	56.00	11.02	27.54	19.67

TABLE 3
MEA as a solvent with different CO2 loading with a steel blast furnace slag which
has 30% calcium oxide

		g
		moles
		of	MEA							Slag
CO2	MEA	20 g	weight	Water	CO2	CO2	CaCO3	CaO	CaO	(30%	CaCO3
(moles)	(Moles)	MEA	(g)	(g)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)

0.40	1.00	0.33	20.00	80.00	0.13	5.77	100.00	56.00	7.34	24.48	13.11
0.50	1.00	0.33	20.00	80.00	0.16	7.21	100.00	56.00	9.18	30.60	16.39
0.60	1.00	0.33	20.00	80.00	0.20	8.66	100.00	56.00	11.02	36.72	19.67

The tables 1, 2, and 3 demonstrate the impact of calcium oxide content in the slag on the carbonation process and product yield. The data shows that as the calcium oxide content in the slag decreases from 50% (Table 1) to 40% (Table 2) and 30% (Table 3), there is a notable change in the carbonation outcomes. With higher calcium oxide content (Table 1), less slag is required to react with the same amount of CO₂, resulting in a more efficient conversion. As the calcium oxide percentage decreases (Tables 2 and 3), more slag is needed to react with the same quantity of CO₂, leading to a larger overall mass of calcium carbonate produced. This is evident from the increasing values in the “calcium carbonate” column across the three tables for the same CO₂ input. The CO₂ loading in the MEA solvent, varying from 0.40 to 0.60 moles in each table, also affects the carbonation process, with higher loadings generally resulting in more calcium carbonate production. These results, as presented in the tables, highlight an ability to adapt to varying feedstock qualities, which is an important factor for practical industrial applications where waste material composition may fluctuate.

Experiment 2

In another experimental setup, Methyl Di-ethanol amine (MDEA) was used as a solvent with varying CO₂ loadings to react with steel blast furnace slag containing different percentages of calcium oxide. Tables 4, 5, and 6 present the results for slags with 50%, 40%, and 30% calcium oxide content respectively, as provided below.

TABLE 4
MDEA as a solvent with different CO2 loading with a steel blast furnace slag which
has 50% calcium oxide.

			MDEA							Slag
CO2	MDEA	20 g	weight	Water	CO2	CO2	CaCO3	CaO	CaO	(50%	CaCO3
(moles)	(Moles)	MEA	(g)	(g)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)

0.40	1.00	0.17	20.00	80.00	0.07	2.95	100.00	56.00	3.76	7.52	6.71
0.50	1.00	0.17	20.00	80.00	0.08	3.69	100.00	56.00	4.70	9.40	8.39
1.00	1.00	0.17	20.00	80.00	0.17	7.38	100.00	56.00	9.40	18.80	16.78

TABLE 1
MDEA as a solvent with different CO2 loading with a steel blast furnace slag which
has 40% calcium oxide.

			MDEA							Slag
CO2	MDEA	20 g	weight	Water	CO2	CO2	CaCO3	CaO	CaO	(40%	CaCO3
(moles)	(Moles)	MDEA	(g)	(g)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)

0.40	1.00	0.17	20.00	80.00	0.07	2.95	100.00	56.00	3.76	9.40	6.71
0.50	1.00	0.17	20.00	80.00	0.08	3.69	100.00	56.00	4.70	11.75	8.39
1.00	1.00	0.17	20.00	80.00	0.17	7.38	100.00	56.00	9.40	23.50	16.78

TABLE 2
MDEA as a solvent with different CO2 loading with a steel blast furnace slag which
has 30% calcium oxide

		g
		moles
		of	MDEA							Slag
CO2	MDEA	20 g	weight	Water	CO2	CO2	CaCO3	CaO	CaO	(30%	CaCO3
(moles)	(Moles)	MDEA	(g)	(g)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)

0.40	1.00	0.17	20.00	80.00	0.07	2.95	100.00	56.00	3.76	12.53	6.71
0.50	1.00	0.17	20.00	80.00	0.08	3.69	100.00	56.00	4.70	15.66	8.39
1.00	1.00	0.17	20.00	80.00	0.17	7.38	100.00	56.00	9.40	31.33	16.78

The data demonstrates the impact of calcium oxide content in the slag on the carbonation process and product yield when using MDEA as a solvent. As observed with the MEA solvent, the calcium oxide percentage in the slag significantly influences the carbonation efficiency and the amount of calcium carbonate produced.

Table 4 shows that with 50% calcium oxide content, less slag is required to react with the same amount of CO₂, resulting in a more efficient conversion. As the calcium oxide percentage decreases to 40% (Table 5) and 30% (Table 6), more slag is needed to react with the same quantity of CO₂, leading to a larger overall mass of calcium carbonate produced. This trend is evident from the increasing values in the “calcium carbonate” column across the three tables for the same CO₂ input.

The CO₂ loading in the MDEA solvent, varying from 0.40 to 1.00 moles in each table, shows a significant impact on the carbonation process. CO₂ has higher molar solubility in Methyl di-ethanol amine (MDEA) up to 1 mole of CO₂ per mole of MDEA. The higher CO₂ loading capacity of MDEA (up to 1 mole of CO₂ per mole of MDEA) allows for more efficient CO₂ utilization, particularly at higher loadings. This is reflected in the substantial increase in calcium carbonate production when CO₂ loading increases from 0.50 to 1.00 moles across all slag types.

These results highlight an adaptability to different solvents and varying feedstock qualities. The use of MDEA, with its higher CO₂ loading capacity, demonstrates the potential for enhanced CO₂ utilization in the mineralization process, particularly when dealing with industrial alkali waste materials of varying calcium oxide content.

Experiment 3

The experimental study investigated the performance of monoethanolamine (MEA) as a solvent for carbon dioxide (CO₂) capture using steel blast furnace slag as the source material. Three sets of experiments were conducted, each with a slag sample containing a different percentage of calcium oxide (CaO): 50%, 40%, and 30%.

For each experiment, the MEA solvent was combined with the slag sample at varying CO₂ loading levels, ranging from 0.40 to 0.60 mol CO₂/mol MEA. The key performance metrics, including the CO₂ mole, CO₂ mole percentage, CaCO₃ (calcium carbonate) formation, and residual CaO content, were analyzed.

TABLE 7
MEA as a solvent with different CO2 loading with a steel blast furnace slag which has 50% calcium oxide.

100

MEA

Slag

MEA

g

NH4Cl

weight

Water

CO2

CO2

CO2

CaCO3

CaO

CaO

(50%

CaCO3

(Moles)

MEA

g

(g)

(g)

(moles)

(moles)

(g)

(MW)

(MW)

(g)

CaO)

(g)

1.00	1.64	34.00	100.00	500.00	0.40	0.66	28.85	100.00	56.00	36.72	73.44	65.57
1.00	1.64	42.50	100.00	500.00	0.50	0.82	36.07	100.00	56.00	45.90	91.80	81.97
1.00	1.64	51.00	100.00	500.00	0.60	0.98	43.28	100.00	56.00	55.08	110.16	98.36

TABLE 8
MEA as a solvent with different CO2 loading with a steel blast furnace slag which has 40% calcium oxide.

100

MEA

Slag

MEA

g

NH4Cl

weight

Water

CO2

CO2

CO2

CaCO3

CaO

CaO

(40%

CaCO3

(Moles)

MEA

g

(g)

(g)

(moles)

(moles)

(g)

(MW)

(MW)

(g)

CaO)

(g)

1.00	1.64	34.00	100.00	500.00	0.40	0.66	28.85	100.00	56.00	36.72	91.80	65.57
1.00	1.64	42.50	100.00	500.00	0.50	0.82	36.07	100.00	56.00	45.90	114.75	81.97
1.00	1.64	51.00	100.00	500.00	0.60	0.98	43.28	100.00	56.00	55.08	137.70	98.36

TABLE 9
MEA as a solvent with different CO2 loading with a steel blast furnace slag which has 30% calcium oxide.

	100		MEA								Slag
MEA	g	NH4Cl	weight	Water	CO2	CO2	CO2	CaCO3	CaO	CaO	(30%	CaCO3
(Moles)	MEA	g	(g)	(g)	(moles)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)
1.00	1.64	34.00	100.00	500.00	0.40	0.66	28.85	100.00	56.00	36.72	122.40	65.57
1.00	1.64	42.50	100.00	500.00	0.50	0.82	36.07	100.00	56.00	45.90	153.01	81.97
1.00	1.64	51.00	100.00	500.00	0.60	0.98	43.28	100.00	56.00	55.08	183.61	98.36

The experimental results, as shown in Tables 7, 8, and 9, provide insights into the system's behavior under different conditions.

When the slag sample contains a higher percentage of CaO (50%), the formation of CaCO₃ is more favorable. This is due to the increased availability of calcium ions, which can readily react with the CO₂ dissolved in the MEA solvent to precipitate CaCO₃. The higher CaO content in the slag promotes a more efficient conversion of CO₂ into stable carbonate minerals, enhancing the overall carbon capture and utilization potential of the process.

In contrast, when the slag sample contains a lower percentage of CaO (40% and 30%), the formation of CaCO₃ is less favored. The reduced availability of calcium ions limits the extent of the carbonation reaction, resulting in a lower CaCO₃ yield. In these cases, the system may exhibit a higher residual CaO content, indicating that the CO₂ capture efficiency is lower compared to the scenario with a higher CaO slag.

The result in tables highlights the impact of CaO percentage in the slag composition in determining the efficiency of the CO₂ capture and mineral carbonation processes. The experimental data provided in the tables may inform the optimization of the overall system, allowing for the selection of the most suitable slag composition and operating conditions to maximize CaCO₃ formation and CO₂ utilization.

Experiment 4

In another experimental setup, Methyl Di-ethanol Amine (MDEA) was employed as a solvent for carbonation reactions using steel blast furnace slag with varying calcium oxide content. The experimental data are summarized in Tables 10, 11, and 12, detailing the reaction outcomes for slags with 50%, 40%, and 30% calcium oxide (CaO), respectively.

TABLE 4
MDEA as a solvent with different CO2 loading with a steel blast furnace slag which has 50% calcium oxide.

			MDEA								Slag
MDEA	20 g	NH4Cl	weight	Water	CO2	CO2	CO2	CaCO3	CaO	CaO	(50%	CaCO3
(Moles)	MDEA	g	(g)	(g)	(moles)	(moles)	(g)	(MW)	(MW)	(g)	CaO)	(g)
1.00	0.84	17.41	100.00	500.00	0.40	0.34	14.77	100.00	56.00	18.80	37.60	33.57
1.00	0.84	21.76	100.00	500.00	0.50	0.42	18.46	100.00	56.00	23.50	46.99	41.96
1.00	0.84	43.51	100.00	500.00	1.00	0.84	36.92	100.00	56.00	46.99	93.99	83.92

TABLE 5
MDEA as a solvent with different CO2 loading with a steel blast furnace slag which has 40% calcium oxide.

MDEA

Slag

MDEA

20 g

NH4Cl

weight

Water

CO2

CO2

CO2

CaCO3

CaO

CaO

(40%

CaCO3

(Moles)

MDEA

g

(g)

(g)

(moles)

(moles)

(g)

(MW)

(MW)

(g)

CaO)

(g)

1.00	0.84	17.41	100.00	500.00	0.40	0.34	14.77	100.00	56.00	18.80	46.99	33.57
1.00	0.84	21.76	100.00	500.00	0.50	0.42	18.46	100.00	56.00	23.50	58.74	41.96
1.00	0.84	43.51	100.00	500.00	1.00	0.84	36.92	100.00	56.00	46.99	117.49	83.92

TABLE 6
MDEA as a solvent with different CO2 loading with a steel blast furnace slag which has 30% calcium oxide.

g

moles

of

MDEA

Slag

MDEA

20 g

NH4Cl

weight

Water

CO2

CO2

CO2

CaCO3

CaO

CaO

(30%

CaCO3

(Moles)

MDEA

g

(g)

(g)

(moles)

(moles)

(g)

(MW)

(MW)

(g)

CaO)

(g)

1.00	0.84	17.41	100.00	500.00	0.40	0.34	14.77	100.00	56.00	18.80	62.66	33.57
1.00	0.84	21.76	100.00	500.00	0.50	0.42	18.46	100.00	56.00	23.50	78.32	41.96
1.00	0.84	43.51	100.00	500.00	1.00	0.84	36.92	100.00	56.00	46.99	156.65	83.92

The data illustrate the influence of calcium oxide content on the efficiency of the carbonation reaction and the yield of calcium carbonate (CaCO₃). It is evident from the experiments that higher calcium oxide content in the slag leads to a more efficient conversion process. Table 10 demonstrates that slag with 50% CaO requires a smaller quantity to react with a fixed amount of CO₂, resulting in efficient utilization of the reactants. Conversely, Tables 11 and 12 reveal that as the calcium oxide content decreases to 40% and 30%, respectively, a larger amount of slag is necessary to achieve the same carbonation.

For each experiment, CO₂ loading in the MDEA solvent was varied between 0.40, 0.50, and 1.00 moles. MDEA's higher CO₂ absorption capacity (up to 1 mole of CO₂ per mole of MDEA) played a pivotal role in enhancing carbonation efficiency. As seen in all tables, increasing CO₂ loading from 0.50 to 1.00 moles significantly improved the CaCO₃ yield, regardless of the slag's CaO content. This highlights MDEA's capability to utilize CO₂ effectively at higher loadings, resulting in a substantial increase in calcium carbonate production.

Table 10, corresponding to slag with 50% CaO, shows the highest efficiency in terms of CaCO₃ production for the same amount of CO₂ input compared to Tables 11 and 12. When slag with 40% CaO was used, as presented in Table 11, slightly more slag was required to achieve comparable results, leading to a reduced conversion efficiency. Finally, Table 12 highlights the challenges associated with slag containing 30% CaO, where even more slag was required for effective carbonation, though a larger mass of CaCO₃ was produced due to the higher slag input.

The results underline the adaptability of the described carbonation method to various industrial alkali waste materials. The use of MDEA, with its superior CO₂ absorption properties, enables effective mineralization across slag types of differing calcium oxide content. This adaptability is crucial for the practical application of this technique in industrial processes, allowing for efficient utilization of CO₂ and optimization of slag resources.

Experiment 5

In one experimental setup, industrial alkali waste material with varying percentages of calcium oxide (CaO) content (30%, 40%, and 50%) was introduced directly into an in-line electrolysis apparatus, followed by carbonation with carbon dioxide captured from a defined source. The process parameters and corresponding results were recorded as shown below:

Parameter	30% CaO	40% CaO	50% CaO

Input water	50	liters	50	liters	50	liters
Industrial alkali waste	10	kg	10	kg	10	kg
Carbonation reaction time	5	minutes	5	minutes	5	minutes

Calcium carbonate purity

92%

94%

95%

Calcium carbonate yield

1.2

kg

1.5

kg

1.8

kg

Reaction uniformity	High	High	High

The results indicate that higher CaO content in the slag results in increased yield and purity of the calcium carbonate produced.

Experiment 6

In another experimental setup, industrial alkali waste material with varying percentages of calcium oxide (CaO) content (30%, 40%, and 50%) was first processed in an extraction reactor with ammonium chloride or hydrogen chloride, followed by electrolysis of the resulting mixture to generate hydroxide ions, and finally subjected to carbonation using captured carbon dioxide. The process parameters and results were recorded as follows:

Parameter	30% CaO	40% CaO	50% CaO

Input water	50	liters	50	liters	50	liters
Ammonium chloride/HCl	5	kg	5	kg	5	kg
Industrial alkali waste	10	kg	10	kg	10	kg
Carbonation reaction time	2	minutes	2	minutes	2	minutes

Calcium carbonate purity

96%

97%

98%

Calcium carbonate yield

1.5

kg

2

kg

2.4

kg

Reaction uniformity	Very High	Very High	Very High

The addition of a pre-step significantly reduced carbonation reaction time while improving both the yield and purity of calcium carbonate for all CaO percentages.

The experimental results show that introducing a pre-step with ammonium chloride or hydrogen chloride enhances the overall process efficiency by accelerating the carbonation reaction due to the better pre-treatment of slag, producing higher yields of calcium carbonate with improved purity, and ensuring greater reaction uniformity. Both setups demonstrate technical feasibility; however, the pre-step setup consistently outperforms in terms of output quality and efficiency, making it a preferred method for applications requiring optimized resource utilization and high-grade calcium carbonate.

Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word “exemplary” is used herein to mean “serving as an example, instance or illustration”. Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word “optionally” is used herein to mean “is provided in some embodiments and not provided in other embodiments”. It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.