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Modeling and Optimization of Aqueous Mineral Carbonation for Cement Kiln Dust Using Response Surface Methodology Integrated with Box-Behnken and Central Composite Design Approaches

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Abstract

Carbon capture and storage (CCS) is an attractive area of research in such fields as CO2 mineral carbonation, global warming and sustainable energy systems. In this study, carbonation efficiency for aqueous mineral carbonation (MC) was achieved through two steps, which include leaching of calcium from cement kiln dust (CKD) followed by the reaction of pure CO2 with the calcium hydroxide precipitates formed by the hydroxylation using NaOH. Response surface methodology (RSM) with a Box-Behnken design (BBD) was applied to optimize the calcium leaching yield, while the carbonation efficiency from CKD was assessed using RSM with central composite design (CCD). Optimization of calcium leaching is highly important, as it is a rate-limiting reaction step in MC and also influences and enhances carbonation efficiency. Different parameters including acid concentration (HNO3), leaching temperature, leaching time, and dose of CKD sample were considered in order to optimize the maximum yield of Ca leaching from the CKD sample. In addition, different CO2 flow rates and temperatures were used as parameters for optimizing carbonation efficiency. Two quadratic regression models were developed for each process, i.e. calcium leaching and carbonation. For calcium leaching, a maximum of 98.55% calcium was extracted under the optimal set of acid concentration 4.13 M, 90 °C, 28 min leaching time, and 13.8 g of CKD sample. For carbonation, the maximum carbonation efficiency of 89.2% was achieved for a CO2 flow rate of 1163 cm3/min at 90 °C. Calcium leaching results indicate that the leaching yield was significantly affected by all the input parameters except leaching time. For carbonation, both factors affected the carbonation efficiency, with the effect temperature shown to be greater than that of the CO2 flow rate. Additionally, the predicted results agreed well with the experimental values for both calcium leaching and carbonation processes, with errors of less than 1% and 5%, respectively.

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Abbreviations

t :

Reaction time, min

T :

Reaction temperature, K

ANOVA:

Analysis of variance

CCS:

Carbon capture and storage

MC:

Mineral carbonation

IDC:

In direct carbonation

CKD:

Cement kiln dust

BBD:

Box-Behnken design

CCD:

Central composite design

RSM:

Response Surface Design

FFD:

Fractional factorial design

ICP–AES:

Inductively coupled plasma-atomic emission spectrometry

OFAT:

One-factor-at-a-time

y :

Predicted response

x i :

Coded variables

β o :

Mode constant

βi (β1, β2, β3, β4):

Linear coefficients

βii (β11, β22, β33, β44):

Quadratic coefficients

βij (β12, β13, β14, β23, β24, β34):

Cross product coefficients

X Ca :

Calcium extraction efficiency, %

V :

Volume of the ligand solution used, ml

C t :

Ca ion concentration analyzed at time t, hr

m b :

mass of the CKD sample, g

w Ca :

wt% of Ca initially present in the parent sample

ηc :

Carbonation efficiency (%)

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Acknowledgements

The authors would like to thank the Department of Chemistry and Nanotechnology Center/Central Labs at the College of Science, University of Bahrain, Kingdom of Bahrain, for allowing us to use the analytical equipment.

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Authors and Affiliations

  1. Department of Chemical Engineering, College of Engineering, University of Bahrain, Isa Town, 32038, Kingdom of Bahrain

    Muhammad Faisal Irfan, S. M. Zakir Hossain, Ihtisham Tariq, Niaz Ali Khan, Abdulaziz Tawfeeqi, Anastasia Goeva & Mohamed Wael

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  1. Muhammad Faisal Irfan
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Irfan, M.F., Hossain, S.M.Z., Tariq, I. et al. Modeling and Optimization of Aqueous Mineral Carbonation for Cement Kiln Dust Using Response Surface Methodology Integrated with Box-Behnken and Central Composite Design Approaches. Mining, Metallurgy & Exploration 37, 1367–1383 (2020). https://doi.org/10.1007/s42461-020-00222-9

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