The carbonation rates of porous mortars, pellets, and extruded forms of Ca(OH)2 were determined to investigate their suitability as functional materials for direct air capture. Samples of 4-15 mm thickness and porosities between 0.2 and 0.8 were tested by monitoring the progress of the carbonation fronts on time scales from 1 to 500 h. The evolution of such carbonation fronts was found to obey Fick's diffusion law under all tested conditions. To reach CaCO3 conversions higher than 0.6, a relative humidity above 50%, preferably between 80 and 100%, was required when using dry, low-grade slaked lime with a surface area of 18 m2/g as CO2 sorbent. For modest relative humidities of 50%, higher grades of Ca(OH)2 (i.e., with a surface area approaching 40 m2/g) still allowed carbonation conversions above 0.8. The results confirm the applicability of these commercial solids for the direct air capture of CO2.
The carbonation rates of porous mortars, pellets, and extruded forms of Ca(OH)2 were determined to investigate their suitability as functional materials for direct air capture. Samples of 4-15 mm thickness and porosities between 0.2 and 0.8 were tested by monitoring the progress of the carbonation fronts on time scales from 1 to 500 h. The evolution of such carbonation fronts was found to obey Fick's diffusion law under all tested conditions. To reach CaCO3 conversions higher than 0.6, a relative humidity above 50%, preferably between 80 and 100%, was required when using dry, low-grade slaked lime with a surface area of 18 m2/g as CO2 sorbent. For modest relative humidities of 50%, higher grades of Ca(OH)2 (i.e., with a surface area approaching 40 m2/g) still allowed carbonation conversions above 0.8. The results confirm the applicability of these commercial solids for the direct air capture of CO2.
The carbonation of Ca(OH)2-containing
solids under ambient
conditions has been studied by a number of researchers investigating
the fundamentals of this gas–solid reaction.[1−9] This type of carbonation has also been investigated because of its
importance with regard to mortars[10−12] and as the basis of
a method for direct CO2 capture from the atmosphere.[9,13−18] Regarding the latter, we have recently investigated[19,20] the possibility of deploying vast volumes of purpose-built passive
carbonation infrastructures of porous Ca(OH)2 stacked in
such a way as to maximize the exposure of active Ca(OH)2 surfaces to ambient air. The development of these applications could
take advantage of the low specific cost of Ca(OH)2 precursor
(i.e., limestone) in many locations as well as the near-term availability
of technologies for the oxy-calcination of CaCO3 for cement
production,[21,22] calcium looping,[23] and other direct air capture systems using CaO.[24−26]Most of the works studying the carbonation reaction of Ca(OH)2 in powder form with the ambient air suggest that the reaction
mechanism under such operational conditions[1,3] differs
from the gas–solid reaction mechanism observed for the carbonation
of Ca-based materials under temperatures above 100 °C. Beruto
and Botter[1] investigated the effect of
relative humidity in the air to promote faster carbonation of Ca(OH)2 powders, reporting extremely slow carbonation rates for the
carbonation of Ca(OH)2 under dry conditions. Following
these observations, a reaction mechanism was proposed based on the
adsorption of liquid water on the internal surface of the particles
to promote the carbonation reaction at low temperatures. This reaction
mechanism was also proposed by Dheilly et al.[2] and Shih et al.[3] when studying the reaction
at temperatures below 90 °C and CO2 concentrations
from 0.03 %v up to 12 %v and has been observed as well for the carbonation
of other Ca-based materials in the cement chemistry.[10−12] In addition to this, several authors[3,5,7] observed linear relations between the CO2 uptake and the Ca(OH)2 material surface area[3,5] as well as improved reaction rates as the surface area increases.[7] More recently, Erans et al.[9] have investigated this reaction for direct air capture
applications, requiring times up to 500–1000 h to carbonate
5 mm deep layers of CaO and Ca(OH)2 powders. These reaction
times are in agreement with those reported in the state-of-the-art
carbonation of large concrete structures, the carbonation rates of
such structures being controlled by pore diffusion.[27]In this work, we experimentally investigate the carbonation
process
of Ca(OH)2 porous solids with potential applicability in
passive carbonation schemes. To this end, pelletized samples of Ca(OH)2 powder, dry mortars of Ca(OH)2 and water, and
extruded shapes of the same mortars (i.e., brick-shape) are tested
under different conditions to monitor the progress of the carbonation
fronts over time and develop models that can be used for the design
of large-scale systems for direct CO2 capture with Ca(OH)2.
Experimental Section
Materials
Ca(OH)2 commercial powders were
used to prepare all samples: dry slaked lime, used for construction
applications, and a high-grade Ca(OH)2, used for environmental
applications. These powders have an average particle size of approximately
5–6 μm (measured by a Beckman–Coulter LS 13320
laser diffraction analyzer using ethanol as a dispersant agent), a
true density of approximately 2.2 g/cm3 (measured by helium
pycnometry with an AccuPyc II-1340, Micromeritics Corp.), and a main
impurity of CaCO3 (between 3 and 8% wt, as measured by
LECO CS130). Their surface areas and pore diameters are, however,
very different: 18.2 and 39.3 m2/g and 223 and 68 nm, respectively,
for dry slaked lime and high-grade Ca(OH)2, measured by
Ar adsorption at −196 °C with an ASAP 2020 instrument,
Micromeritics Corp., and applying the BET equation and mercury pycnometry
with Autopore IV 9500 instruments, Micromeritics Corp.
Preparation of Ca(OH)2 Porous Samples
Three
different preparation methods were used to obtain porous solid samples
with different initial porosities and characteristic lengths: the
pelletization of dry powder (under a range of different pressures),
the preparation of mortars with water that were then dried in molds
to obtain the desired shapes, and the extrusion of mortars to obtain
brick-like shapes.Because the bulk open porosity of solids
is known to be a major variable during the carbonation of Ca materials
in ambient air,[10,16,27,28] a wide range of porosities, between 0.2
and 0.8, were tested. To obtain highly porous samples (i.e., with
porosities εCa(OH) between 0.6 and 0.8),
dry Ca(OH)2 powder was placed in cylindrical plastic vessels
1.5 cm in diameter and height, with the top open as the only contacting
surface. Then, the powder was compressed using a dynamometer (SHIMPO
FGE-100X) by applying forces of up to 200 N. The porosities of the
resulting compacted beds were determined by comparing the Ca(OH)2 true density with that calculated from the weight and volume
occupied by the compressed powder inside the vessels. A similar dry
preparation method was used to obtain Ca(OH)2 pellets with
porosities between 0.2 and 0.4. The Ca(OH)2 powder was
shaped in a TDP-1.5 single-punch tablet manual press fitted with a
550 W engine that supplied a maximum pressure of 15 kN, producing
cylindrical pellets 6 mm in diameter and approximately 4 mm in height.Wet mortars were prepared by mixing Ca(OH)2 powder with
approximately 40% wt distilled water, allowing the shaping of the
mortar in molds of dimensions comparable to the dry samples prepared
above. The conformed mortar was then dried in an oven at 110 °C
under N2. After drying, the pellets were weighed in a precision
balance and their final dimensions were measured to calculate their
initial porosity. From this method, samples with εCa(OH) values between 0.4 and 0.6 were obtained.Finally,
wet mortars of a similar likeness to those above were
extruded in a laboratory-scale extruder machine designed and manufactured
by Talleres Felipe Verdés S.A.[29] The equipment (model DEX LAB) is based on a helix 80 mm in diameter
capable of providing up to 7.5 kW and 80 bar for extrusion. The extrusion
velocity can be adjusted to between 5 and 15 rpm, allowing for a maximum
production of 500 kg/h. From wet mortar (with approximately 32% wt
humidity), brick-like shapes were produced and then dried in an oven
at 110 °C overnight. Figure shows an image of one of the obtained extruded forms.
The motivation for investigating these brick-shaped Ca(OH)2 materials is the possible use of carbonated bricks as construction
materials. However, for the scope of the investigation described in
this work, these extruded brick shapes are not too different from
the handmade mortars of similar dimensions and porosities when tested
under ambient conditions, as will be shown below.
Figure 1
Photograph of a brick-shaped
Ca(OH)2 sample obtained
from wet mortar extruded with the DEX LAB equipment and then dried.
Photograph of a brick-shaped
Ca(OH)2 sample obtained
from wet mortar extruded with the DEX LAB equipment and then dried.
Carbonation Tests
Carbonation experiments were carried
out on the samples in three setups: by simply allowing their carbonation
to proceed in a test room, by arranging the samples in a sealed glass
container surrounded by a thermostatic bath to ensure a homogeneous
temperature and fluxed by air containing CO2 with a high
relative humidity, and by using a thermogravimetric analyzer (TGA)
fully described elsewhere[30] to test the
carbonation of the powdered samples of parent solids and pellet samples
of less than 100 mg.The tests under ambient room conditions
typically lasted 500 h. Such a long carbonation time facilitates the
frequent weighing of the samples and the use of destructive analysis
by arranging the carbonation of several samples in parallel. The CO2 concentration in the test room was 500 ± 25 ppmv CO2, the relative humidity (RH) was 52 ±
3%, and the temperature was 19 ± 2 °C, as shown in Figure , which were measured
by analyzing the ambient conditions using a PCE-AQD 10 Air Quality
Data Logger device (for measuring over the ranges of 0 to 4000 ppmv CO2, 10–90% RH and 0–50 °C).
A fan was located in front of the samples to ensure a velocity of
approximately 0.5 m/s in their proximity, thus allowing differential
conditions with respect to the ambient air.
Figure 2
Illustrative variation
over time of the CO2 concentration
(in ppmv), relative humidity (RH) and temperature in the
test room (black lines), and compressed air (blue lines).
Illustrative variation
over time of the CO2 concentration
(in ppmv), relative humidity (RH) and temperature in the
test room (black lines), and compressed air (blue lines).In the setup designed for carbonation under conditions
of high
RH, the samples were placed in a sealed glass container situated in
a thermostatic bath (JP Selecta Unitronic 27 L for temperatures of
5–99.9 °C). The system was heated at controlled temperatures
between 20 and 80 °C and flushed by a flow of about 200 L/h of
compressed air. As shown in Figure , the concentration of CO2 in the compressed
air was 450 ± 35 ppmv CO2, and the RH was
below 2%. This air flow was then saturated with humidity by bubbling
it in a distilled water glass placed in the thermostatic bath. To
avoid condensation and heat losses, the top of the glass container
was heated using a heating cord, and the whole system was covered
with insulated material. Additionally, in this setup, some accelerated
carbonation tests (typically less than 24 h to reach maximum conversions)
were carried out with CO2 concentrations 2 orders of magnitude
larger than those in ambient air (8 and 12 %v CO2), as
will be discussed below.When testing the solid samples either
in the glass container or
in the testing room, their lateral and bottom surfaces were covered,
thus allowing the carbonation process to be monitored in just the
axial direction (i.e., on one of the flat sides). For these samples,
their weights were periodically monitored with a precision balance
to calculate their Ca molar conversion to CaCO3. Additionally,
the carbonate contents of certain samples extracted at different experimental
times were checked by LECO analysis in order to estimate their maximum
Ca molar conversion to CaCO3 (Xmax). To visually observe the carbonation mechanism, some porous samples
were axially cut, and a phenolphthalein solution (1% wt in 96 %v ethanol)
was sprayed on their interior surfaces. Phenolphthalein is a sensitive
pH indicator that turns colorless in acid solutions and pink in basic
solutions, thus allowing us to distinguish between Ca(OH)2 (colored) and CaCO3 (colorless).Small samples
(i.e., pellets 6 mm in diameter) and Ca(OH)2 parent solids
(approximately 10–15 mg in powder form) were
also tested in a TGA described elsewhere.[30] The variations in sample weight over time under different temperatures
(20 and 65 °C) and gas atmospheres (from compressed air with
ppmv CO2 up to 5 %v CO2 in air and
different RHs up to 95% and a total gas velocity around the sample
of about 0.02 m/s) were continuously monitored during these tests.Finally, crushing strength (CS) tests of the dried samples were
conducted and the evolution of CS with the carbonation degree was
measured using a SHIMPO FGE-100X dynamometer. The peak force (in Newtons)
required to break the samples[31] was used
as an indicator of their mechanical strength.
Results and Discussion
The first set of carbonation
experimental results obtained under
the testing room ambient conditions (Figure above) are presented in Figure , which was constructed by
plotting the depth of the carbonated product layer, zcarb, as a function of time up to 500 h. Such depth has
been determined from the weight measurements of the samples, considering
the established fact that the carbonation of Ca materials reaches
maximum carbonation conversion Xmax <
1 due to the formation of passivating CaCO3 product layer
on the Ca(OH)2 surface[1,3,5]
Figure 3
(a) Evolution of the
depth of the carbonated layer (zcarb)
vs time during the carbonation of Ca(OH)2 samples with
different porosities under testing room conditions
(500 ± 25 ppmv CO2, RH 52 ± 3% and
19 ± 2 °C). The lines are predictions from Fick’s
law as in Eq for samples
with measured porosity εCa(OH) of 0.83,
0.71, 0.52, and 0.25 and the best fit values of the tortuosity factor
(τ of 1.20, 1.29, 1.30, and 1.85, respectively). (b) Xmax obtained from LECO analyses at different
approximate depths in samples with average εCa(OH) ≈ 0.8 after 350 h (top) and 500 h (bottom).
(a) Evolution of the
depth of the carbonated layer (zcarb)
vs time during the carbonation of Ca(OH)2 samples with
different porosities under testing room conditions
(500 ± 25 ppmv CO2, RH 52 ± 3% and
19 ± 2 °C). The lines are predictions from Fick’s
law as in Eq for samples
with measured porosity εCa(OH) of 0.83,
0.71, 0.52, and 0.25 and the best fit values of the tortuosity factor
(τ of 1.20, 1.29, 1.30, and 1.85, respectively). (b) Xmax obtained from LECO analyses at different
approximate depths in samples with average εCa(OH) ≈ 0.8 after 350 h (top) and 500 h (bottom).In Eq , W0 and W are
the sample weights (in kg) measured at the beginning of the experiment
and at different testing times, respectively; Mi is the molar mass of each compound (in kg/kmol); wCa(OH)2,0 is the initial mass fraction of active
Ca(OH)2 (considering CaCO3 as the main impurity
in the powders); and zsample is the axial
height of the sample. The value of Xmax is determined experimentally by analyzing the carbon contents of
the different layers of carbonated material with a LECO analyzer.
As shown in Figure b, all values of Xmax reached a maximum
stable value of 0.6 under this particular set of experimental conditions
(a relative humidity of approximately 52% and a Ca(OH)2 surface area of 18.2 m2/g).Figure a also includes
lines that represent the predictions of a carbonation model considering
the rate at which the carbonation front advances away from the exposed
interface of the solid sample, with the ambient air being proportional
to the flux of CO2 given by Fick’s lawwhere DCO is the diffusion coefficient of CO2 in air (1.6
× 10–5 m2/s at 20 °C), ρCa(OH) is the molar density of Ca(OH)2 (29.9 kmol/m3), τ is the tortuosity factor, CCO2 is the CO2 concentration (in kmol/m3), and Xmax is the maximum carbonation
conversion of the Ca(OH)2 material. Because the reaction
is assumed to be controlled by the diffusion of CO2 in
the stagnant volume of air contained in the porous carbonated layer
resulting from the carbonation of Ca(OH)2, the porosity
of this carbonated layer (εCarb) is the one considered
in Eq . This has been
calculated assuming that there is no expansion of the porous solid
during carbonation [i.e., ρCa(OH)·(1
– εCa(OH)) = ρCaCO·(1 – εCaCO), where εCaCO is the porosity of a
CaCO3 layer and ρCaCO3 is the molar density
of CaCO3 of 27.1 kmol/m3] and considering the
maximum carbonation conversion, as followsIn an integrated form, Eq gives the √t dependency similar to
the one used in other studies of the slow carbonation of cementitious
materials.[10,16,27,28]In Eqs –4, εCa(OH) refers to
the open porosity of the Ca(OH)2 samples. This value can
be obtained by comparing the Ca(OH)2 true density with
the one calculated by measuring the weight (W0) and total volume of the sample (Vsample); thus, εCa(OH) can be calculated as
in Eq .The best fits of Eq to the experimental results noted in Figure a have been obtained
when using tortuosity
factor values of 1.20, 1.29, 1.30, and 1.85 for samples with εCa(OH) of 0.83, 0.71, 0.52, and 0.25, respectively.
These fitted τ values are consistent with those reported in
the literature for other porous media.[32]Figure shows
similar
experiments under testing room conditions but using samples of high-grade
Ca(OH)2 (i.e., with a higher surface area of 39.3 m2/g vs 18.2 m2/g of those used in Figure ) and εCa(OH) values of 0.80 and 0.66 and fitted τ values of
1.15 and 1.42, respectively. The most remarkable difference is the
much higher carbonation conversion of this material due to the increased
specific surface, with Xmax values reaching
0.85–0.90, as noted in Figure b. These results are consistent with those of previous
studies on the carbonation of Ca(OH)2[1,3,5] and can be explained by taking into account
the impact on the maximum conversion of the passivating CaCO3 product layer. From a practical point of view, the use of these
commercial high-surface-area Ca(OH)2 materials in direct
air capture applications seems justified in view of both their larger
CO2-capture capacity and maximum carbonation conversion
and their lower requirements of relative humidity to achieve said
maximum conversions.
Figure 4
(a) Evolution of zcarb vs
time during
the carbonation experiments of compacted high-grade Ca(OH)2 powder with two different porosities under testing room conditions
(500 ± 25 ppmv CO2, RH 52 ± 3%, and
19 ± 2 °C). The lines are predictions from Fick’s
law as in Eq using
τ values of 1.15 and 1.42 for εCa(OH) of 0.80 and 0.66, respectively. (b) Xmax obtained from LECO analyses at different depths for samples
with average εCa(OH) ≈ 0.8 after
350 h (top) and after 500 h (bottom).
(a) Evolution of zcarb vs
time during
the carbonation experiments of compacted high-grade Ca(OH)2 powder with two different porosities under testing room conditions
(500 ± 25 ppmv CO2, RH 52 ± 3%, and
19 ± 2 °C). The lines are predictions from Fick’s
law as in Eq using
τ values of 1.15 and 1.42 for εCa(OH) of 0.80 and 0.66, respectively. (b) Xmax obtained from LECO analyses at different depths for samples
with average εCa(OH) ≈ 0.8 after
350 h (top) and after 500 h (bottom).The capability of Fick’s law (i.e., Eq ) to properly fit the observations
in Figures and 4, once the values of Xmax, εCa(OH), and τ are considered,
suggests that
the carbonation reaction rates at the transition between the unreacted
Ca(OH)2 and the layer of carbonated solids at Xmax must be very fast compared to the rate of carbonation
defined by Eq . In other
words, it implies a rapid conversion, from 0 to Xmax, of the Ca(OH)2 grains near this reaction
front. This is consistent with the results from studies of Ca(OH)2 carbonation,[1−3] in which the high conversion of Ca(OH)2 to CO2 under suitable conditions of RH has been reported.
As stated in the Introduction section, the
importance of an intermediate H2O adsorption step in the
mechanism of carbonation, enhanced by high values of RH, has been
discussed in other works[1−5] by proposing that the carbonation of Ca(OH)2 at temperatures
below 100 °C takes place in solution, with the CO2 first dissolving in adsorbed layers of liquid water. Under low RH,
the CaCO3 formed would cover the Ca(OH)2 surface
more uniformly and passivate the material. In contrast, when RH increases
(to values above 70%), the increased number of adsorbed water layers
would provide a wider volume for the species to move all along the
interfacial reaction regions and thus promote faster carbonation.[1,3,5] Based on this, the proposed carbonation
model of Eqs and 4 has been applied only when the relative humidity,
RH ≥ 50%.To confirm the reported trends, we carried
out dedicated experiments
using TGA and intensified carbonation conditions, as shown in Figure . As seen, RHs close
to saturation allowed a molar Ca conversion to CaCO3 over
0.9 in less than 10 min (see Figure a for the TGA of the carbonation at 65 °C and
5 %v CO2). After a first rapid step, the carbonation of
Ca(OH)2 enters a slower phase. As the RH decreases, a transition
in the carbonation rate appears at conversions between 0.2 and 0.3,
with the rate of conversion progressively decreasing over time but
still evolving slowly toward the maximum level of conversion reachable
in time scales of several hours (not shown in the figure for simplicity).
In contrast with the previous results, dry air with 5 %v CO2 (but RH = 0%) is unable to facilitate the carbonation of samples
beyond conversions of 0.05.
Figure 5
Ca(OH)2 molar conversion to CaCO3 vs time
for different relative humidities (RHs) for high surface are Ca(OH)2 in the TGA: (a) powder at 65 °C and 5 %v CO2 and (b) pellet of 6 mm diameter carbonated under compressed air
(450 ± 35 ppmv CO2) at 20 °C.
Ca(OH)2 molar conversion to CaCO3 vs time
for different relative humidities (RHs) for high surface are Ca(OH)2 in the TGA: (a) powder at 65 °C and 5 %v CO2 and (b) pellet of 6 mm diameter carbonated under compressed air
(450 ± 35 ppmv CO2) at 20 °C.This strong impact of RH on carbonation rates can
also be observed
in Figure b, although
at different time scales. In this case, a Ca(OH)2 porous
pellet is carbonated with air, and abrupt changes in the slope of
the conversion curve were measured when changing from dry compressed
air to fully saturated air. From a practical point of view, it is
clear that RH values > 80% guarantee fast carbonation rates of
any
Ca(OH)2 material and the highest values of Xmax at the grain level, making the overall carbonation
process controlled by diffusion, as shown in Figure . Consistent with the proposed mechanism,[1−3,5] and for long reaction times, it
is also beneficial to use Ca(OH)2 materials with high surface
areas when there is a need to moderate the RH values to just over
50% (e.g., to minimize the large consumption of water if a direct
capture system is located in desert regions), as observed in the results
reported in Figure . However, due to the extremely slow carbonation rate of Ca(OH)2 observed in dry air conditions,[1−4,6,9] treating dry air should be avoided in future capture
systems relying on the carbonation of Ca(OH)2.To
further confirm these observations with extruded shapes at the
macroscopic level, experiments were carried out in a sealed glass
container fluxed with compressed air saturated with humidity (i.e.,
RH > 95%) on extruded materials of different porosities (i.e.,
with
measured εCa(OH) values of 0.51, 0.44,
and 0.34). These were prepared using slaked Ca(OH)2 with
a modest initial surface area. These tests revealed that RHs close
to saturation enhanced the overall degree of carbonation of the sample
by increasing the value of Xmax to approximately
0.9 as measured by LECO analysis, making the use of high-surface-area
Ca(OH)2 unnecessary. As shown in Figure , the curves of zcarb vs time can be well adjusted with Eq , as with previous samples, by fitting the τ
values to 1.42, 1.49, and 1.95, respectively.
Figure 6
Evolution of zcarb vs time during the
carbonation of extruded materials with different porosities tested
in the sealed glass container fluxed with compressed air (450 ±
35 ppmv CO2) saturated with humidity (i.e.,
RH > 95% and Xmax approximately 0.9)
at
20 °C. Lines represent the predictions from Fick’s law
(Eq ) for samples with
εCa(OH) of 0.51, 0.44, and 0.34 using
τ values of 1.42, 1.49, and 1.95, respectively. Please note
the different Y-axis scale with respect to other
figures.
Evolution of zcarb vs time during the
carbonation of extruded materials with different porosities tested
in the sealed glass container fluxed with compressed air (450 ±
35 ppmv CO2) saturated with humidity (i.e.,
RH > 95% and Xmax approximately 0.9)
at
20 °C. Lines represent the predictions from Fick’s law
(Eq ) for samples with
εCa(OH) of 0.51, 0.44, and 0.34 using
τ values of 1.42, 1.49, and 1.95, respectively. Please note
the different Y-axis scale with respect to other
figures.To assess the validity of Fick’s diffusion
model under a
wider range of conditions and time scales, accelerated tests using
air with 2 orders of magnitude larger concentrations of CO2 (12 %v CO2 and 8 %v), characteristic of combustion flue
gases, were carried out in sealed glass containers under humidity
saturation conditions at 25 and 80 °C. Under these conditions,
less than 24 h is sufficient to ensure the complete conversion of
the samples, as shown in Figures a and 8 (for extruded materials,
as in Figure ). Remarkably,
the fitting quality of Fick’s model in Figure a was retained for samples prepared from
Ca(OH)2 powder with porosities of about 0.4–0.5
when using tortuosity factors comparable to those used in previous
figures (i.e., τ of about 1.4–1.5). Figure b also shows the clear evolution
of the depth of the carbonated layer over time by spraying a phenolphthalein
solution over the axial section of the samples.
Figure 7
Evolution of zcarb vs time for dry
mortar samples prepared from Ca(OH)2 powder tested in the
sealed glass container at temperatures of 25 and 80 °C with air
saturated with humidity (i.e., RH > 95%) and 12 %v and 8 %v CO2, respectively. (a) Experimental measurements and the predictions
of Eq using τ
values of 1.42 and 1.55 for samples with εCa(OH) of 0.50 and 0.40, respectively. (b) Images of samples extracted
at different times and sprayed with a phenolphthalein solution over
the axial section to follow the progress of the carbonation front.
Figure 8
Evolution of zcarb vs time
for extruded
samples with different porosities tested in the sealed glass container
at 25 °C with air saturated with humidity (i.e., RH > 95%)
and
12 %v CO2 (dots) and the predictions of Eq when τ is fitted to 1.62,
1.75, and 3.05 for samples with εCa(OH) of 0.51, 0.44, and 0.34 (lines).
Evolution of zcarb vs time for dry
mortar samples prepared from Ca(OH)2 powder tested in the
sealed glass container at temperatures of 25 and 80 °C with air
saturated with humidity (i.e., RH > 95%) and 12 %v and 8 %v CO2, respectively. (a) Experimental measurements and the predictions
of Eq using τ
values of 1.42 and 1.55 for samples with εCa(OH) of 0.50 and 0.40, respectively. (b) Images of samples extracted
at different times and sprayed with a phenolphthalein solution over
the axial section to follow the progress of the carbonation front.Evolution of zcarb vs time
for extruded
samples with different porosities tested in the sealed glass container
at 25 °C with air saturated with humidity (i.e., RH > 95%)
and
12 %v CO2 (dots) and the predictions of Eq when τ is fitted to 1.62,
1.75, and 3.05 for samples with εCa(OH) of 0.51, 0.44, and 0.34 (lines).In the case of extruded materials of Figure , larger τ values are
required to fit
the experimental results using Eq when compared to the non-extruded. Values of 1.62,
1.75, and 3.05 have been used to fit the experimental results obtained
for samples with porosities of 0.51, 0.44, and 0.34, with the differences
of special relevance in the case of the sample with the lowest porosity.
This can be attributed to the existence of a certain fraction of inaccessible
voids resulting from the higher pressures needed in the extrusion
process to reach these lower porosities. Other effects, such as bottlenecks,
could also reduce the effective porosity,[33] thus increasing the tortuosity factor.In previous Figures , 4, and –8, the tortuosity factor
in Eq was used as an
adjustable parameter to obtain the best fit of the Fick’s model
to the experimental results. This parameter depends on porous media
characteristics such as the porosity, pore diameter, channel shape,
and so forth.[32] In the absence of experimental
data to fit such tortuosity factor, τ can be estimated from
empirical equations such as that proposed by Bruggeman[34] (relating tortuosity and porosity as τ
= 1/√εCa(OH)). As shown in Figure , there is a good
agreement between the fitted values from this work and those predicted
by the empirical equation, with the main deviation observed in the
extruded sample with the lowest porosity. As mentioned above, such
discrepancy can be attributed to the formation of inaccessible voids
during the extrusion process.
Figure 9
Tortuosity factor (τ) used in Eq to fit the experimental
results in Figures , 4, and –8 (dots) and calculated
using the empirical Bruggeman
equation[34] (line) vs the open porosity
of the samples (εCa(OH)).
Tortuosity factor (τ) used in Eq to fit the experimental
results in Figures , 4, and –8 (dots) and calculated
using the empirical Bruggeman
equation[34] (line) vs the open porosity
of the samples (εCa(OH)).To complete the characterization of the carbonating
samples, crushing
strength measurements as a function of carbonation conversion were
performed for some pelletized samples. As shown in Figure , the measured CSs significantly
increased with the conversion of Ca(OH)2 to CaCO3. This improvement in CS with increasing levels of carbonation is
consistent with observations of other Ca-based carbonating materials.[6,12,35−38] Although it is beyond the scope
of this work to elaborate on large-structure manufacturing aspects,
the results of Figure support the viability of future direct CO2-capture systems
relying on the carbonation of large-scale Ca(OH)2 structures
arranged to be exposed to air.[19,20]
Figure 10
Evolution of the crushing
strength (CS) with the Ca(OH)2 molar conversion to CaCO3 for 6 mm diameter pelletized
samples tested in the sealed glass container under compressed air
(450 ± 35 ppmv CO2) saturated with humidity
(i.e., RH > 95%) at 20 °C.
Evolution of the crushing
strength (CS) with the Ca(OH)2 molar conversion to CaCO3 for 6 mm diameter pelletized
samples tested in the sealed glass container under compressed air
(450 ± 35 ppmv CO2) saturated with humidity
(i.e., RH > 95%) at 20 °C.
Conclusions
The carbonation of Ca(OH)2 porous
solids on the millimeter-to-centimeter
scale follows Fick’s diffusion law under a variety of CO2 concentrations in air (from 12 %v to ambient conditions at
approximately 450 ppmv). The advance with time of the carbonation
front for Ca(OH)2 samples in the form of pellets, dry mortars,
and extrudes with porosities between 0.2 and 0.8 can be well fitted
in most cases when considering the governing diffusion equation, the
maximum carbonation conversion of the Ca solids, the porosities of
the samples, and the tortuosity factor. The relative humidity (RH)
in the air played an essential role in maximizing the Ca(OH)2 solid carbonation conversion, with an RH of >50% required to
achieve
maximum conversion values of 0.6. This maximum value of conversion
can be increased by up to approximately 0.9 by using high-grade Ca(OH)2 (i.e., with specific surface areas of approximately 40 m2/g compared to the less than 20 m2/g measured for
dry slaked limes) or RHs in the air close to saturation (i.e., RH
> 95%). The crushing strengths of the carbonated Ca(OH)2 porous samples increased with increasing carbonate conversion, which
supports the viability of the use of large structures composed of
these solids to capture CO2 directly from air.