Pilot-Scale Operation of a Concrete Sludge Recycling Plant and Simultaneous Production of Calcium Carbonate

A pilot-scale plant to treat concrete sludge and produce calcium carbonate (CaCO₃) and an environmental purification agent (phosphorus adsorbent derived from concrete sludge, PAdeCS®) was designed, constructed, and operated. Concrete sludge from a concrete pile and pole production plant, boiler gas containing CO₂, and groundwater were used in the plant. The process involved calcium extraction from concrete sludge into water, followed by reaction of the calcium with CO₂ to produce crystalline CaCO₃. The pilot-scale plant was operated for 1 week, and the mass flows, conversion of CO₂ to CaCO₃, and net CO₂ emissions of the process were estimated. High-purity CaCO₃ (>97%) suitable for industrial use was obtained. Based on the power consumption of the process and the amount of CO₂ sequestered into CaCO₃, a net reduction in CO₂ emissions can be achieved using this process. The produced PAdeCS can be used as an inexpensive substitute for calcium series environmental purification agents.