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Steel slag is a solid waste product generated during the carbonation stage of steelmaking. It has high levels of heavy metals and substantial amounts of free calcium and magnesium oxide, making it unsuitable for use as a cement material. Furthermore, the disposal of steel slag in landfills requires many resources and can seriously contaminate the surrounding environment. One method of reducing its negative environmental impact is carbonation, which involves reacting steel slag with carbon dioxide to form stable minerals. However, many parameters influence the carbonation efficiency of steelmaking slag, including temperature, time, particle size, pressure, CO2 concentration, liquid-to-solid ratio, moisture content, humidity, additives, etc. To this end, this paper comprehensively reviews the most important steel slag carbonation-influencing factors. Moreover, it compares the characteristics from two perspectives based on their causes and effects on carbonation. Finally, this article reviews earlier studies to identify the factors that affect steel slag carbonation and the potential of carbonated steel slag as a sustainable construction material. Based on previous research, it systematically examines all the elements for future work that need to be improved.

Magnetic separation is an effective method to recover iron from steel slag. However, the ultra-fine tailings generated from steel slag become a new issue for utilization. The dry separation processes generates steel slag powder, which has hydration activity and can be used as cement filler. However, wet separation processes produce steel slag mud, which has lost its hydration activity and is no longer suitable to be used as a cement filler. This study investigates the potential of magnetically separated steel slag for carbonation curing and the potential use of the carbonated products as an artificial reef. Steel slag powder and steel slag mud were moulded, carbonation-cured and seawater-cured. Various testing methods were used to characterize the macro and micro properties of the materials. The results obtained show that carbonation and hydration collaborated during the carbonation curing process of steel slag powder, while only carbonation happened during the carbonation curing process of steel slag mud. The seawater-curing process of carbonated steel slag powder compact had three stages: C-S-H gel formation, C-S-H gel decomposition and equilibrium, which were in correspondence to the compressive strength of compact increasing, decreasing and unchanged. However, the seawater-curing process of carbonated steel slag mud compact suffered three stages: C-S-H gel decomposition, calcite transfer to vaterite and equilibrium, which made the compressive strength of compact decreased, increased and unchanged. Carbonated steel slags tailings after magnetic separation underwent their lowest compressive strength when seawater-cured for 7 days. The amount of CaO in the carbonation active minerals in the steel slag determined the carbonation consolidation ability of steel slag and durability of the carbonated steel slag compacts. This paper provides a reference for preparation of artificial reefs and marine coagulation materials by the carbonation curing of steel slag.

Carbonation curing on steel slag is one of the most promising technologies for the iron and steel industry to manage its solid waste and carbon emissions. However, the technology is still in its demonstration stage. This paper investigates the market stakeholders of carbonation curing on steel slag for construction materials for its effective application by taking China as a case study. A holistic analysis of the competition, market size, and stakeholders of carbonation curing on steel slag was carried out through a literature review, a survey, a questionnaire, and interviews. The results showed that carbonation curing on steel slag had the advantages of high quality, high efficiency, low cost, and carbon reduction compared with other technologies. Shandong province was the most suitable province for the large-scale primary application of the technology. Stakeholder involvement to establish information platforms, enhance economic incentives, and promote adequate R&D activities would promote carbonation curing of steel slag into practice. This paper provides a reference for the commercialization of carbonation curing on similar calcium- and magnesium-based solid waste materials.

Carbonation curing has demonstrated potential of improving concrete performance while facilitating carbon dioxide utilization. However, reinforcement corrosion behavior in carbonation-cured concrete has not been documented. This paper presents a study on chloride-induced corrosion in reinforced concrete subjected to carbonation curing. A special carbonation curing process was developed for precast non-prestressed applications. Performance of carbonation curing was evaluated by concrete compressive strength, pH value, and carbon dioxide uptake, while corrosion resistance of the carbonation-cured concrete was assessed by reinforcing bar mass loss and concrete chloride content. To understand the mechanism, concrete and cement paste were further characterized using mercury intrusion porosimetry, absorption, and electrical resistivity tests. Micromorphology was assessed by scanning electron microscopy. It was found that apart from rapid early-age strength gain, carbonation curing could significantly reduce chloride permeation in concrete concerning both total and free chloride contents. It was attributed to the reduced pore size and pore volume by calcium carbonate precipitation. With subsequent 28-day hydration, the carbonation-cured concrete displayed a pH over 12.0 at the surface of steel reinforcing bars and a micromorphology similar to the non-carbonated reference. The direct corrosion tests showed that the corrosion-induced mass loss of steel reinforcing bar was lessened by 50% in concrete subjected to carbonation curing. Keywords: carbon dioxide utilization; carbonation curing; concrete durability; corrosion; pore structure.

The early-age carbonation curing technique is an effective way to improve the performance of cement-based materials and reduce their carbon footprint. This work investigates the early mechanical properties and microstructure of calcium sulfoaluminate (CSA) cement specimens under early-age carbonation curing, considering five factors: briquetting pressure, water–binder (w/b) ratio, starting point of carbonation curing, carbonation curing time, and carbonation curing pressure. The carbonization process and performance enhancement mechanism of CSA cement are analyzed by mercury intrusion porosimetry (MIP), thermogravimetry and derivative thermogravimetry (TG-DTG) analysis, X-ray diffraction (XRD), and scanning electron microscope (SEM). The results show that early-age carbonation curing can accelerate the hardening speed of CSA cement paste, reduce the cumulative porosity of the cement paste, refine the pore diameter distribution, and make the pore diameter distribution more uniform, thus greatly improving the early compressive strength of the paste. The most favorable w/b ratio for the carbonization reaction of CSA cement paste is between 0.15 and 0.2; the most suitable carbonation curing starting time point is 4 h after initial hydration; the carbonation curing pressure should be between 3 and 4 bar; and the most appropriate time for carbonation curing is between 6 and 12 h.

The feasibility of carbonation curing of ternary blend Portland cement–metakaolin–limestone was investigated. Portland cement was substituted by the combination of metakaolin and limestone at levels of 15%, 30%, and 45% by the mass. The ternary blends were cured with four different combinations of ambient and carbonation curing. The mechanical property, CO2 uptake, and mineralogical variations of the ternary blend pastes were investigated by means of compressive strength test, thermogravimetric analysis, and X-ray diffractometry. In addition, volume of permeable voids and sorptivity of the ternary blends were also presented to provide a fundamental idea of the pore characteristics of the blends. The test results showed that the increasing amount of metakaolin and limestone enhanced the CO2 uptake, reaching 20.7% for the sample with a 45% cement replacement level at 27 d of carbonation. Meanwhile, the compressive strength of the samples was reduced up to 65% upon excessive incorporation of metakaolin and limestone. The samples with a replacement level of 15% exhibited a comparable strength and volume of permeable voids to those of the sample without substitution, proving that the ternary blend Portland cement–metakaolin–limestone can be a viable option toward the development of eco-friendly binders.

This paper presents a study on the carbonation reaction heat and products of tricalcium silicate (C3S) paste exposed to carbon dioxide (CO2) for rapid curing. Reaction heat was measured using a retrofitted micro-calorimeter. The highest heat flow of a C3S paste subject to carbonation curing was 200 times higher than that by hydration, and the cumulative heat released by carbonation was three times higher. The compressive strength of a C3S paste carbonated for 2 h and 24 h was 27.5 MPa and 62.9 MPa, respectively. The 24-h carbonation strength had exceeded the hydration strength at 28 days. The CO2 uptake of a C3S paste carbonated for 2 h and 24 h was 17% and 26%, respectively. The X-ray diffraction (XRD), transmission electron microscope coupled with energy dispersive spectrometer (TEM-EDS), and 29Si magic angle spinning–nuclear magnetic resonance (29Si MAS-NMR) results showed that the products of a carbonated C3S paste were amorphous silica (SiO2) and calcite crystal. There was no trace of calcium silicate hydrate (C–S–H) or other polymorphs of calcium carbonate (CaCO3) detected.

Normally, the acidic impurities in hemihydrate phosphogypsum (HPG) must be neutralized when HPG is utilized, and a little amount of calcium hydroxide (CH) is the best choice. In this paper, the effects of excessive CH (5 wt.%, 10 wt.%, 15 wt.% and 20 wt.% of HPG) for carbonation curing on the performance of hardened HPG paste were studied. According to the results of macro tests and microanalyses of XRD, TG, SEM-EDS, MIP and N2 physisorption, it could be verified that CaF2, Ca3(PO4)2 and a large amount of nanoscale CaCO3 crystals were produced as a result of neutralization and carbonation, and the compressive strength and the water resistance of carbonated HPG + CH paste were significantly improved due to the effects of nanoscale CaCO3 crystals on pore refinement and the coverage on the surfaces of gypsum crystals of the hardened paste. Therefore, this study suggests a feasible and green method for recycling HPG/PG, with the collaborative effects of neutralization, performance enhancement and reductions in CO2 emissions.

This study delves into the effects of carbonation curing and autoclave–carbonation curing on the properties of calcium oxide–belite–calcium sulfoaluminate (CBSAC) cementitious material aerated concrete. The objective is to produce aerated concrete that adheres to the strength index in the Chinese standard GB/T 11968 while simultaneously mitigating CO2 emissions from cement factories. Results show that the compressive strength of CBSAC aerated concrete with different curing regimes (autoclave curing, carbonation curing, and autoclave–carbonation curing) can reach 4.3, 0.8, and 4.1 MPa, respectively. In autoclave–carbonation curing, delaying CO2 injection allows for better CO2 diffusion and reaction within the pores, increases the carbonation degree from 19.1% to 55.1%, and the bulk density from 603.7 kg/m3 to 640.2 kg/m3. Additionally, microstructural analysis reveals that delaying the injection of CO2 minimally disrupts internal hydrothermal synthesis, along with the formation of calcium carbonate clusters and needle-like silica gels, leading to a higher pore wall density. The industrial implementation of autoclavecarbonation curing results in CBSAC aerated concrete with a CO2 sequestration capacity ranging from 40 to 60 kg/m3 and a compressive strength spanning from 3.6 to 4.2 MPa. This innovative approach effectively mitigates the carbon emission pressures faced by CBSAC manufacturers.

This study explores an integrated strategy combining gypsum activation and pressurized flue gas heat curing (FHC) to enhance the interfacial transition zone (ITZ) in concrete incorporating over 80% circulating fluidized bed fly ash (CFBFA)-based artificial coarse aggregates. The inherently weak ITZ, characterized by low bonding strength and high porosity, remains a major limitation to the mechanical performance of CFBFA-based concrete. Gypsum promotes the formation of ettringite (AFt) and facilitates the development of a dense CaCO3 shell through enhanced carbonation. Their synergistic effect improves microstructural homogeneity and reduces crack connectivity at the interface. A novel grayscale image-based double-peak gradient method is developed for non-contact, quantitative measurement of ITZ thickness, revealing a strong inverse correlation (R2 = 0.87) between ITZ thickness and compressive strength. Microstructural analyses confirm that the dual treatment significantly refines the ITZ, resulting in denser aggregate interiors, improved matrix continuity, and more structurally integrated interfaces. The failure mode correspondingly shifts from interface-dominated fracture to composite-controlled behavior. These findings demonstrate the effectiveness of the FHC–gypsum approach in tailoring ITZ morphology and enhancing mechanical integrity, offering a viable pathway for high-performance, low-carbon cementitious composites utilizing industrial by-products.