Experimental Optimization, Scaling Up, and Characterization for Continuous Aragonite Synthesis from Lime Feedstock Using Magnesium Chloride as Chemical Inducer

The current state of the art research, and latest engineering technology application in the synthesis of the aragonite crystalline phase of calcium carbonate is presented here. Aragonite crystalline products are highly valuable in selected industries, such as medical and personal care, and in food additives using MgCl₂ as a chemical inducer. The outcome of this literature review provides the outlook of the available research whitespace opportunity in optimizing the current process parameters and in ensuring that sustainable and economically feasible continuous production of aragonite products could be achieved. One of the major improvements proposed in this study is to investigate the methods of synthesizing aragonite crystalline particles using a continuous mineral carbonation reactor system and optimizing the operating parameters. An experimental design was established to identify all the main effects to maximize aragonite production. The three main effects investigated are the effect of feedstock or reactant concentration, the effect of reaction temperature, and the effect of reaction time towards aragonite yield in the final products synthesized. An optimized operating parameter for maximum aragonite yield at 95% purity was proposed at the reaction temperature T of 90 °C, reaction time t of 10 min, and feedstock ratio Mg-to-Ca of 0.4. Subsequently, the continuous reactor system was designed, operated, and tested for at least 50 h operation, where the lime CaO(s) feed was successfully converted into aragonite products with purity between 75 and 81%. The properties and quality of the aragonite produced were analytically characterized from the following laboratory methods which include the thermalgravimetric analysis, TGA; X-Ray Diffraction, XRD; scanning electron microscopy, SEM; and induction coupled plasma, ICP. TGA mass balance after decomposition suggests that 44% of the mass balance represents the weight of CO₂ sequestered in the aragonite crystalline carbonates. Hence, the aragonite crystalline carbonates can be labeled as a green product which sequesters 0.44 kg of CO₂ per 1 kg of precipitated aragonite products synthesized. Interestingly, SEM microscopy characterization results revealed that the aragonite precipitate has a physical morphology of needle-like shape with a good aspect ratio (length/diameter) AR of between 8.67 micron and 11.35 micron. The properties were found to be suitable for paper making fillers, medical, personal care, and food additive applications.