Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO.sub.2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO.sub.2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO.sub.2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

Provided herein are compositions and methods of carbonation processing for the fabrication of cementitious materials and concrete products. Embodiments include manufacturing processes of a low-carbon concrete product comprising: forming a cementitious slurry including portlandite; shaping the cementitious slurry into a structural component; and exposing the structural component to a CO.sub.2 waste stream, thereby enabling manufacture of the low-carbon concrete product.

A hydrated lime product exhibiting superior reactivity towards HCl and SO.sub.2 in air pollution control applications. Also disclosed is a method of providing highly reactive hydrated lime and the resultant lime hydrate where an initial lime feed comprising calcium and impurities is first ground to a particle-size distribution with relatively course particles. Smaller particles are then removed from this ground lime and the smaller particles are hydrated and flash dried to form a hydrated lime, which is then milled to a significantly smaller particle size than that of the relatively course particles. The resultant lime hydrate product has available CaOH of greater than 92%, a citric acid reactivity of less than 20 seconds, a BET surface area greater than 18, a D90 less than 10 m, a D50 less than 4 m, a D90/D50 less than 3, and a large pore volume of greater than 0.2 BJH.

A hydrated lime product exhibiting superior reactivity towards HCl and SO.sub.2 in air pollution control applications. Also disclosed is a method of providing highly reactive hydrated lime and the resultant lime hydrate where an initial lime feed comprising calcium and impurities is first ground to a particle-size distribution with relatively course particles. Smaller particles are then removed from this ground lime and the smaller particles are hydrated and flash dried to form a hydrated lime, which is then milled to a significantly smaller particle size than that of the relatively course particles. The resultant lime hydrate product has available CaOH of greater than 92%, a citric acid reactivity of less than 20 seconds, a BET surface area greater than 18, a D90 less than 10 m, a D50 less than 4 m, a D90/D50 less than 3, and a large pore volume of greater than 0.2 BJH.

A hydrated lime product exhibiting superior reactivity towards HCl and SO.sub.2 in air pollution control applications. Also disclosed is a method of providing highly reactive hydrated lime and the resultant lime hydrate where an initial lime feed comprising calcium and impurities is first ground to a particle-size distribution with relatively course particles. Smaller particles are then removed from this ground lime and the smaller particles are hydrated and flash dried to form a hydrated lime, which is then milled to a significantly smaller particle size than that of the relatively course particles. The resultant lime hydrate product has available CaOH of greater than 92%, a citric acid reactivity of less than 20 seconds, a BET surface area greater than 18, a D90 less than 10 m, a D50 less than 4 m, a D90/D50 less than 3, and a large pore volume of greater than 0.2 BJH.

A hydrated lime product exhibiting superior reactivity towards HCl and SO.sub.2 in air pollution control applications. Also disclosed is a method of providing highly reactive hydrated lime and the resultant lime hydrate where an initial lime feed comprising calcium and impurities is first ground to a particle-size distribution with relatively course particles. Smaller particles are then removed from this ground lime and the smaller particles are hydrated and flash dried to form a hydrated lime, which is then milled to a significantly smaller particle size than that of the relatively course particles. The resultant lime hydrate product has available CaOH of greater than 92%, a citric acid reactivity of less than 20 seconds, a BET surface area greater than 18, a D90 less than 10 m, a D50 less than 4 m, a D90/D50 less than 3, and a large pore volume of greater than 0.2 BJH.

The instant disclosure sets forth a process for re-activating a mineral residue. The process includes providing a mineral residue, which includes a core and a shell around the core. In certain examples, the core comprises calcium (Ca), magnesium (Mg), or a combination thereof. The Ca and Mg is not present as elemental Ca or Mg but rather as a compound of Ca or of Mg, such as but not limited to Ca(OH).sub.2 or Mg(OH).sub.2. In certain examples, the shell comprises an oxide, a hydroxide, a carbonate, a silicate, a sulfite, a sulfate, a chloride, a nitrate, or nitrite, of calcium (Ca) or of magnesium (Mg), or a combination thereof. The process includes (a) fractionating the mineral residue; (b) contacting the mineral residue with an acid and fractionating the mineral residue; or (c) contacting the mineral residue with a base and fractionating the mineral residue. As a result, the mineral residue's core is exposed. In some examples, the shell is passivating and inhibits the Ca or Mg, or both, in the core from reacting with carbon dioxide (CO.sub.2). By exposing the core as described herein, a mineral residue's reactivity with carbon dioxide is increased.

The instant disclosure sets forth a process for re-activating a mineral residue. The process includes providing a mineral residue, which includes a core and a shell around the core. In certain examples, the core comprises calcium (Ca), magnesium (Mg), or a combination thereof. The Ca and Mg is not present as elemental Ca or Mg but rather as a compound of Ca or of Mg, such as but not limited to Ca(OH).sub.2 or Mg(OH).sub.2. In certain examples, the shell comprises an oxide, a hydroxide, a carbonate, a silicate, a sulfite, a sulfate, a chloride, a nitrate, or nitrite, of calcium (Ca) or of magnesium (Mg), or a combination thereof. The process includes (a) fractionating the mineral residue; (b) contacting the mineral residue with an acid and fractionating the mineral residue; or (c) contacting the mineral residue with a base and fractionating the mineral residue. As a result, the mineral residue's core is exposed. In some examples, the shell is passivating and inhibits the Ca or Mg, or both, in the core from reacting with carbon dioxide (CO.sub.2). By exposing the core as described herein, a mineral residue's reactivity with carbon dioxide is increased.