Waste to Value - A pilot demonstration and economic analysis of vaterite calcium carbonate production using brine, CKD, and CO2

Seungwon Ihm, Abdallatif Satti Abdalrhman, Mohammed Al-Talibi, Omar Al-Raqibah, Ammar Alnumani, Eslam Alwaznani, Youngho Lee, Kichul Park, Jinuk Heo, Won Jo, Sehun Kim, Myoung-Jin Kim

https://doi.org/10.5004/po2024113

Waste to Value - A pilot demonstration and economic analysis of vaterite calcium carbonate production using brine, CKD, and CO₂

Seungwon Ihm¹*, Abdallatif Satti Abdalrhman¹, Mohammed Al-Talibi¹, Omar Al-Raqibah¹, Ammar Alnumani¹, Eslam Alwaznani¹, Youngho Lee², Kichul Park², Jinuk Heo², Won Jo³, Sehun Kim³, Myoung-Jin Kim³

¹ Water Technologies Innovation Institute and Research Advancement (WTIIRA), Saudi Water Authority (SWA), Al-Jubail 31951, Saudi Arabia
² Taekyung R&D Center, Seoul 07570, Republic of Korea
³ Korea Maritime and Ocean University, Busan 49112, Republic of Korea

* Corresponding author

https://doi.org/10.5004/po2024113

ABSTRACT

This study presents a pilot-scale demonstration and techno-economic assessment of producing high-purity vaterite-type calcium carbonate (CaCO₃) through indirect carbonation, by utilizing SWRO (seawater reverse osmosis) brine, cement kiln dust (CKD), and captured carbon dioxide (CO₂). A 50-ton-per-annum (TPA) pilot plant was constructed and operated in Jubail, Saudi Arabia, producing spherical vaterite CaCO₃ with verified purity and whiteness suitable for premium industrial applications. CKD provided the calcium source (40–60% CaO content), while brine served as an effective solvent, eliminating the need for synthetic chemicals. CO₂ was directly injected to precipitate vaterite CaCO₃, achieving the major quality targets of ≥ 97% CaCO₃ purity, ≥ 80% vaterite content, ≥ 99% whiteness, and ≤ 3μm particle size. Economic analysis for a scaled-up 100,000 TPA plant revealed a highly attractive internal rate of return (IRR > 60%) and short ROI (< 1.5 years), even under conservative market and CO₂ pricing assumptions. The process also demonstrated substantial greenhouse gas (GHG) reduction potential, particularly when integrated with low-carbon electricity. This work highlights a practical pathway for valorizing desalination brine, utilizing industrial waste, and enhancing CO₂ utilization through the production of value-added vaterite CaCO₃.

Keywords: Indirect carbonation; Beneficial use of desalination brine; Vaterite; Calcium carbonate; Carbon capture utilization and storage (CCUS); Brine valorization