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Vol 281 Iss. 2
Pages:
1-15
In press
Article
Geotechnical Engineering and Engineering Geology

Production of calcium carbonate with tailored particle size characteristics as a factor in efficient recycling of gypsum-containing technogenic raw materials

Authors:
Denis V. Suchkov1
Tatyana E. Litvinova2
Andrei P. Lebedev3
About authors
  • 1 — Ph.D. Senior Lecturer Empress Catherine ΙΙ Saint Petersburg Mining University ▪ Orcid
  • 2 — Ph.D., Dr.Sci. Professor Empress Catherine ΙΙ Saint Petersburg Mining University ▪ Orcid
  • 3 — Ph.D. Assistant Empress Catherine ΙΙ Saint Petersburg Mining University ▪ Orcid
Date submitted:
2026-03-31
Date accepted:
2026-06-25
Online publication date:
2026-09-18

Abstract

This study focuses on developing a method for utilizing phosphogypsum, a large-tonnage waste product from phosphate raw material processing, whose disposal sites are sources of complex negative impacts on the environment. As a promising approach to the utilization of gypsum-containing waste, the study considers the interaction of phosphogypsum with a sodium carbonate solution (carbonate conversion), which yields calcium carbonate, a marketable product referred to as phosphochalk. Existing technologies typically produce a fine-grained material, which hinders filtration and restricts the potential applications of phosphochalk. This study aims to determine the carbonate conversion parameters that enable the production of phosphochalk with tailored particle size characteristics while maintaining a high degree of feedstock conversion. A series of single-factor experiments was carried out to evaluate the influence of reaction conditions – temperature, Na2CO3 concentration in the carbonate solution, liquid-to-solid (L:S) ratio, and phase contact time – on the conversion of CaSO4·2H2O. The results showed that raising the conversion temperature to 90-100 °C and increasing the L:S ratio to 10 promote intensive nucleation of CaCO3 crystals and the formation of large agglomerates. A Na2CO3 concentration of 250 g/dm3 and a phase contact time of up to 3 h together yield phosphochalk with a particle size of D90 = 45 μm at a conversion degree of 98.8 %. In terms of its characteristics, the resulting product is suitable for use in the metallurgical industry as a raw material for flux production, which demonstrates its competitiveness in the secondary raw materials market. The recommendations developed in this work enable the design of a low-waste technology for processing technogenic raw materials, consistent with the principles of sustainable development and helping to reduce the environmental burden.

Область исследования:
Geotechnical Engineering and Engineering Geology
Keywords:
gypsum-containing waste calcium carbonate carbonate conversion waste utilization pulp filtration rate phosphogypsum phosphochalk
Funding:

None

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