Synergistic CO2 Mineralization and Performance Optimization of FA-CS-PG Ternary Solid Waste System

In recent years, there has been an urgent need for integrated solutions to synergistically manage industrial solid waste stockpiling and CO2 emissions. Single-component solid waste mineralization, such as those using only fly ash (FA) or carbide slag (CS), often encounters performance bottlenecks, typically characterized by a compressive strength of less than 2 MPa and a carbonation efficiency of under 10%. Furthermore, a systematic quantitative understanding of the synergistic interactions within multi-component systems remains absent. This study employs Response Surface Methodology to investigate the interactive effects of solid waste ratios, the water-to-solid ratio, and alkali content, aiming to elucidate the synergistic mineralization mechanism and overcome the bottlenecks of single solid waste mineralization. Under optimized conditions—specifically, 34% CS, 30% phosphogypsum (PG), a water-to-solid ratio of 0.48, and an alkali content of 27%—the system achieved a 7-day compressive strength of 3.5 MPa and a CO2 mineralization efficiency of approximately 16%, representing a significant improvement over typical single solid waste mineralization materials. Microstructural and spectroscopic analyses indicate that CS serves a dual function as both a calcium source for CaCO3 precipitation and an alkaline activator for FA. FA constructs a dense aluminosilicate network via pozzolanic reactions, while SO42− released from PG promotes the formation of ettringite, facilitating efficient pore filling and early strength development. Additionally, it was observed that surface pores were filled with more products compared to the interior, forming a gradient pore structure that is dense on the outside and sparse on the inside. The AFt and silicate gel were identified as the key microstructural driver for the performance enhancement. This study not only explores the ternary synergistic mechanism of FA, CS, and PG but also provides a viable pathway for developing high-performance solid waste-based mineralization materials that combine mechanical properties with efficient CO2 sequestration.