BaCO3 dispersed PVC composites were prepared through a polymer re-precipitation method. The composites were tested for sulfate removal using rapid small scale column test (RSSCT) and found to significantly reduce sulfate concentration. The method was extended to synthesize barium carbonate-loaded silica aero-gels-polyvinyl chloride (PVC) polymer composites. The PVC composites were characterized using scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray mapping, X-ray diffraction (XRD), thermogravimetric analysis (TGA) and inductively coupled plasma mass spectrometry (ICP-MS) analysis. The method has advantages over conventional sulfate precipitation (sulfate removal process) using BaCO3 wherein clogging of the filter can be avoided. The method is environmentally friendly and does not interfere with natural organic matter as the conventional resin does. Some of the composites were thermally more stable as compared with the pure PVC discussed in the literature. Published by Elsevier B.V.