Hazardous aluminum dross characterization and recycling strategies: A critical review

Mechanism for leaching of fluoride ions from carbon dross generated in high-temperature and low-lithium aluminum electrolytic systems

Carbon dross, a hazardous solid waste generated during aluminum electrolysis, contains large amounts of soluble fluoride ions for the main components of the electrolyte (such as Na3AlF6 and NaF). Response surface methodology (RSM) was used to investigate the mechanism for fluoride ion leaching from carbon dross via water leaching, acid leaching and alkali leaching, and the kinetic and thermodynamic principles of the leaching process were revealed. The RSM predicted the optimum conditions of water leaching, alkali leaching and acid leaching, and the conditions are as follows: temperature, 50 °C; shaking speed, 213 r·min-1; particle size, 0.075 mm; shaking speed, 194 r·min-1; liquid-solid ratio, 12.6 mg·L-1; sodium hydroxide concentration, 1.53 mol·L-1; liquid-solid ratio, 25.0 mg·L-1; sulfuric acid concentration, 2.00 mol·L-1; and temperature, 60 °C，and actual results which were almost consistent with the predicted results were gained. The fluoride ions in the alkaline and acid leaching solutions were mainly the dissociation products of fluorides such as Na3AlF6, Na5Al3F14 and CaF2, as indicated by thermodynamics calculations. In particular, the fluoride compounds dissolved in alkali solution were Na3AlF6, Na5Al3F14, AlF3, ZrF4, K3AlF6, while the acid solution could dissolve only Na3AlF6 and CaF2. The leaching kinetics experiments showed that the leaching rate fit the unreacted shrinking core model [1-2/3α-(1-α)2/3 =kt] and that the leaching process was controlled by internal diffusion. This study provides theoretical guidance for the removal of soluble fluoride ions from carbon dross and will also assist in the separation of electrolytes from carbon dross. ENVIRONMENTAL IMPLICATION: Carbon dross, a hazardous waste generated during the aluminum electrolysis production process, contains a large amount of soluble fluoride. Improper storage will lead the fluoride ions pollution in soil, surface water or groundwater under the direct contact between carbon dross and rainfall, snow or surface runoff. The influence of wind will cause carbon dross dust to pollute further areas. With the human body long-term contact with fluoride ion contaminated soil or water, human health will be seriously harmed.

Field-tested innovation: Sustainable utilization of secondary alumina dross for flash setting admixtures production

Secondary alumina dross (SAD) has emerged as an alternative to bauxite in the production of flash setting admixtures (FSA), a critical admixture in shotcrete. However, the presence of hazardous components has hampered its large-scale adoption. This study conducted field tests at an FSA factory, utilizing SAD as the primary raw material, to evaluate the feasibility and environmental risks. The results confirmed that SAD can effectively replace bauxite in FSA production without compromising quality, as it closely resembled the chemical properties of bauxite. Emissions of fluorides, heavy metals, dioxins in flue gases during production met the relevant Chinese standards. The analysis of hazardous component distribution revealed that more than 50% of volatile components, such as Cl, Cd, Pb, and Zn, were directed into fly ash, exhibiting a significant internal accumulation pattern. In contrast, more than 95% of low-volatility components, including Cu, Cr, Mn, and F, were transferred to the FSA, and the introduction of CaCO3 was confirmed to effectively immobilize F. Moreover, the leaching risk of heavy metals and fluorides in FSA applications slightly increased but remained minimal and within acceptable limits. This technology provides an environmentally sound solution for the disposal of SAD.

Transformation and Detoxification of Typical Metallurgical Hazardous Waste into a Resource: A Review of the Development of Harmless Treatment and Utilization in China

The production process of the metallurgical industry generates a significant quantity of hazardous waste. At present, the common disposal method for metallurgical hazardous waste is landfilling, which synchronously leads to the leaching of toxic elements and the loss of valuable metals. This paper presents a comprehensive review of the research progress in the harmless treatment and resource utilization of stainless steel dust/sludge (including stainless steel dust and stainless steel pickling sludge) and aluminum ash (including primary aluminum ash and secondary aluminum dross), which serve as representative hazardous wastes in ferrous metallurgy and nonferrous metallurgy, respectively. Additionally, the general steps involved in the comprehensive utilization of metallurgical hazardous waste are summarized. Finally, this paper provides a prospective analysis on the future development and research trends of comprehensive utilization for metallurgical hazardous waste, aiming to offer a basis for the future harmless, high-value, resource-based treatment of metallurgical hazardous waste and the realization of industrial applications in China.

Mapping the research landscape of bauxite by-products (red mud): An evolutionary perspective from 1995 to 2022

The global population growth has significantly impacted energy and raw material consumption, unmatched since the Industrial Revolution. Among metals, aluminium ranks second only to steel, with annual production exceeding 69 million tonnes. Due to its high demand, bauxite, the primary ore from which aluminium is extracted, is now classified as a critical material in the EU and the US, given the potential risk of supply shortages for essential applications. Geographical and production challenges surround bauxite, presenting geo-economic and environmental challenges. A critical concern in aluminium production is managing by-products, notably red mud, a bauxite residue, generating over 175 million tonnes annually worldwide. Comprehensive bibliometric research is imperative due to the high amount of bibliographical resources related to this topic, encompassing circular economy, re-valorisation, sustainability, and disposal. This study employs bibliometric methods to assess red mud valorisation, offering insights into research topics, influential authors, and key journals, shedding light on the past, present, and future of red mud research. Such bibliometric analysis not only highlights the current state of the field but also serves as a valuable tool for decision-making, enabling researchers and policymakers to identify trends, gaps, and areas for further exploration, fostering informed and sustainable advancements in the by-products of the aluminium industry.

Thermal utilization techniques and strategies for secondary aluminum dross: A review

Secondary aluminum ash (SAD) disposal is challenging, particularly in developing countries, and presents severe eco-environmental risks. This paper presents the treatment techniques, mechanisms, and effects of SAD at the current technical-economic level based on aluminum ash's resource utilization and environmental properties. Five recovery techniques were summarized based on aluminum's recoverability in SAD. Four traditional utilization methods were outlined as per the utilization of alumina in SAD. Three new utilization methods of SAD were summarized based on the removability (or convertibility) of aluminum nitride in SAD. The R-U-R (recoverability, utilizability, and removability) theory of SAD was formed based on several studies that helped identify the fingerprint of SAD. Furthermore, the utilization strategies of SAD, which supported the recycling of aluminum ash, were proposed. To form a perfect fingerprint database and develop various relevant techniques, future research must focus on an extensive examination of the characteristics of aluminum ash. This research will be advantageous for addressing the resource and environmental challenges of aluminum ash.

Aluminium dross waste utilization for phosphate removal and recovery from aqueous environment: Operational feasibility development

The need to minimize eutrophication in water bodies and the shortage of phosphate rock reserves has stimulated the search for sequestration and recovery of phosphate from alternative sources, including wastewater. In this study, aluminium dross (AD), a smelting industry waste/by-product, was converted to high-value material by encapsulation in calcium alginate (Ca-Alg) beads, viz. Ca-Alg-AD and utilized for adsorptive/uptake removal and phosphate recovery from an aqueous environment. Encapsulation of AD in alginate beads solves serious operational difficulties of using raw AD material directly due to density difference constraining efficient contact of AD with pollutants present in water and post-treatment recovery of AD material. The phosphate removal was evaluated in both batch and continuous flow operation modes. The batch adsorption study revealed 96.86% phosphate removal from 10 mg L-1 of initial phosphate concentration in 70 min of optimal contact time. Further, the phosphate removal potential of Ca-Alg-AD beads turned out to be independent of solution pH, with an average of 95.93 ± 1.40 % phosphate removal in the 2-9 pH range. The result reflects phosphate adsorption on Ca-Alg-AD beads following a second-order pseudo-kinetic model. Ca-Alg-AD beads-based adsorption followed Freundlich and Langmuir isotherm models. Further, a continuous packed bed column study revealed a total phosphate adsorption capacity of 1.089 mg g-1. The chemical composition, physical stability, and surface properties of Ca-Alg-AD beads were analyzed by means of state-of-the-art analytical techniques, such as Scanning Electron Microscopy-Energy Dispersive X-ray spectroscopy (SEM-EDX), Fourier Transform Infrared Spectroscopy (FTIR) and thermogravimetry/Differential Thermal Analysis (TG/DTA). These characterization techniques comprehend the mechanism and influence of surface properties and morphology on the phosphate adsorption behaviour, which induce the involvement of multiple mechanisms such as ligand complexation, ion exchange, and electrostatic attraction for phosphate adsorption on Ca-Alg-AD beads.

Comprehensive treatments of aluminum dross in China: A critical review

Aluminum is an important lightweight and high-value metal that is widely used in the transportation, construction, and military industries. China is the largest producer of Al in the world, and vast quantities of Al dross (ash) are generated and stored every year. Aluminum dross contains fluoride and heavy metals, and easily reacts with water and acid to produce stimulating, toxic, and explosive gases. Owing to a lack of developed technologies, most of this dross cannot be safely treated, resulting in a waste of resources and serious environmental and ecological risks. This review briefly describes the distribution and proportions of bauxite deposits in China, the Al extraction process, and the hazardous solid waste that is generated. It also discusses the comprehensive treatments for Al dross, including the hydrometallurgy and pyrometallurgy recovery processes, and reuse of Al, Al2O3, SiO2, and chloride salts as a summarized comparison of their advantages and disadvantages. In particular, this review focuses on the efforts to analyze the relationship between existing processes and the attempts to establish a comprehensive technology to treat Al dross. Additionally, areas for future research are suggested, which may provide new ideas for the closed-loop treatment of Al dross.

The Effect of Secondary Aluminum Ash on the Properties of Reactive Powder Concrete

Secondary aluminum ash is a kind of common solid waste which will pollute the environment without any treatment. In this study, the influence of secondary aluminum ash on the rheological properties and the initial setting time of fresh reactive powder concrete (RPC) are researched. Meanwhile, the mechanical properties and the drying shrinkage rates of RPC with the secondary aluminum ash are determined. The electrical parameters of RPC with the secondary aluminum ash are measured. Scanning electron microscopy is obtained to reflect the internal structure of RPC. Results show that the addition of secondary aluminum ash can lead to decreasing the fluidity and increase the yield shear stress of fresh RPC paste by varying rates of 16.1% and 58.3%, respectively. The addition of secondary aluminum ash can decrease the flexural and compressive strengths of RPC cured for 1 day by the decreasing rates of 0~18.7% and 0~19.3%. When the curing age is 28 days, the flexural and compressive strengths of RPC are increased by 0~9.1% and 0~19.1% with adding the secondary aluminum ash. The secondary aluminum ash can promote the condensation of RPC. The addition of the secondary aluminum ash can decrease the electrical resistance of RPC by an order of magnitude. The relationship between the electrical resistance and the electrical reactance fits the quadratic function equation. The electrical resistance of the pore solution increases in the form of a quadratic function with the mass ratio of the secondary aluminum ash. The dry shrinkage rates of RPC cured for 1 day and 28 days are decreased by 0~36.4% and 0~41.3% with the increasing dosages of secondary aluminum ash. As obtained from the microscopic testing results, the secondary aluminum ash can improve the compactness of hydration products.

Effects of Bi-Sn-Pb Alloy and Ball-Milling Duration on the Reactivity of Magnesium-Aluminum Waste-Based Materials for Hydrogen Production

In the present study, composite materials were elaborated of mixed scrap of Mg-based casting alloys and low melting point Bi-Sn-Pb alloy by high energy ball milling, and their reactivity in NaCl solution with hydrogen release was tested. The impacts of the additive content and ball milling duration on their microstructure and hydrogen generation performance were investigated. Scanning electron microscopy (SEM) analysis revealed significant microstructural transformations of the particles during milling, and X-ray diffraction analysis (XRD) proved the formation of new intermetallic phases Mg₃Bi₂, Mg₂Sn, and Mg₂Pb. The said intermetallic phases were anticipated to act as 'microcathodes' enhancing galvanic corrosion of the base metal. The dependency of the samples' reactivity on the additive content and milling duration was determined to be nonmonotonic. For the samples with 0, 2.5, and 5 wt.% Rose alloy, ball-milling during 1 h provided the highest hydrogen generation rates and yields (as compared to 0.5 and 2 h), while in the case of the maximum 10 wt.%, the optimal time shifted to 0.5 h. The sample activated with 10 wt.% Rose alloy for 0.5 h provided the highest 'metal-to-hydrogen' yield and rapid reaction, thus overperforming those with lower additive contents and that without additives.

Understanding landfill gas behavior at elevated temperature landfills

Landfill gas (LFG) wellhead data were compared to understand the range of observations due to unique conditions at five elevated temperature landfills (ETLFs) in the U.S. Correlations of the primary gas ratio, CH4:CO2, show distinct compositional indicators for (1) typical operation, (2) subsurface exothermic reactions (SERs), (3) high moisture content, and (4) air intrusion that can help operators and regulators diagnose conditions across gas extraction wells. ETLFs A, B, D, and E showed similar trends, such as decreasing CH4 and increasing CO2, CO, and H2 that have been previously described. ETLF C uniquely exhibited elevated CH4 and temperatures simultaneously due to carbonation (i.e., CO2 consumption) of a steel slag which was used as alternative daily cover (ADC). At the maximum gas well temperature, T = 82 °C/180 °F, CH4 and CO2 concentrations were 47% and 28%, respectively. At ETLFs A, B, and E, H2 > 50% were regularly observed in affected gas wells for several years. At the five ETLFs, maximum CO concentrations ranged from 1400-16,000 ppmv. Like the analysis of CH4:CO2, it is hypothesized here that H2 (%):CO (ppmv) may infer the types of waste that are thermally degrading. Co-disposal of industrial wastes and MSW and the use of potentially reactive ADCs should remain an important consideration for landfill operators and regulators because of their potential long-term impacts to LFG quality.

Particle sorting to improve the removal of fluoride and aluminum nitride from secondary aluminum dross by roasting

It is important to remove active substances from secondary aluminum dross (SAD) to meet the reuse of SAD. In this work, the removal of active substances from different particle sizes of SAD was studied using roasting improvement with particle sorting. The results showed that roasting after particle sorting pretreatment can effectively remove fluoride and aluminum nitride (AlN) from SAD, while getting the high-grade alumina (Al₂O₃) crude materials. The active substances of SAD mainly contribute to AlN, aluminum carbide (Al₄C₃), and soluble fluoride ions. AlN and Al₃C₄ mainly exist in particles of 0.05-0.1 mm, while Al and fluoride are mainly in particles of 0.1-0.2 mm. The SAD of particle size ranging 0.1-0.2 mm has high activity and leaching toxicity; the gas emission was reached 50.9 mL/g (limit value of 4 mL/g), and the fluoride ion concentration in the literature was 137.62 mg/L (limit value of 100 mg/L) during the identification for reactivity and leaching toxicity according to GB5085.5-2007 and GB5085.3-2007, respectively. Roasting at 1000 °C for 90 min, the active substances of SAD were converted to Al₂O₃, N₂, and CO₂; meanwhile, soluble fluoride converted to stable CaF₂. The final gas release was reduced to 2.01 mL/g while soluble fluoride from SAD residues was reduced to 6.16 mg/L, respectively. The Al₂O₃ content of SAD residues was determined at 91.8% and has been classified as category I solid waste. The results suggested that the roasting improvement with particle sorting of SAD can meet the reuse of valuable materials at full scale.

Composites of Layered Double Hydroxides and ANA-Type Zeolite Synthesized from Hazardous Secondary Aluminum Dross for Cationic Dye Wastewater Treatment

This work first transformed hazardous aluminum waste into low-cost MgAl−layered double hydroxide@ANA zeolite (LDHs@ANA) composite for dye wastewater adsorption, which was meaningful for waste recovery and pollution control. Based on this strategy, the Al(OH)3 extracted from secondary aluminum dross (a hazardous waste in the aluminum industry) was used as an aluminum source to synthesize LDHs@ANA composite, which had more excellent adsorption capacity to methylene blue than MgAl−LDHs and ANA alone. The composite consisted of spherical ANA particles uniformly covered with LDH nanosheets, which effectively avoided a large amount of aggregation between nanosheets and increased specific surface areas and pore volumes. The kinetic results indicated that the adsorption process conformed to the pseudo-second-order kinetic model, and the adsorption site was the main factor affecting the adsorption process. The equilibrium studies showed the adsorption process was exothermic, and the Langmuir model best fitted for the adsorption process, with a maximum adsorption capacity reaching 65.27 mg/g. Meanwhile, the effects of pH, adsorbent concentration, initial methylene blue concentration, and adsorption time on the LDHs@ANA were analyzed. Overall, this work provides a fresh concept for the preparation of low-cost adsorbents from aluminum waste.

Adding Value to Secondary Aluminum Casting Alloys: A Review on Trends and Achievements

Aluminum is a critical element of the circular economy as it can be recycled several times. Moreover, Al recycling is a more economically and environmentally efficient procedure than the primary Al production from ores. Secondary aluminum alloys are mostly used in casting applications since it is possible to accommodate their chemical composition through secondary manufacturing processes. However, the quality of the alloys may be considerably altered during the different steps of the recycling process. Inadequate waste sorting might result in excessive contamination. Iron is the most dangerous contaminant because it causes brittle and fragile intermetallic phases, which significantly impacts the mechanical characteristics of alloys. In addition, the microstructure of the alloy changes significantly after multiple cycles of remelting. These issues lead to the downcycling of aluminum, i.e., in other words, the reduction in the overall quality of the alloys. Thus, it has been shown that a number of procedures, including ultrasonic melt treatment and microalloying with rare earths, can somewhat alter the shape of the Fe-rich phases in order to reduce the shortcomings of downcycling. However, a solid mechanical characterization is still missing in order to improve the Fe-rich phase alteration.

Removal of nitrides and fluorides from secondary aluminum dross by catalytic hydrolysis and its mechanism

Secondary aluminum dross (SAD) refers to hazardous waste from secondary aluminum refinement. It contains a large amount of aluminum nitride and fluorides that cause serious environmental pollution for direct discharge and hinder the resource utilization of SAD. However, it is difficult to remove nitride and fluoride simultaneously for their complicated phases. In this paper, the catalytic hydrolysis of SAD using NaOH as a catalyst to remove nitrides and fluorides synchronously was investigated systemically through single factor and response surface experiments. In addition, the chemical speciation and transformation of nitrides and fluorides were analyzed systematically. The catalytic hydrolysis removal mechanism was summarized. The optimal conditions for catalytic hydrolysis were established as follows: reaction temperature 96.60 °C; reaction time 2.85 h; liquid-solid ratio 9.28 mL/g and catalyst addition 12.62 wt %; and removal efficiency of nitrides and fluorides reached 99.03% and 81.93%, respectively. The mechanism of nitrides removal was that aluminum nitride was hydrolyzed to Al(OH)₃ and NH₃. NaOH reacting with Al(OH)₃ covering on the surface of AlN and the rapid escape of NH₃ promoted the hydrolysis of AlN under the catalysis of NaOH. The mechanism of fluorides removal was that the encapsulated fluoride particles were opened by catalytic hydrolysis to be dissolved in the solution. In this research, nitrides and fluorides were removed efficiently and synchronously. The hydrolysis residues can be used to prepare polyaluminum chloride (PAC) and ceramic materials. The hydrolysate can be prepared NH₃·H₂O by evaporative in alkaline solution. Then the solution without NH₄ ⁺ was prepared Al(OH)₃ by precipitation of adjusting pH value using HCl. And the remained liquid after removing NaAlO₂ was used to prepare refining agent by evaporative crystallization. The work in this paper was beneficial for the utilization of SAD.

Effect of Silicon Source (Fly Ash, Silica Dust, Gangue) on the Preparation of Porous Mullite Ceramics from Aluminum Dross

Aluminum dross (AD) is a waste product produced during aluminum processing and can be used to prepare mullite ceramic materials. However, the research on the preparation of mullite porous ceramics entirely from solid waste is still in the development stage. In this paper, porous mullite ceramics were successfully fabricated using a solid-phase sintering process with AD and different silicon sources (fly ash, silica dust, and gangue) as raw materials. The bulk density, apparent porosity, and compressive strength of the specimens were obtained, and the phase compositions and microstructures of the sintered specimens were measured using XRD and SEM, respectively. The average activation energy of the phase transition of fly ash, silica dust, and gangue as silicon sources were 984 kJ/mol, 1113 kJ/mol, and 741 kJ/mol, respectively. The microstructures of the mullite in the specimens were prisms, random aggregates, and needle-shaped, respectively. The formation of needle-shaped mullite combined with the substrate enhanced the mechanical strength of the porous mullite ceramics. The apparent porosity, density, and compressive strength of the specimens with gangue as the silicon source were 33.13%, 1.98 g/cm³, and 147.84 MPa, respectively, when sintered at 1300 °C for 2 h.

Preparation of Ca2Al1–mFem(OH)6Cl·2H2O-Doped Hydrocalumites and Application of Their Derived Mixed Oxides in the Photodegradation of Ibuprofen

Aluminum from saline slags generated during the recycling of this metal, extracted under reflux conditions with aqueous NaOH, was used in the synthesis of hydrocalumite-type solids with the formula Ca2Al1–mFem(OH)6Cl·2H2O. The characterization of the obtained solids was carried out by powder X-ray diffraction, infrared spectroscopy, thermal analysis, element chemical analysis, N2 adsorption-desorption at −196 °C and electron microscopy. The results showed the formation of Layered Double Hydroxide-type compounds whose characteristics varied as the amount of incorporated Fe3+ increased. These solids were calcined at 400 °C and evaluated for the catalytic photodegradation of ibuprofen, showing promising results in the elimination of this drug by advanced oxidation processes. The CaAl photocatalyst (without Fe) showed the best performance under UV light for the photodegradation of ibuprofen.

Effective Extraction of the Al Element from Secondary Aluminum Dross Using a Combined Dry Pressing and Alkaline Roasting Process

Secondary aluminum dross (SAD) is a hazardous solid waste discharged from aluminum electrolysis and processing and the secondary aluminum industries, which causes severe environmental pollution and public health disasters. The stable presence of the α-Al₂O₃ and MgAl₂O₄ phases in SAD makes it difficult for it to be efficiently utilized. A combined dry pressing and alkaline roasting process was proposed for extracting the valuable Al element from SAD. Two alkaline additives (NaOH and Na₂CO₃) were selected as a sodium source for extracting the aluminum source from SAD in order to perform the thermodynamic analysis and roasting experiments. The phase transition behavior and the leaching performance tests were conducted using X-ray diffraction, scanning electron microscopy, X-ray fluorescence, leaching kinetics and thermal analysis. The recovery of Al and Na reached the values of 90.79% and 92.03%, respectively, under the optimal conditions (roasting temperature of 1150 °C, Na₂CO₃/Al₂O₃ molar ratio of 1.3, roasting time of 1 h, leaching temperature of 90 °C, L/S ratio of 10 mL·g^-1 and leaching time of 30 min). Meanwhile, the removal efficiency of N and Cl reached 98.93% and 97.14%, respectively. The leaching kinetics indicated that the dissolution of NaAlO₂ clinkers was a first-order reaction and controlled by layer diffusion process. The green detoxification and effective extraction of the Al element from SAD were simultaneously achieved without any pretreatments.

Hydrolysis Behavior and Kinetics of AlN in Aluminum Dross during the Hydrometallurgical Process

In this study, the hydrolysis behavior and kinetics of AlN in aluminum dross (AD) were investigated in order to better identify the steps controlling the AlN hydrolysis reaction and the factors influencing the hydrolysis rate to enhance the removal efficiency of AlN. The hydrolysis behavior of AlN, including AlN content, phase composition, chemical composition, microstructure, and element distribution, was determined by a leaching test, X-ray diffraction, X-ray fluorescence, scanning electron microscopy, and energy dispersive spectroscopy, respectively. The results showed that increasing the leaching liquid-solid ratio as well as the temperature was helpful for the removal efficiency of AlN. When the liquid--solid ratio was 4:1, temperature was 90 °C, and leaching time was 300 min, the removal efficiency of AlN reached 89.05%. The kinetics were described using the unreacted core model, and when the temperature was 30-40, 50-70, and 80-90 °C, the hydrolysis reaction rate of AlN was controlled by boundary layer diffusion, chemical reaction control, and product layer diffusion control, respectively.

Sustainable Management of Salt Slag

The management of salt slag, a waste from the secondary aluminum industry, is associated with huge environmental concerns due to the risk of atmospheric pollution (emission of toxic gases), groundwater contamination (high salt content that can percolate and cause an increase in salinity) and soil unavailability (large extensions required for disposal). Therefore, the development of a sustainable process for its treatment and recovery is of the utmost importance. In this work, a two-step process for the valorization of salt slag was developed that rendered zeolite as the main added-value product and NaCl and NH3 as byproducts. First, salt slag was hydrolyzed at 90 °C and at a solid/water ratio of 1/3. More than 90% of salt and ~90% of ammonia were recovered. In a second step, the hydrolyzed slag was completely transformed into a NaP zeolite under mild hydrothermal conditions. The zeolite exhibited specific surface area (17 m2 g−1), cation exchange capacity (2.12 meq g−1) and zeta potential (−52 mV) values that represent good characteristics for use in the removal of metal ions from aqueous effluents. The transformation of salt slag into zeolite can be considered a sustainable process with a high contribution to the circular economy.

Manganese and Aluminium Recovery from Ferromanganese Slag and Al White Dross by a High Temperature Smelting-Reduction Process

The recovery of Mn and Al from two industrial waste of ferromanganese and aluminum production processes was investigated via implementing a high temperature smelting—aluminothermic reduction process. The experiments were carried out with or without CaO flux addition, and two dross qualities. It was observed that the prepared mixtures of the materials yield homogeneous metal and slag products in terms of chemical composition and the distribution of phases. However, the separation of produced metal phase from the slag at elevated temperatures occurs when a higher amount of CaO is added. Viscosity calculations and equilibrium study indicated that the better metal and slag separation is obtained when the produced slag has lower viscosity and lower liquidus. It was found that the process yields Al-Mn-Si alloys, and it is accompanied with complete recovery of Mn, Si and Fe and the unreacted Al in the process. Moreover, the quality of metal product was less dependent on the slightly different dross quality, and the concentration of minor Ca in metal is slightly increased with significant increase of CaO in the slag phase.

Red Mud from the Aluminium Industry: Production, Characteristics, and Alternative Applications in Construction Materials—A Review

About 120 million tons of red mud is produced worldwide each year. Due to its high basicity and potential leaching, its storage is a critical environmental problem. This material is typically stored in dams, which demands prior care of the disposal area and includes monitoring and maintenance throughout its useful life. Consequently, it is crucial to figure out an industrial solution able to consumes large volumes of this material. At this moment, there are several studies, the majority in metallurgical procedures, building materials, and in the chemical industry, discussing how to reuse red mud. This paper provides a review of the aluminium process, including metal importance, its global production, and the environmental impact due to its manufacture process. It presents a review of the potential application of red mud showing its overall generation, some relevant characterisation results collected from the literature, and its utilisation in diverse areas of engineering. The study aimed to highlight applications where red mud characteristics may be favourable.

Fabrication of Carbon-Alumina Composites via Catalytic Pyrolysis of Pine Sawdust on Aluminum Dross for Cr(VI) Removal

Carbon-alumina composites are prepared for the efficient removal of Cr(VI) from wastewater. Pristine and acid-treated alumina dross (AD and AAD) are copyrolyzed with pine sawdust to form the respective composites, ADPC and AADPC. Excellent absorption properties with Cr(VI) removal efficiency of 95.08% are demonstrated at 60 °C for an initial concentration of 6 μg/mL. The composites combine the merits of char, which provides a high surface-to-volume ratio with abundant functional groups on the surface, and alumina, which provides metal ions for coprecipitation. Carbon structures of pine, char, and composite were analyzed semiquantitatively using ¹³C NMR by a curve-fitting method. Cr(VI) adsorption is accurately described with chemisorption by the Langmuir isotherm model and a pseudo-second-order kinetic model. The results show that AADPC has more alcohol hydroxyl groups substituted to glucosyl units in amorphous cellulose assigned to the peak at 80 ppm and hemicellulose assigned to peaks at 97 and 101 ppm. Also, it has more phenolic groups in lignin distributed at syringyl units assigned to peaks at 129 and 146 ppm. These oxygen-containing functional groups have a significant influence on Cr(VI) adsorption and reduction to Cr(III) governed by the mechanisms of diffusion, adsorption, complexation, reduction, and coprecipitation. The results of this work provide a new direction for the reuse of biomass and industrial solid wastes to fabricate higher value-added products, i.e., adsorption materials for Cr(VI) removal and stabilization.

Preparation of Sintered Brick with Aluminum Dross and Optimization of Process Parameters

Aluminum dross is produced in the process of industrial production and regeneration of aluminum. Currently, the main way to deal with aluminum dross is stacking and landfilling, which aggravates environmental pollution and resource waste. In order to find a green and environmental protection method for the comprehensive utilization, the aluminum dross was used as raw materials to prepare sintered brick. Firstly, the raw material ratio, molding pressure and sintering process were determined by single factor test and orthogonal test, and the mechanism of obvious change of mechanical strength of sintered brick was studied by XRD and SEM. The experimental results show that, the optimal formula of sintered brick is 50% aluminum dross, 37.50% engineering soil and 12.50% coal gangue. The optimum process parameters are molding pressure 10 MPa, heating rate 8 °C/ min, sintering temperature 800 °C, holding time 60 min. The samples prepared under the above formula and process parameters present outstanding performance, and the compressive strength, flexural strength and water absorption rate are 16.21 MPa, 3.42 MPa and 17.12% respectively.

Extraction of alumina from aluminum dross by a non-hazardous alkaline sintering process: Dissolution kinetics of alumina and silica from calcined materials

The aluminum dross (AD), which causes numerous problems of its management and disposal to environment is a useful resource to extract alumina. This study explains a novel process to extract highly pure alumina (Al₂O₃) from AD at a high extraction rate without producing the residues and exhaust gases. An experimental set up was designed to perform the grinding of AD for the decomposition of aluminum nitride (AlN) and the removal of salts. Thereby, the desalted dross was used to detect the optimum alkaline (NaOH) calcination parameters and leaching conditions, as well as the dissolution kinetics of alumina and silica. The leaching residues were used to produce Ettringite mineral with calcium-based compounds (including CaO and CaSO₄) to avoid the problems of solid waste disposal from the leaching process. Moreover, to purify the alumina, slightly soluble CaSO₄ was added in leaching solution to precipitate silicate and the optimum additive/solution ratio (g/mL) was determined. The aluminum hydroxide (Al(OH)₃), precipitated after the carbonization was calcinated at 900.0 °C for 2 h to produce γ-alumina. The morphological and mineralogical characterizations of AD, γ-Al₂O₃ and the synthesized Ettringite mineral were studied by X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM) and X-ray fluorescence (XRF). It was observed that activation temperature of 1000.0 °C, Na₂O/Al₂O₃ molar ratio of 1.4, leaching temperature of 60.0 °C, leaching time of 40.0 min, and the leaching liquid/solid ratio (mL/g) of 25/1 were the optimal parameter conditions to extract alumina with the extraction rate at 86.7% and purity of more than 98%. The results of leaching kinetics' study showed that the dissolution of alumina and silica were both controlled by layer diffusion process with the apparent activation energy of 11.4010 kJ·mol^-1 and 2.0556 kJ·mol^-1, respectively.

Harmless disposal and resource utilization for secondary aluminum dross: A review

Secondary aluminum dross (SAD) is solid waste of primary aluminum dross extracted aluminum, which contains approximately 40-60 wt% alumina, 10-30 wt% aluminum nitride (AlN), 5-15 wt% salts and other components. The salts include sodium chloride, potassium chloride and fluorine salts. SAD has dual attributes as resource and pollutant. SAD landfill disposal has the disadvantages of occupying land, wasting resources, a high cost and great environmental impact. SAD utilization methods are currently pyrometallurgy and hydrometallurgy. In pyrometallurgy, AlN is oxidized and the salts are evaporated at high temperature. After mixing, molding and calcination, firebricks and ceramics can be manufactured from SAD. In hydrometallurgy, AlN is hydrolyzed and salts are dissolved in water. After dissolving, filtrating, precipitating, washing and calcination, γ-Al₂O₃ can be prepared from SAD. Resource consumption and emission from both utilization methods were assessed. A ton of magnesium aluminum titanate based ceramics by pyrometallurgy consumes 1043 kg raw materials and releases 69 kg of waste gas, 4.17 t of waste water and no solid waste. A ton of γ-Al₂O₃ by hydrometallurgy consumes 3389 kg raw materials and releases 111 kg of waste gas, 12.98 t of waste water and 267 kg of solid waste. Therefore, the resource consumption and emission of SAD utilization by pyrometallurgy is lower than that by hydrometallurgy. We should focus on reducing the emission of the three wastes from pyrometallurgy. We are sure that SAD can be utilized for glass ceramics by pyrometallurgy. AlN and salts can be transformed into alumina and glass phases at high temperature with no emission. We should clarify mechanisms for SAD composition adjustment to lower the glass ceramics' melting point, AlN and salts transformed into alumina and glass phases respectively, and nucleation and crystal growth of glass ceramics at high temperature.

Characterisation of aluminium black dross before and after stepwise salt-phase dissolution in non-aqueous solvents

Aqueous leaching to recover salts from black dross is accompanied by hazardous gas generation. The gas-generating phases vary significantly across differently sourced black dross. The challenge for the industry is how to accurately qualify and quantify the problematic components of black dross, especially minor reactive phases. This paper employed XRF, EDX, XRD, Raman and FTIR to analyse two industrial black dross samples from various sources. A novel pre-treatment method before characterisation was devised using water-free glycerol and anhydrous ethanol to remove the major salt components, without reacting the gas-generating phases. The results show that around 80 % of the salts existent in the black dross had been removed successfully through pre-treatment. This method facilitated the determination of minor reactive phases characterised by XRD, XRF and EDX, and had little effect on the characterisation by Raman and FTIR spectroscopy. The ammonia-generating nitride phase was detected by XRD, Raman and FTIR. The FTIR, moreover, allowed the successful identification of carbide. Best practice guidelines for the industrial analysis of black dross has been proposed. The guidelines would provide industry with evidence to include or adjust gas treatment methods and operational parameters when dealing with compositional variability in industrially-sourced black dross.

A Study on Mechanical Properties of Concrete Incorporating Aluminum Dross, Fly Ash, and Quarry Dust

The amount of waste, associated waste disposal costs, and environmental contamination may be minimized by identifying effective recycling approaches. These promising approaches will also lead to the protection of natural resources and economic gains. One example of waste disposal maybe by using it as a filling material or as a pozzolanic material for the production of concrete. In this regard, this study proposes to partially replace cement with aluminum dross and fly ash, and partially replace natural sand with quarry dust. Aluminum dross, cement, sand, and quarry dust were used in a variety of proportions with a constant percentage of fly ash for the design of nine concrete mixtures. Aluminum dross was replaced by 5, 10, 15, and 20% of the cement mass. At first, the optimum replacement of aluminum dross without using quarry dust was determined at a constant percentage of fly ash-15% based on the strength results. Later, by introducing the optimum substitution of aluminum dross with cement and fly ash, the quarry dust was partially replaced at 10, 20, 30, and 40% of river sand to determine the overall optimum mix. The mechanical and durability characteristics of the concrete using the three mixtures were analyzed. It has been observed that the mechanical and durability characteristics of a concrete mixture incorporating a fly ash-15%, aluminum dross-10%, and quarry dust-20% are better than that of standard concrete. Production of concrete using industrial waste can minimize infrastructure construction costs and reduce environmental impacts.

Reutilization of silicon- and aluminum- containing wastes in the perspective of the preparation of SiO2-Al2O3 based porous materials for adsorbents and catalysts

The waste materials available as sources of silicon and aluminum for producing porous materials like amorphous silicas, aluminas, amorphous silica-aluminas, and zeolites, to be used as catalyst and adsorbents, are briefly summarized. The procedures for preparing these materials from wastes are also taken into account. The limits of this approach in terms of economy and environmental protection are also briefly considered. It is concluded that mesoporous materials can be prepared from wastes, but care to product quality and to overall process efficiency is needed.

Aluminium removal and recovery from wastewater and soil using isolated indigenous bacteria

This paper elucidates the capability of isolated indigenous bacteria to remove aluminium from wastewater and soil. Two indigenous species of Brochothrix thermosphacta and Vibrio alginolyticus were isolated from an aluminium-contaminated site. These two species were used to treat aluminium-containing wastewater and contaminated soil using the bioaugmentation method. B. thermosphacta showed the highest aluminium removal of 57.87 ± 0.45% while V. alginolyticus can remove aluminium up to 59.72 ± 0.33% from wastewater. For aluminium-contaminated soil, B. thermosphacta and V. alginolyticus, showed a highest removal of only 4.58 ± 0.44% and 5.48 ± 0.58%, respectively. The bioaugmentation method is more suitable to be used to treat aluminium in wastewater compared to contaminated soil. The produced biomass separation after wastewater treatment was so much easier and applicable, compared to the produced biomass handling from contaminated soil treatment. A 48.55 ± 2.45% and 40.12 ± 4.55% of aluminium can be recovered from B. thermosphacta and V. alginolyticus biomass, respectively, with 100 mg/L initial aluminium concentration in wastewater.

Kinetics of aluminium removal by locally isolated Brochothrix thermosphacta and Vibrio alginolyticus

The emergence of the aluminium recycling industry has led to an increase in aluminium-containing wastewater discharge to the environment. Biological treatment of metal is one of the solutions that can be provided as green technology. Screening tests showed that Brochothrix thermosphacta and Vibrio alginolyticus have the potential to remove aluminium from wastewater. Brochothrix thermosphacta removed up to 49.60%, while Vibrio alginolyticus was capable of removing up to 59.72% of 100 mg/L aluminium in acidic conditions. The removal of aluminium by V. alginolyticus was well fitted with pseudo-first-order kinetics (k₁ = 0.01796/min), while B. thermosphacta showed pseudo-second-order kinetics (k₂ = 0.125612 mg substrate/g adsorbent. hr) in the process of aluminium removal. V. alginolyticus had a higher rate constant under acidic conditions, while B. thermosphacta had a higher rate constant under neutral pH conditions.

Synthesis and characterization of tamarugite from aluminium dross: Part I

Aluminium dross, which is otherwise a hazardous waste, can be used for the synthesis of Tamarugite. Since aluminium dross is a good source of aluminium, utilizing the aluminium dross for the generation of valuable products is a reliable method of recycling this industrial waste. The motivation of the present research is to jointly recycle aluminium dross and synthesize Tamarugite. In this research article, the synthesis of Tamarugite was carried out using the addition of NaOH and H₂SO₄ solutions to aluminium dross. The dross reacts with NaOH to form NaAl(OH)₄ and the addition of H₂SO₄ results in the generation of NaAl(SO₄)₂.6H₂O. Since Tamarugite is a relatively rare mineral, its applications have not yet been reported much. However, the authors have explored the possibility of using Tamarugite as a coagulant and found that the mineral has excellent coagulation tendency. The authors believe that present research shall expand the new horizon for utilization of Tamarugite and recycling of aluminium dross.