Production of electrolytic iron from red mud in alkaline media

Synthesis of Porous Red Mud/Slag-Based Spherical Geopolymers for Efficient Methylene Blue and Ni2+ Removal from Water

To reuse red mud and slag wastes as raw materials, a green type of porous spherical red mud/slag-based geopolymer (RSG) was synthesized by utilizing suspension curing and foaming techniques. Because methylene blue (MB) and nickel ion (Ni2+) were common and difficult to treat in wastewater, the adsorption characteristics of MB and Ni2+, as well as the phase and microstructure of the porous RSG spheres prior to and after adsorption, were thoroughly investigated. The porous RSG spheres showed a stable and mesoporous structure with a BET surface area of 31.36 m2/g. The spheres achieved the maximum removal efficiencies of 99.81% (MB) and 99.01% (Ni2+) at dosages of 16 and 10 g/L, respectively. The pseudo-second-order kinetic model and the Langmuir model could match the adsorption data of these spheres, with predicted maximum adsorption capacity (Qmax) values of 19.88 mg/g for MB and 12.39 mg/g for Ni2+, respectively. After three adsorption-desorption cycles, porous RSG spheres demonstrated good recycling capability with removal efficiencies of 98.10% (MB) and 54.60% (Ni2+). The spheres were also effective in adsorbing additional dyes (methyl orange (MO), crystal violet (CV), and malachite green (MG)) and heavy metal ions (Cd2+, Pb2+, Zn2+, and Cu2+). The spheres have potential use in water treatment.

Synthesis of BiOX-Red Mud/Granulated Blast Furnace Slag Geopolymer Microspheres for Photocatalytic Degradation of Formaldehyde

Release of formaldehyde gas indoors is a serious threat to human health. The traditional adsorption method is not stable enough for formaldehyde removal. Photocatalytic degradation of formaldehyde is effective and rapid, but photocatalysts are generally expensive and not easy to recycle. In this paper, geopolymer microspheres were applied as matrix materials for photocatalysts loading to degrade formaldehyde. Geopolymer microspheres were prepared from red mud and granulated blast furnace slag as raw materials by alkali activation. When the red mud doping was 50%, the concentration of NaOH solution was 6 mol/L, and the additive amount was 30 mL, the prepared geopolymer microspheres possessed good morphological characteristics and a large specific surface area of 38.80 m2/g. With the loading of BiOX (X = Cl, Br, I) photocatalysts on the surface of geopolymer microspheres, 85.71% of formaldehyde gas were adsorbed within 60 min. The formaldehyde degradation rate of the geopolymer microspheres loaded with BiOI reached 87.46% within 180 min, which was 23.07% higher than that of the microspheres loaded with BiOBr, and 50.50% higher than that of the microspheres loaded with BiOCl. While ensuring the efficient degradation of formaldehyde, the BiOX (X = Cl, Br, I)-loaded geopolymer microspheres are easy to recycle and can save space. This work not only promotes the resource utilization of red mud and granulated blast furnace slag, but also provides a new idea on the formation of catalysts in the process of photocatalytic degradation of formaldehyde.

Clean dealkalization technology from aluminum industry hazardous tailings-red mud by displacement with Mg-based agent

Red mud is a kind of strong alkaline hazardous slag discharged from aluminum metallurgy industry. In this study, the water immersion with high temperature and high pressure was developed for the selective dealkalization from red mud by adding Mg-based additives. The removal efficiency of alkali could reach 92% by using 12% MgCl₂ with 9 mL/g at 250 °C for 60 min. The MgCl₂ was the most effective leaching reagent to promote the decomposion of cancrinite lattice. The new minerals bearing Mg, i.e., chlorite (Mg₅Al₂Si₃O₁₀(OH)₈) and pyrope (Mg₃Al₂Si₃O₁₂) could be formed, which was in favor of transforming the structural alkali into the free alkali by the analysis and validation of XRD and SEM-EDS. The dealkalization process was mainly controlled by chemical reactions according to the analysis of unreacted shrinking core model (USCM) of leaching kinetics. The leaching kinetics equation of 1 - (1 - x)^1/3 = 32.2 × exp[4582.6 / T] × t was built and the apparent activation energy of 38.1 kJ/mol was obtained. This method may provide a new and cleaner way for the efficient dealkalization of red mud and a basis for the utilization of leaching residue as the soil amendment.

Iron Recovery Technology of Red Mud—A review

RM (red mud), which comes from the Bayer process, has a huge annual output and is harmful to the environment. Because of the high iron content in RM, the process of iron recovery from RM can reduce the amount of RM well and create economic benefits, so it is a promising process. The paper focuses on the review on the research of the iron recovery method from RM, which includes the physical recovery method, chemical recovery method and emerging recovery method. By comparing the advantages and disadvantages of these processes, it is concluded that the fluidized bed reduction is a promising process that can be rapidly applied to the industry, but it still needs more investigation to overcome the current technical difficulties in the near future.

Red Mud as a Secondary Resource of Low-Grade Iron: A Global Perspective

Managing red mud (RM), a solid waste byproduct of the alumina recovery process, is a serious ecological and environmental issue. With ~150 million tons/year of RM being generated globally, nearly 4.6 billion tons of RM are presently stored in vast waste reserves. RM can be a valuable resource of metals, minor elements, and rare earth elements. The suitability of RM as a low-grade iron resource was assessed in this study. The utilization of RM as a material resource in several commercial, industrial operations was briefly reviewed. Key features of iron recovery techniques, such as magnetic separation, carbothermal reduction, smelting reduction, acid leaching, and hydrothermal techniques were presented. RMs from different parts of the globe including India, China, Greece, Italy, France, and Russia were examined for their iron recovery potential. Data on RM composition, iron recovery, techniques, and yields was presented. The composition range of RMs examined were: Fe2O3: 28.3–63.2 wt.%; Al2O3: 6.9–26.53 wt.%; SiO2: 2.3–22.0 wt.%; Na2O: 0.27–13.44 wt.%; CaO: 0.26–23.8 wt.%; Al2O3/SiO2: 0.3–4.6. Even with a high alumina content and high Al2O3/SiO2 ratios, it was possible to recover iron in all cases, showing the significant potential of RM as a secondary resource of low-grade iron.

Persulfate activation by modified red mud for the oxidation of antibiotic sulfamethoxazole in water

Different pre-conditioning treatments were evaluated in order to stabilize red mud, a waste product from bauxite processing, for obtaining heterogeneous catalysts (named as B1-B3) that can be employed as suitable activators of sodium persulfate (SPS) for the degradation of sulfamethoxazole (SMX), a model antibiotic, in water. The presence of Fe₃O₄ in the composition of the catalysts was found to be a key factor for a suitable activation of SPS, according to the XPS measurements. The oxidation of SMX was successfully fitted to a pseudo-first-order kinetic model (r² > 0.96), obtaining a 68% removal after 180 min when 0.8 mg/L of SMX was oxidized with 2 g/L of SPS and 2 g/L of catalyst B3. The presence of organic and/or inorganic constituents in the water matrix significantly hindered the degradation rate of SMX, the apparent kinetic constants being from 2 to 3 times lower than that determined in ultrapure water test. The use of ultrasound irradiation coupled to the addition of B3 catalyst improved importantly the SMX oxidation in real aqueous matrices, thus attaining values of removal which almost triplicated the ones obtained in absence of ultrasounds.