Alkalinity neutralization and structure upgrade of bauxite residue waste via synergistic pyrolysis with biomass

Bauxite residue (red mud) treatment: Current situation and promising solution

Bauxite residue, an industrial solid waste generated during alumina production, with over 80 % of bauxite residue worldwide being accumulated around alumina plants, which occupying a significant amount of land resources and posing a threat to the natural environment in the surrounding areas. This paper reviews recent advances in extracting valuable resources from bauxite residue, and its applications in building materials, environmental adsorbents, energy storage materials, and soil alkalinization. It also highlighted the main problem existing in these researches, which is the inability of the existing single processes to achieve the comprehensive utilization of various types of bauxite residue or maximize the utilization of bauxite residue components, resulting in a low comprehensive utilization rate and insignificant absorption effects of bauxite residue. To address these issues, we proposed a strategy of classifying and utilizing bauxite residue based on its components and establishing a multi-industry application system, involving sectors such as steel and building materials. This collaborative approach aims to handle various types of bauxite residue more effectively. Additionally, we suggest selecting suitable treatment methods based on the specific characteristics of bauxite residue and implementing measures to promote its comprehensive and large-scale utilization.

Rapid conversion of alkaline bauxite residue through co-pyrolysis with waste biomass and its revegetation potential

The extreme alkalinity of bauxite residue (BR) leads to difficulty with its reuse. Alkaline leachate and dust generation during the stacking process can pollute surrounding soil, air and water. In this work, co-pyrolysis of bauxite residue and sawdust was applied to rapidly produce a soil-like matrix that met the conditions for plant growth as demonstrated by ryegrass pot experiments. The present study aimed to characterize the detailed changes in physicochemical, mineral weathering, and microbial communities of the pyrolyzed BR with different ratios of saw dust after plant colonization for 2 months. With increasing sawdust addition during co-pyrolysis, the pH of BR decreased from 11.21 to 8.16, the fraction of macro-aggregates 0.25-2 mm in the water-stable agglomerates increased by 29.3%, and the organic carbon concentration increased from 12.5 to 320 mg/kg, whilst facilitating the degree of humification, which were all beneficial to its revegetation performance. The backscattered electron-scanning electron microscope-energy-dispersive X-ray spectrometry (BSE-SEM-EDS) results confirmed the occurrence of sodalite and calcite weathering on aggregate surfaces, and X-ray photoelectron spectroscopy (XPS) results of surface Al and Si compounds identified that some weathering products were clay minerals such as kaolinite. Furthermore, bacterial community composition and structure shifted towards typical soil taxonomic groups. These results demonstrate soil development of treated BR at an early stage. The technique is a combination of alkalinity regulation and agglomerate construction, which accelerates soil formation of BR, thus proving highly promising for potential application as an artificial soil substitute.

Red mud recycling by Fe and Al recovery through the hydrometallurgy method: a collaborative strategy for aluminum and iron industry

In this work, a collaborative strategy for the aluminum and iron industry based on red mud recycling through the hydrometallurgy method was proposed. In this method, Fe³⁺ and Al³⁺ were firstly separated from the red mud by using H₂SO₄ as a leaching agent, which was by-produced from the sintering process of an iron and steel industry. Multiple influence factors on the leaching process were investigated, with the H₂SO₄ addition amount showing the strongest influence on the leaching rates of Al and Fe. The main components of the filter residue were CaSO₄, TiO₂, and SiO₂, which could be reused as additives in the building materials. Subsequently, the final Fe recovery product was obtained through the co-precipitation, Fe/Al separation, and Fe(OH)₃ calcination. In the final product, the content of Fe₂O₃ reached 82.87%, and the iron grade was 58.01%, meeting the requirement being raw materials for sinter production.

Magnetization of Bauxite Residue to Enhance the Removal Efficiency Towards Heavy Metals

Bauxite residues are a mass of industrial wastes derived from aluminum metallurgy. This work provided a simple pyrolysis method to magnetize the bauxite residue to serve as a magnetic adsorbent towards heavy metals removal. The X-ray diffraction patterns and Mossbauer spectrum results confirmed the partial reduction of iron species with an obvious enhancement in magnetization. The magnetized bauxite residue exhibited excellent removal efficiencies for Cu²⁺, Cd²⁺ and Pb²⁺ with maximum adsorption capacities of 219.0 mg g^-1, 275.4 mg g^-1, and 100.4 mg g^-1, which could be quickly separated through a magnet. The adsorption equilibrium data were fitted to the Langmuir isotherm model, while the adsorption kinetics followed a pseudo-first-order model. According to the characterization results, chemical precipitation and sorption was the major mechanism for the removal of Cu²⁺, Pb²⁺, and Cd²⁺. Thus, the magnetized bauxite residue exhibited promising applications for heavy metals removal in wastewater.

Calcification-Carbonation Method for Bayer Red Mud Treatment: Carbonation Performance of Hydrogarnets

Hydrogarnets are vital intermediate products in the calcification- carbonation method, which is designed for Bayer red mud treatment. Their carbonation performance greatly depends on SiO₂ substitution. In this study, different SiO₂-substituted hydrogarnets were synthesized and characterized. Then, batch experiments were performed to evaluate the potential effects of important parameters such as CO₂ pressure, and SiO₂ substitution degree (x) on the carbonation process. The SiO₂ substitution degrees of the hydrogarnets synthesized at 60, 120, 180, and 240°C were 0.27, 0.36, 0.70, and 0.73, respectively. As the SiO₂ substitution degree increased, the hydrogarnet carbonation extents gradually declined. With an increase in CO₂ pressure, the hydrogarnet carbonation percentages increased gradually and rose from 80.33% to 98.19% within 120 min. The phases detected in the carbonized products were strip-like aragonite as well as some calcite; the Al-rich and Si-rich phases in the carbonized products were amorphous.

An Eco-Friendly Acid Leaching Strategy for Dealkalization of Red Mud by Controlling Phase Transformation

The alkaline components in red mud represent one of the crucial factors restricting its application, especially for the construction and building industry. The phase state of alkaline components has a significant influence on the dealkalization of red mud. In this work, an environmentally friendly acid leaching strategy is proposed by controlling the phase transformation of red mud during active roasting pretreatment. With a moderate roasting temperature, the alkaline component is prevented from converting into insoluble phases. After acid leaching with a low concentration of 0.1 M, a high dealkalization rate of 92.8% is obtained. Besides, the leachate is neutral (pH = 7) and the valuable metals in red mud are well preserved, manifesting a high selectivity and efficiency of diluted acid leaching. The calcination experiment further confirms the practicability of the strategy in the construction field, where the cementitious minerals can be formed in large quantities. Compared with the traditional acid leaching routes, the diluted acid leaching strategy in this work is acid saving with low valuable element consumption. Meanwhile, the secondary pollution issue can be alleviated. Hence, the findings in this work provide a feasible approach for the separation and recovery of alkali and resource utilization of red mud.

Accelerated alkalinity regulation and long-term dry-wet aging durability for bauxite residue remediated with biomass pyrolysis

Biomass fermentation provides a potential route toward the ecological disposal for the bauxite residue (BR) with high alkalinity issues. However, how to accelerate the remediation of the alkaline problem with a long-term durability is still a big challenge. Herein, we investigated the acceleration of the decomposition of straw toward organic acid species via a pyrolysis strategy as well as the pH stability during long-term dry-wet aging for the treated BR. The pH of pyrolytic BR at 300 °C is stabilized at around 8.90 after 70 days' dry-wet aging. During the aging, the main Ca-contained alkaline minerals of calcite and cancrinite are dissolved and the content of exchangeable Na⁺ is reduced. This pyrolysis process can decompose straw quickly and produce more organic matters that are easily degraded to fulvic and humic acid as evidenced by 3D fluorescence spectrum analysis. Compared to the fermentation with straw under natural conditions, the alkalinity regulation of BR after pyrolysis is featured with shorter period and lower pH as well as long-term pH stability. Therefore, the synergistic pyrolysis of BR with straw provides an alternative method to address the alkaline issues, which is conducive to promoting the soil formation of BR.