Application of Bayer red mud for iron recovery and building material production from alumosilicate residues

Unveiling the oxidation mechanism of persistent organic contaminants via visible light-induced dye-sensitized reaction by red mud suspension with peroxymonosulfate

A dye-sensitized photocatalysis system was developed for degrading persistent organic contaminants using solid waste (i.e., red mud, RM) and peroxymonosulfate (PMS) under visible light. Complete degradation of acid orange 7 (AO7) was achieved in RM suspension with PMS, where the co-existence of amorphous FeO(OH)/α-Fe2O3 was the key factor for PMS activation. The experimental results obtained from photochemical and electrochemical observations confirmed the enhanced PMS activation due to the Fe-OH phase in RM. DFT calculations verified the acceleration of PMS activation due to the high adsorption energy of PMS on FeO(OH) and low energy barrier for generating reactive radicals. Compared to the control experiment without AO7 showing almost no degradation of other organic contaminants (phenol, bisphenol A, 4-chlorophenol, 4-nitrophenol, and benzoic acid), photo-sensitized AO7* enhanced electron transfer in the FeIII/FeII cycle, dramatically enhancing the degradation of organic contaminants via radical (•OH, SO4•-, and O2•-) and non-radical (dye*+ and 1O2) pathways. Therefore, the novel finding of this study can provide new insights for unique PMS activation by heterogeneous Fe(III) containing solid wastes and highlight the importance of sensitized dye on the interaction of PMS with Fe charge carrier for the photo-oxidation of organic contaminants under visible light.

Iron Compounds in Anaerobic Degradation of Petroleum Hydrocarbons: A Review

Waste and wastewater containing hydrocarbons are produced worldwide by various oil-based industries, whose activities also contribute to the occurrence of oil spills throughout the globe, causing severe environmental contamination. Anaerobic microorganisms with the ability to biodegrade petroleum hydrocarbons are important in the treatment of contaminated matrices, both in situ in deep subsurfaces, or ex situ in bioreactors. In the latter, part of the energetic value of these compounds can be recovered in the form of biogas. Anaerobic degradation of petroleum hydrocarbons can be improved by various iron compounds, but different iron species exert distinct effects. For example, Fe(III) can be used as an electron acceptor in microbial hydrocarbon degradation, zero-valent iron can donate electrons for enhanced methanogenesis, and conductive iron oxides may facilitate electron transfers in methanogenic processes. Iron compounds can also act as hydrocarbon adsorbents, or be involved in secondary abiotic reactions, overall promoting hydrocarbon biodegradation. These multiple roles of iron are comprehensively reviewed in this paper and linked to key functional microorganisms involved in these processes, to the underlying mechanisms, and to the main influential factors. Recent research progress, future perspectives, and remaining challenges on the application of iron-assisted anaerobic hydrocarbon degradation are highlighted.

Characterization and Modification of Red Mud and Ferrosilicomanganese Fines and Their Application in the Synthesis of Hybrid Hydrogels

In this work, hybrid hydrogels were synthesized with the inclusion of two types of clay materials that are considered industrial waste: red mud (RM) and ferrosilicomanganese fines (FeSiMn). These solid waste materials were characterized by studying their particle size and chemical composition, which are two key variables for their application in the synthesis of hybrid hydrogels. The morphology imaged by transmission electron microscopy (TEM) and scanning electron microscopy (SEM), showed, in the case of RM, heterogeneous size and shape particles, with 73% of the particles having lengths of less than 5 μm. On the other hand, FeSiMn had particles with a circular morphology of nanometric sizes. Regarding the synthesis of the hybrid hydrogels, it was determined that the incorporation of small percentages (0.1%) of the inorganic phases improved the capacity of the materials to absorb water (swelling indices of 1678% and 1597% for the RM and FeSiMn hydrogels, respectively) compared to the conventional polyacrylamide hydrogel (1119%). An improvement in Vickers microhardness and storage modulus (G') was also observed: the hybrid with 10% RM presented a G', 50 times higher than conventional hydrogel. The results show the merit of RM and FeSiMn in improving the properties of hydrogels.

Physical and chemical separation of Ti, rare earth elements, Fe, and Al from red mud by carbothermal reduction, magnetic separation, and leaching

In this study, a combination of physical and chemical separation processes was used to recover the metallic components of red mud. At first, the impact of carbothermal reduction on magnetic separation of iron was studied. Low magnetic properties of iron minerals resulted in insignificant separation of iron from other components in the non-carbothermally reduced sample. Various carbothermal reduction parameters were optimized to maximize iron separation from other components. The optimum conditions were found T = 1350 °C, t = 120 min, coal/red mud ratio of 3, reaction time of 120 min, and the soda ash/red mud ratio of 0.2. Under the optimum condition, the iron recovery of the magnetic product was observed 91% with 81% Fe content, while the non-magnetic product has contained 90% of Ti and Al and 80% of rare earth elements (REEs). Following the physical separation of iron, the chemical separation of remaining red mud components was investigated using leaching with sulfuric, hydrochloric, and nitric acids. The leaching experiments were performed on two samples, treated red mud with carbothermal reduction and an untreated sample. The untreated sample had a higher dissolution efficiency for Ti and REEs than the carbothermally reduced sample. Different dissolution behavior of the red mud components was explained by samples' mineralogy. In the end, considering the obtained results, various scenarios for the recovery of red mud components were evaluated from technical and environmental aspects.

Research on Bayer Red Mud Slurry Electrolysis

The Bayer red mud is the solid waste generated during the production of alumina by the Bayer process. At present, the stock of red mud in China exceeds 1.1 billion tons, covering an area of more than 120,000 mu, and the annual production volume is increasing by 100 million tons. The comprehensive utilization of red mud is still a difficult problem. Therefore, it is of great significance to actively explore new methods for removing sodium from red mud. In this study, the traditional red mud desalination process and the slurry electrolysis process are combined, and the influence of three different leaching agents on the leaching and sodium removal of red mud slurry in the presence of an electric field is explored. In the slurry electrolysis experiment, it was found that the sodium removal rate obtained by different leaching agents was CaO > CaCl₂ > HCl. The red mud leached with pure dilute hydrochloric acid has the highest Na removal rate, which is 93.11%. In view of this situation, a pre-slurry-electrolysis cycle process with HCl as leaching agent was proposed. The core of slurry electrolysis is electrolyzing NaCl solution, and HCl only participates in the process as circulating medium. The design of this process reduces cost and increases efficiency.

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.

Utilization of Modified Red Mud Waste from the Bayer Process as Subgrade and Its Performance Assessment in a Large-Sale Application

The utilization of red mud waste discharged from the Bayer production process used for extracting alumina from bauxite presents a pressing demand in the aluminum industry. This study aims to adopt a chemical modifier to solidify the Bayer red mud for its application in highway subgrade. The mechanism and properties of the modified red mud using a modifier composed of cement, phosphogypsum and organic polymer, were analyzed and investigated. It was found that the optimal modifier dosage of the solidified modifier was 8%. The three-day unconfined compressive strength of the modified Bayer red mud could reach up to 3 MPa and its strength loss when immersed in water at 7 days and 28 days measured less than 20%. For its real application as subgrade, its road performance could be achieved with good bearing capacity, including a resilient modulus value greater than 90 MPa, a dynamic deformation modulus reaching up to 140 MPa and the Falling Weight Deflectometer (FWD) value measuring less than 100 (0.01 mm). Compared with traditional lime or cement stabilized soil, using locally modified Bayer red mud for subgrade filling can reduce the project cost, minimize the consumption of non-renewable resources and reduce the emission of environmental hazards, thus providing an engineering reference for large-scale and resource-based road applications.

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.

Sustainable biodiesel generation through catalytic transesterification of waste sources: a literature review and bibliometric survey

Sustainable renewable energy production is being intensely disputed worldwide because fossil fuel resources are declining gradually. One solution is biodiesel production via the transesterification process, which is environmentally feasible due to its low-emission diesel substitute. Significant issues arising with biodiesel production are the cost of the processes, which has stuck its sustainability and the applicability of different resources. In this article, the common biodiesel feedstock such as edible and non-edible vegetable oils, waste oil and animal fats and their advantages and disadvantages were reviewed according to the Web of Science (WOS) database over the timeframe of 1970–2020. The biodiesel feedstock has water or free fatty acid, but it will produce soap by reacting free fatty acids with an alkali catalyst when they present in high portion. This reaction is unfavourable and decreases the biodiesel product yield. This issue can be solved by designing multiple transesterification stages or by employing acidic catalysts to prevent saponification. The second solution is cheaper than the first one and even more applicable because of the abundant source of catalytic materials from a waste product such as rice husk ash, chicken eggshells, fly ash, red mud, steel slag, and coconut shell and lime mud. The overview of the advantages and disadvantages of different homogeneous and heterogeneous catalysts is summarized, and the catalyst promoters and prospects of biodiesel production are also suggested. This research provides beneficial ideas for catalyst synthesis from waste for the transesterification process economically, environmentally and industrially.

Sustainable renewable energy production is being intensely disputed worldwide because fossil fuel resources are declining gradually.

Dealkalization and Leaching Behavior of Fe, Al, Ca, and Si of Red Mud by Waste Acid from Titanium White Production

Dealkalization is the necessary step for the multipurpose use of red mud (RM), and acid leaching is a productive method to realize the dealkalization of RM. Most researches focus on recovering metals from the highly alkaline waste by pure acid leaching or stabilization by dealkalization. In this study, according to the strong alkalinity of RM and strong acidity of the waste acid from titanium dioxide production, the waste acid was used for the dealkalization of RM. The effects of leaching temperature, reaction time, the concentration of waste acid, liquid-solid ratio (L/S), and stirring rate on the dealkalization of RM were investigated, and the main metal ions in the dealkalization solution were analyzed. The results show that the leaching ratio of sodium can reach 92.3591% when the leaching temperature is 30 °C, the reaction time is 10 min, the concentration of waste acid is 0.6238 mol/L, the L/S is 4:1, and the stirring rate is 300 rpm. The residual alkali content in the treated RM is 0.2674%, which is a reduction to less than 1%. The phase analysis results show that the sodalite and cancrinite in RM are dissolved, decomposed, and transformed after acid leaching. Therefore, RM meets the requirements of building materials after dealkalization, which provides further development as building material products.

Environmental Safety Analysis of Red Mud-Based Cemented Backfill on Groundwater

As one of the main industrial solid wastes, there are a large number of free alkaloids, chemically bound alkaloids, fluoride, and heavy metal ions in Bayer process red mud (BRM), which are difficult to remove and easily pollute groundwater as a result of open storage. In order to realize the large-scale industrial application of BRM as a backfilling aggregate for underground mining and simultaneously avoid polluting groundwater, the material characteristics of BRM were analyzed through physical, mechanical, and chemical composition tests. The optimum cement–sand ratio and solid mass concentration of the backfilling were obtained based on several mixture proportion tests. According to the results of bleeding, soaking, and toxic leaching experiments, the fuzzy comprehensive evaluation method was used to evaluate the environmental impact of BRM on groundwater. The results show that chemically bound alkaloids that remained in BRM reacted with Ca²⁺ in PO 42.5 cement, slowed down the solidification speed, and reduced the early strength of red mud-based cemented backfill (RMCB). The hydration products in RMCB, such as AFT and C-S-H gel, had significant encapsulation, solidification, and precipitation inhibition effects on contaminants, which could reduce the contents of inorganic contaminants in soaking water by 26.8% to 93.8% and the leaching of toxic heavy metal ions by 57.1% to 73.3%. As shown by the results of the fuzzy comprehensive evaluation, the degree of pollution of the RMCB in bleeding water belonged to a medium grade Ⅲ, while that in the soaking water belonged to a low grade II. The bleeding water was diluted by 50–100 times to reach grade I after flowing into the water sump and could be totally recycled for drilling and backfilling, thus causing negligible effects on the groundwater environment.

Mechanistic study on calcium ion diffusion into fayalite: A step toward sustainable management of copper slag

Copper slag, which contains Fe-rich fayalite (Fe₂SiO₄), is a valuable solid waste that warrants further research in order to recover iron. Calcium oxide (CaO) can significantly enhance iron recovery from copper slag; however, the associated mechanism has not yet been explored. In this study, we investigated the interaction between CaO and Fe₂SiO₄ to obtain detailed understanding of the role of CaO in enhancing iron recovery. The presence of CaO was found to accelerate the decomposition of Fe₂SiO₄ via an ion-exchange-like process. Specifically, CaO dissociated into Ca(II) and a Ca-deficient Ca_1-yO species at high temperatures. The Fe(II) ion at the M2 site of Fe₂SiO₄ was substituted by the released Ca(II) ion, resulting in the formation of [(Fe_(2-x)Ca_x)SiO₄]∙xFe(II). Subsequently, the substituted Fe(II) occupied the Ca vacancy in Ca_1-yO to form (Ca_(1-y)Fe(II)_y)O. The disproportionation of Fe(II) and the combination reaction between CaO and the SiO₂ separated from Fe₂SiO₄ led to the generation of the final products, viz. Fe₂O₃, Fe₃O₄, and CaSiO₃. This study explains the specific role of CaO in decomposing Fe₂SiO₄. It would not only provide theoretical guidance for iron recovery from copper slag but also present a new perspective on the recycling of valuable resources from many other smelting slags (e.g., iron slag, lead slag, and nickel slag).

Environmentally benign solid catalysts for sustainable biodiesel production: A critical review

Versatile bio-derived catalysts have been under dynamic investigation as potential substitutes to conventional chemical catalysts for sustainable biodiesel production. This is because of their unique, low-cost benefits and production processes that are environmentally and economically acceptable. This critical review aspires to present a viable approach to the synthesis of environmentally benign and cost-effective heterogeneous solid-base catalysts from a wide range of biological and industrial waste materials for sustainable biodiesel production. Most of these waste materials include an abundance of metallic minerals like potassium and calcium. The different approaches proposed by researchers to derive highly active catalysts from large-scale waste materials of a re-usable nature are described briefly. Finally, this report extends to present an overview of techno-economic feasibility of biodiesel production, its environmental impacts, commercial aspects of community-based biodiesel production and potential for large-scale expansion.

Physical and thermal insulation properties of the composites based on seawater-neutralised bauxite residue

The objective of this study is to evaluate the possibility of using bauxite residue (BR), which is a highly hazardous waste, as a filler in thermoset polymer matrices for applications in insulating construction materials to minimise heat loss in buildings. Unsaturated polyester resin (UPR) blended with the seawater-neutralised BR in a ratio of 0-60 vol.% was transformed into a solid via a crosslinking process at room temperature. The pristine polyester and BR-UPR composites were characterised to ascertain their structural, physical and thermal properties. The results indicate that BR is a good filler that can be used with UPR to develop thermal insulation/construction materials. The UPR composite containing 40 vol.% BR is considered to be the optimum mixture with respect to the tested physical and thermal properties because it utilises a large amount of filler and shows promising thermal insulation characteristics with a thermal conductivity of 0.096 W/(m∙K), a thermal diffusivity of 0.161 mm²/s, a 24-h water retention of 0.15 % and a bulk density of 1484 kg/m³. Furthermore, the thermal stability of the prepared composites is positively influenced by the incorporation of BR. The overall weight loss upon heating to 900 °C decreased from 99.85 % (pristine polyester) to 46.68 % (60 vol.% BR composite).

Dealkalization processes of bauxite residue: A comprehensive review

Bauxite residue is a kind of strong alkaline waste produced in the production of alumina. Its long-term storage poses a potential threat to the environment. With the tightening of environment policies in various countries, the strong alkalinity of bauxite residue has become a bottleneck restricting the sustainable development of aluminum industry all over the world. This review covers the composition characteristics of bauxite residue, and describes the Bayer process in detail, where emphasis is put on the formation of alkaline substances in bauxite residue and its release process in long-term storage. This review focuses on several typical processes for the management of bauxite residue alkalinity in recent decades around the world. The phase transformation mechanisms, merits and limitations, as well as application status are discussed. The potential application values of these typical methods are evaluated based on process characteristics. The large amount and varied characteristics of bauxite residue determine that it is unrealistic to solve the dealkalization problem of all bauxite residue with one method. It is recommended that the appropriate dealkalization process of bauxite residue should be selected according to the characteristics of bauxite residue and regional resources, as well as the planning of subsequent application.

Preparation and Physico-Chemical Performance Optimization of Sintering-Free Lightweight Aggregates with High Proportions of Red Mud

Sintering-free lightweight aggregates were prepared with high proportions of red mud and a binder material derived from whole solid wastes through rolling granulation at room temperature. The preparation process was optimized by changing the material matching and size parameters of the SFLAs. The physico-chemical performance, including the density, mechanical strength, water absorption, hydration products, heavy metal leaching, and microstructure were evaluated by jointly employing X-ray Fluorescence, X-ray Diffraction, and Inductively Coupled Plasma Optical Emission Spectrometry, Shadow Electron Microscope, etc. The results indicated that the red mud and waste-based binders were highly compatible in the granulation process, with up to 80% red mud being successfully added. The sintering-free lightweight aggregates products at the binder content of 30% and the size coverage of 10-16 mm exhibited a bulk density of 900-1000 kg·m-3, a 28 d cylinder compressive strength of 9.2-11.3 MPa, and water absorption of less than 10%. Owing to the formation of important hydration products, ettringite, the heavy metal leaching of the sintering-free lightweight aggregates was also proven to be environmentally acceptable. This work provides a promising pathway to prepare low-cost, high-strength, and green lightweight aggregates through the large-scale utilization of solid waste red mud.

Influence of Sodium Sulfate Addition on Iron Grain Growth during Carbothermic Roasting of Red Mud Samples with Different Basicity

Red mud is an iron-containing waste of alumina production with high alkalinity. A promising approach for its recycling is solid-phase carbothermic roasting in the presence of special additives followed by magnetic separation. The crucial factor of the separation of the obtained iron metallic particles from gangue is sufficiently large iron grains. This study focuses on the influence of Na2SO4 addition on iron grain growth during carbothermic roasting of two red mud samples with different (CaO + MgO)/(SiO2 + Al2O3) ratio of 0.46 and 1.21, respectively. Iron phase distribution in the red mud and roasted samples were investigated in detail by Mössbauer spectroscopy method. Based on thermodynamic calculations and results of multifactorial experiments, the optimal conditions for the roasting of the red mud samples with (CaO + MgO)/(SiO2 + Al2O3) ratio of 0.46 and 1.21 were duration of 180 min with the addition of 13.65% Na2SO4 at 1150 °C and 1350 °C followed by magnetic separation that led to 97% and 83.91% of iron recovery, as well as 51.6% and 83.7% of iron grade, respectively. The mechanism of sodium sulfate effect on iron grain growth was proposed. The results pointed out that Na2SO4 addition is unfavorable for the red mud carbothermic roasting compared with other alkaline sulfur-free additives.

A review on approaches for hazardous organics removal from Bayer liquors

Alumina is a valuable raw material for the production of adsorbents, abrasives, polishing agents, refractory materials, and aluminum. It is generally produced from bauxites through the Bayer process. Several organic compounds such as humic matters and oxalates are introduced into the Bayer liquor during the digestion process, resulting in significant hazards to precipitation of aluminum hydroxide. Therefore, it is crucial to remove these organic compounds from Bayer liquor to enhance the production of alumina. It is difficult to remove these organic compounds. Various approaches for organics removal from Bayer liquors have been developed in the past few decades, including thermal treatment, chemical precipitation, membrane technology, photocatalytic degradation, biodegradation, and wet oxidation. This paper reviews the technologies for organics removal from Bayer liquor and the relative mechanisms proposed in the literature to identify its essential parameters. Chemicals dosage, temperature, pH value, reaction time, and solution concentration are essential factors in the process. Removal efficiency, green principle, and economic viability of various methods are discussed, and potential technologies are suggested. Wet oxidation appears to be a promising method for removing organic matters in Bayer liquors. Moreover, the combination of wet oxidation and electrooxidation shows excellent potential in organics removal. Various approaches for removing organic compounds and perspectives for further investigation are proposed.

Progress on the Industrial Applications of Red Mud with a Focus on China

Red mud (RM), also called bauxite residue, is a strong alkaline industrial waste generated during the alumina production process. The annual production of RM in China is large, but its average utilization rate is low (only 4%). High generation and low consumption make the disposal of RM mainly by stockpiling, which has caused serious heavy metal pollution and radioactive contamination. In this paper, the various industrial utilization methods of RM in China during the past 60 years have been introduced. Moreover, some recent industrial progresses were referred. The results show that RM can be widely used in building materials, valuable metals extraction, and some novel utilization methods, such as silica-calcium fertilizer, inorganic polymer material and desulfurizer. Most of the industrial utilization methods of RM have been used until now and some successfully applied to other aluminum plants, providing some feasible routes for a large amount utilization of RM. Some industrial utilization methods (such as oil well cement and calcium silicon fertilizer) have not been used due to some problems that cannot be ignored, but it provided a lot of valuable experience and was helpful for the subsequent RM utilization. Moreover, some novel and feasible RM utilization methods were proposed and successfully industrialized, which showed that RM has a broader application prospect. Many actual practices showed that the best way to safely dispose of RM was to develop technology that could consume large amounts of RM or transform it into secondary resources, which may need more time and effort.

Lightweight carbon-red mud hybrid foam toward fire-resistant and efficient shield against electromagnetic interference

Lightweight, porous, high-performance electromagnetic interference (EMI) shielding and fire-resistant materials are highly demanded in aerospace and defense applications. Due to the lightweight, open porosity and high surface area, carbon foam has been considered as one of the most promising candidates for EMI shielding applications. In the present investigation, we demonstrate the development of novel carbon-red mud hybrid foams with excellent EMI shielding effectiveness (SE). The carbon-red mud hybrid foams are prepared using phenolic resin as a carbon source and red mud (industrial waste) as filler. We observed that the inclusion of red mud in carbon-red mud hybrid foams significantly enhances their dielectric, magnetic, EMI shielding and thermal properties. The EMI shielding results show that absorption is the main contributor to the total EMI SE. The maximum total EMI shielding effectiveness is achieved to be 51.4 dB in the frequency range of 8.2–12.4 GHz for carbon-red mud hybrid foam having 20 wt. % of red mud. The CF-RM20 also showed excellent fire resistance and high thermal stability at elevated temperatures.

Recovery of Fe and Al from red mud by a novel fractional precipitation process

The development of cheap and effective approach for utilizing red mud (RM) waste is a long and arduous task. This work provided a technically and economically feasible route to utilize RM waste for the production of high valuable chemicals by use of the industrial wastes as cheap raw materials. The Fe and Al elements were first leached from RM through hydrothermal reaction and then were separated by precipitation after the Fe(III) in leachate was reduced to Fe(II) by iron powder. Above 90% Fe and Al were extracted from RM with the Fe and Al purity of about 95% and 45%, respectively. The control test revealed that the main impurity of Al product was caused by the adsorbed SO₄^2- during the precipitation of the Al³⁺. The structural characterization demonstrated that the obtained Fe products were in nanoscale, and the Ti-Si residue has high BET area of 203.7 m²/g. Four products of nano-Fe₃O₄/nano-Fe, aluminum oxide, Ti-Si residue, and (NH₄)₂SO₄ were obtained as valuable chemical materials for industry. This demonstrated utilization of industrial waste to produce high added-value products with high efficiency and low cost will possess promising application prospect for the resource utilization of RM in industry.

Removal of Cr (Ⅲ) from aqueous solution by using bauxite residue (red mud): Identification of active components and column tests

Bauxite residue is the by-product of the aluminium industry with an annual output of more than 200 million metric tons in China. Its treatment is still a big problem because more than 96% of that is stockpiled on land causing environmental pollution and threatening the human health. This study used bauxite residue to remove Cr (Ⅲ) from aqueous solution and analyzed the removal mechanism. The removal time was dependent on the initial concentrations of Cr (Ⅲ) and different active components acted on different reaction period. Reaction time increased from <5 min to >2 h with an increase of Cr (Ⅲ) concentration from 5 to 100 and 170 mg/L. The existing forms of adsorbed-Cr were iron oxide-bound Cr (40.80%-87.85%), sulfide-bound Cr (4.04%-20.28%) and residue (6.60%-33.72%). All the components started to react as soon as bauxite residue was added. Cr did not precipitate in the presence of high alkalinity bauxite residue due to the slow release of alkalinity maintaining pH < 6, thus producing Cr(OH)²⁺, Cr₂(OH)₂⁴⁺ and Cr₃(OH)₄⁵⁺ by hydrolysis without precipitation. Fe₂O₃ and Al-containing components were the main active phases for Cr (Ⅲ) removal, with the reaction time lasting more than 2 h and producing Ca₆Al₄Cr₂O₁₅, AlCr₂, (Si, Al)₂O₄, Fe(Cr, Al)₂O₄, FeCr₂Si₃O₁₂, MgCr_0·1Fe_1·9O₄ and MgCr_0·4Fe_1·6O₄. Finally, bauxite residue was granulated and used for column tests. Cr (Ⅲ) wastewater (1 and 50 mg/L) was treated and the effluent can meet the first level of the Shanghai standard (0.1 mg/L) defined by Integrated Wastewater Discharge Standard (DB 31/199-2009).

Iron Recovery from Bauxite Tailings Red Mud by Thermal Reduction with Blast Furnace Sludge

More than 100 million tons of red mud were produced annually in the world over the short time range from 2011 to 2018. Red mud represents one of the metallurgical by-products more difficult to dispose of due to the high alkalinity (pH 10–13) and storage techniques issues. Up to now, economically viable commercial processes for the recovery and the reuse of these waste were not available. Due to the high content of iron oxide (30–60% wt.) red mud ranks as a potential raw material for the production of iron through a direct route. In this work, a novel process at the laboratory scale to produce iron sponge (≤ 1300 °C) or cast iron (> 1300 °C) using blast furnace sludge as a reducing agent is presented. Red mud-reducing agent mixes were reduced in a muffle furnace at 1200, 1300, and 1500 °C for 15 min. Pure graphite and blast furnace sludges were used as reducing agents with different equivalent carbon concentrations. The results confirmed the blast furnace sludge as a suitable reducing agent to recover the iron fraction contained in the red mud. For all the conditions tested, the metallization degree was higher than 70%, and the best condition to reduce red mud through blast furnace sludge was identified at 1:1 red mud/blast furnace (B.F.) sludges equal to 0.85 C/Fe2O3.

Recovery of scandium from Canadian bauxite residue utilizing acid baking followed by water leaching

The current study put the emphasis on developing a novel and environmentally friendly waste valorization process, called "acid-baking water-leaching", to recover scandium from bauxite residue produced by the aluminum industry. In this process, bauxite residue is mixed with concentrated sulfuric acid, baked in a furnace at 200-400 °C, and leached in water at ambient conditions. Compared with direct acid leaching processes, the developed process offers the advantages of less acid consumption, less wastewater generation, and fast kinetics. With fundamental investigation into the reaction mechanism, acid baking temperature was shown to be the controlling factor that dictates the final phases of the process. Baking at 200 °C results in the formation of (H₃O)Fe(SO₄)₂ that leaches in water rapidly (<5 min), but extraction efficiency is low (58% scandium). In contrast, baking at 400 °C results in the formation of Fe₂(SO₄)₃ that leaches at slower kinetics (>45 min), but results in higher extraction efficiency (80% scandium). The acid baking water leaching process proves to be a promising technique as the first step of a potential near-zero-waste integrated process for the sustainable valorization of bauxite residue to help build the circular economy.

A Review on Comprehensive Utilization of Red Mud and Prospect Analysis

Red mud (RM) is a by-product of extracting of alumina from bauxite. Red mud contains high quantities of alkali-generating minerals and metal ions, which can cause significant environmental damage. Many valuable components such as rare-earth elements, Al, and Fe, in RM are difficult to be utilized owing to their particle size and alkalinity. Thus, developing an economical and efficient technology to consume a large amount of RM can efficiently solve RM disposal issues. This paper systematically reviews the comprehensive utilization methods for reducing RM environmental pollution and divides the comprehensive utilization of RM into three aspects: the effective extraction of valuable components, resource transformation, and environmental application. Based on resource, economic, and environmental benefits, the development of new technologies and new processes with market competitiveness, environmental protection, and ecological balance should be the prerequisite for the low-energy, low-pollution, low-cost, and high-efficiency comprehensive utilization of RM. The direction of future research to solve RM disposal issues is also suggested.

Engineered biochar composite fabricated from red mud and lipid waste and synthesis of biodiesel using the composite

Co-pyrolysis of lipid waste and red mud was investigated to achieve valorization of red mud by fabricating biochar composite. For the further sustainable approach, this study intentionally employed carbon dioxide (CO₂) as reaction medium in the co-pyrolysis process. The use of CO₂ on co-pyrolysis of lipid waste and red mud enabled manipulation of the carbon distributions between pyrogenic products. CO₂ expedited the thermal cracking of lipid waste and further reacted with lipid waste during the thermolysis. These mechanistic roles of CO₂ were catalytically enhanced by the presence of mineral phases (Fe₂O₃) in red mud, thereby resulting in the enhanced formation of CO (40 times more at 550 °C). However, CO₂ suppressed dehydrogenation of lipid waste (∼ 50%), which resulted in the different pathway for reducing iron oxide in red mud. Moreover, as an aspect of valorization of red mud, catalytic capability of biochar composite was evaluated. As a case study, biodiesel (FAMEs) were synthesized, and all experimental findings suggested that biochar composite could be an effective catalyst for biodiesel synthesis. As compare to biodiesel synthesis using silica (92% yield at 360 °C), the equivalent biodiesel yield was achieved with the biochar at much lower temperature (130 °C).

Effects of red mud on emission control of NOx precursors during sludge pyrolysis: A protein model compound study

The nitrogen-containing gases pyrolyzed from sewage sludge can be converted into NO_x compounds, which would cause severe environmental pollution. This study developed a new strategy to reduce the emission of NO_x precursors such as ammonia (NH₃) and hydrogen cyanide (HCN) using red mud. The highest reduction efficiencies (15.10% for NH₃ and 24.72% for HCN) were achieved at 900 °C while compared with those pyrolyzed from raw sludge without the addition of red mud. The transformation and distribution of nitrogenous compounds in three-phase pyrolysates were studied at 400-800 °C for pyrolysis process of a model soybean protein compound. The nitrogenous compounds, i.e., amine-N, heterocyclic-N, and nitrile-N, were identified as the three main intermediates related with the production of NO_x precursors. Ferric oxide (Fe₂O₃) and calcium oxide (CaO) presented in red mud were identified as the driving force which facilitated nitrogen stabilization in char (e.g., at 800 °C, 21.63% increase of char-N after addition of Fe₂O₃, and 41.54% increase of char-N after addition of CaO). These metal oxides possibly reacted with protein-N to form Fe_xN and CaC_xN_y, inhibited the secondary cracking of amine-N compounds in tar (e.g., at 800 °C, 2.33% increase of amine-N after addition of Fe₂O₃, and 0.38% increase of amine-N after addition of CaO), and reduced the production of nitrile-N (e.g., at 800 °C, 30.41% reduction of nitrile-N after addition of Fe₂O₃, and 27.40% reduction of nitrile-N after addition of CaO) and heterocyclic-N compounds (e.g., at 800 °C, 21.60% reduction of heterocyclic-N after addition of Fe₂O₃, and 13.98% reduction of heterocyclic-N after addition of CaO). Hence, the emission of NH₃ and HCN in gas phase can be controlled. Moreover, Fe₂O₃ showed better capability in controlling the emission of NO_x precursors than CaO (higher reduction of NH₃-N and higher reduction of HCN-N). These results indicate that red mud is an efficient catalyst to reduce emission of NO_x precursors through controlling intermediates at 400-800 °C.

Increased As Adsorption on Maghemite-Containing Red Mud Prepared by the Alkali Fusion-Leaching Method

This study investigates the use of red muds as adsorbents for As (V) removal. Red mud is a waste that contains a large amount of iron oxides and hydroxides, which are excellent adsorbents of arsenic, especially those possessing magnetic properties and a large specific surface area. The purpose of the experiments was to study the possibility of obtaining an effective adsorbent by the direct extraction of alumina from bauxite using the caustic alkali fusion method and to compare the arsenic removal effectiveness and other properties of these red muds with industrial samples. Red muds were described using methods such as X-ray diffraction spectrometry (XRD), X-ray fluorescence spectrometry (XRF), SEM, vibrating sample magnetometry (VSM), and the Brunauer–Emmett–Teller (BET) method. The main iron-containing phase of the red muds obtained by fusing bauxite with caustic alkali is maghemite, which has a large specific surface area. The specific surface area of the obtained samples varied in the range of 6.1–54.9 m2/g. Arsenic adsorption experiments were carried out using five different types of red muds: industrial Bayer, industrial sintering, and red mud obtained through bauxite alkali fusion at 300, 500, and 700 °C. The red muds obtained by fusing bauxite with caustic alkali at 300 and 500 °C had the highest effectiveness removing arsenic; their As(V) uptake capacity was over 30 mg/g.

Hazardous aluminum dross characterization and recycling strategies: A critical review

By finding appropriate recycling approaches, the volume of wastes, corresponding disposal cost, and the pollution of environment could be diminished. Also, such promising approaches can result in the conservation of natural sources and economic benefits. Aluminum dross as a hazardous solid waste in aluminum production industries has caused serious environmental and public health challenges. Various methods have been introduced for management, utilization, and recycling of the waste. The present review describes, firstly, different types of aluminum dross, their environmental and health hazards, composition, and production process and then focuses on the direct and indirect recycling approaches and recovery strategies.

Recovery of tailings from the vanadium extraction process by carbothermic reduction method: Thermodynamic, experimental and hazardous potential assessment

A cleaner process is tremendously required to deal with the vanadium tailings, which may cause serious environmental problem due to the high content of water soluble hazardous elements such as V and Cr. This problem can be possibly solved by proposed high temperature reduction-magnetic separation process, in which, V, Cr and Fe can be recycled as ferroalloy. The thermodynamic calculation results reveal that a higher temperature (>1127.8 °C) promotes the reduction of Fe, V and Cr, and improves the recovery rates of V and Cr in liquid iron. The reduction behavior of vanadium tailings was investigated using XRD, TG/DSC, SEM, EDS and ICP-OES techniques. The EDS results show that a small portion of V was remained in the slag phase when roasted at 1300 °C, while nearly all of V and Cr can concentrate in ferroalloy at 1400 °C. Approximatly 90% of V and 95% of Cr recovery in magnetic fraction can be obtained for the magnetic separation step. A small portion of V and Cr is remained in the non-magnetic final tailings, however, the hazardous potential assessments results indicate that such kind of tailings can safely use as secondary materials or stockpiled as an end-waste.

Re-using bauxite residues: benefits beyond (critical raw) material recovery

Since the world economy has been confronted with an increasing risk of supply shortages of critical raw materials (CRMs), there has been a major interest in identifying alternative secondary sources of CRMs. Bauxite residues from alumina production are available at a multi-million tonnes scale worldwide. So far, attempts have been made to find alternative re-use applications for bauxite residues, for instance in cement / pig iron production. However, bauxite residues also constitute an untapped secondary source of CRMs. Depending on their geological origin and processing protocol, bauxite residues can contain considerable amounts of valuable elements. The obvious primary consideration for CRM recovery from such residues is the economic value of the materials contained. However, there are further benefits from re-use of bauxite residues in general, and from CRM recovery in particular. These go beyond monetary values (e.g. reduced investment / operational costs resulting from savings in disposal). For instance, benefits for the environment and health can be achieved by abatement of tailing storage as well as by reduction of emissions from conventional primary mining. Whereas certain tools (e.g. life-cycle analysis) can be used to quantify the latter, other benefits (in particular sustained social and technological development) are harder to quantify. This review evaluates strategies of bauxite residue re-use / recycling and identifies associated benefits beyond elemental recovery. Furthermore, methodologies to translate risks and benefits into quantifiable data are discussed. Ultimately, such quantitative data are a prerequisite for facilitating decision-making regarding bauxite residue re-use / recycling and a stepping stone towards developing a zero-waste alumina production process. © 2018 The Authors. Journal of Chemical Technology & Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.

Applications of bauxite residue: A mini-review

Bauxite residue is the waste generated during alumina production by Bayer's process. The amount of bauxite residue (40-50 wt%) generated depends on the quality of bauxite ore used for the processing. High alkalinity and high caustic content in bauxite residue causes environmental risk for fertile soil and ground water contamination. The caustic (NaOH) content in bauxite residue leads to human health risks, like dermal problems and irritation to eyes. Moreover, disposal of bauxite residue requires a large area; such problems can only be minimised by utilising bauxite residue effectively. For two decades, bauxite residue has been used as a binder in cement industries and filler/reinforcement for composite materials in the automobile industry. Valuable metals and oxides, like alumina (Al₂O₃), titanium oxide (TiO₂) and iron oxide Fe₂O₃, were extracted from bauxite residue to reduce waste. Bauxite residue was utilised in construction and structure industries to make geopolymers. It was also used in the making of glass-ceramics and a coating material. Recently bauxite residue has been utilised to extract rare earth elements like scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), neodymium (Nd) and dysprosium (Dy). In this review article, the mineralogical characteristics of bauxite residue are summarised and current progresses on utilisation of bauxite residue in different fields of science and engineering are presented in detail.

Study on dealkalization and settling performance of red mud

At present, the dealkalization and comprehensive utilization of red mud is a worldwide problem. Studies on the settling performance and phase transformation of red mud by HCl, CaO, and H₂O leaching are limited. In this study, the characteristics of red mud were systematically analyzed. The average sizes of graded and initial red mud were 4.11 and 9.20 μm, respectively. X-ray diffraction (XRD), X-ray fluorescence spectra (XRF), and thermogravimetry-differential scanning calorimetry (TG-DSC) results indicated the different mineralogical phases, composition, and thermal behavior. The addition of HCl could neutralize the alkalization in the red mud slurry, and CaO could replace the Na and K. Notably, the pH of the red mud slurry had no obvious change with the increase in water washing times in a certain pH. Interestingly, soluble Al and Fe were not detected in the HCl-red mud and CaO-red mud. In addition, the settling ratio was used to express the settling performance of the red mud slurry. Their interaction mechanisms were proposed, which may include phase transformation and the changing of the size and surface area. The research provided a better understanding of the phase transformation and settling performance in the treatment of red mud by HCl, CaO, and H₂O leaching.

Calcification-carbonation method for red mud processing

Red mud, the Bayer process residue, is generated from alumina industry and causes environmental problem. In this paper, a novel calcification-carbonation method that utilized a large amount of the Bayer process residue is proposed. Using this method, the red mud was calcified with lime to transform the silicon phase into hydrogarnet, and the alkali in red mud was recovered. Then, the resulting hydrogarnet was decomposed by CO2 carbonation, affording calcium silicate, calcium carbonate, and aluminum hydroxide. Alumina was recovered using an alkaline solution at a low temperature. The effects of the new process were analyzed by thermodynamics analysis and experiments. The extraction efficiency of the alumina and soda obtained from the red mud reached 49.4% and 96.8%, respectively. The new red mud with <0.3% alkali can be used in cement production. Using a combination of this method and cement production, the Bayer process red mud can be completely utilized.

Effects of thermal treatments on the characterisation and utilisation of red mud with sawdust additive

Extremely large amounts of red mud (bauxite residue) are generated globally every year from alumina refining industries, which are being disposed of on engineered landfills. The objective of this study is to investigate the effects of thermal treatments on red mud for development of utilisation strategies. Thermal treatments of red mud samples and their characterisations were investigated under inert (N2) and oxidative (air) conditions with and without sawdust addition at 200-600°C. After calcination, the resulting samples were analysed using thermogravimetric-infrared spectroscopy (TG-IR) for functional group transformations, thermogravimetric analysis (TGA) for thermal loss profiles and X-ray diffraction (XRD) for mineral transformations. The characterisation results showed that in N2 environment, boehmite in red mud was transferred to transition alumina at around 400°C while losing water from structural components. The addition of sawdust for incubation and calcination of red mud in air increased the surface area, whereas that in nitrogen atmosphere lead to reduction of hematite to magnetite at around 500°C. The incorporated carbon materials played a major role in increasing the surface area especially for pore size less than 2.5 nm. This treated red mud with altered mineral composition and improved properties for binding contaminants can be used for environmental remediation and in the process of metal recovery such as iron.