Competitive removal of water-borne copper, zinc and cadmium by a CaCO3-dominated red mud

Trends in research on characterization, treatment and valorization of hazardous red mud: A systematic review

Meta-analysis of red mud-related literature in English published from 1976 to 2022 and in Chinese from 1990 to 2022 was performed to support critical analysis and evaluation of the available literature based on the following aspects of red mud research: (a) characterization, (b) treatment for harmfulness minimization, (c) recovery of valuable metals, (d) environmental applications, and (e) uses as construction materials. It was found that (a) sinter red mud tended to contain more silica and calcium, and less iron, sodium and aluminium compared to Bayer red mud; (b) gypsum was the most frequently used agent for harmfulness reduction treatment of red mud, followed by flue gas/CO2; (c) the mean optimal pH for adsorption of major anionic pollutants was 8.42 ± 1.13 (arsenite), 3.73 ± 0.68 (arsenate), 3.50 ± 2.38 (phosphate), 4.43 ± 1.04 (fluoride) and 3.80 ± 1.54 (chromate); (d) wastewater treatment has attracted more attention compared to contaminated soils and waste gases; (e) recovery of iron and scandium has attracted more attention compared to other metals; (f) cement making has been the focus in construction uses. Most of the research findings were based on laboratory-scale experiments that focused on efficacy rather than efficiency. There was a lack of integrated approaches for research in red mud valorization.

Red Mud-Amended Soil as Highly Adsorptive Hybrid-Fill Materials for Controlling Heavy Metal Sewage Seepage in Industrial Zone

With the rapid development of urbanization, the problem of environmental pollution is becoming more and more serious. As a major pollutant, heavy metals have caused serious contamination in soil and groundwater. In order to prevent the diffusion of heavy metals in the soil from industrial sewage, the concept of hybrid-fill layer construction improved by red mud was proposed in this study. This study examines the adsorption capacities of lead and zinc ions and engineering characteristics on red mud-amended soils by direct shear, permeability, adsorption, desorption batch and column tests. Two mixing methods, full particle size displacement mixing and partial particle size displacement mixing, were adopted. The results showed that red mud effectively increased the adsorption capacity of soil to heavy metal ions, and the desorption rate of ions after adsorption was less than 3%, which had good anti-desorption ability. The optimum content of red mud in hybrid-fill material can be determined as 20%. The direct shear test showed that the internal friction angle of hybrid-fill material was 38.9°, and the cohesive force was 30.3 kPa, which met the engineering strength requirements of foundation materials. Based on the test results, red mud can be used as a barrier material to prevent heavy metal contamination in industrial sewage from diffusion, which controls not only heavy metal contamination but also consumes industrial by-products.

Red mud-biochar composites (co-pyrolyzed red mud-plant materials): Characteristics and improved efficacy on the treatment of acidic mine water and trace element-contaminated soils

The use of commercially sourced dopants for synthesizing biochar-based composites could be economically undesirable. The current work aimed to explore the possibility of making low-cost biochar-based composites using red mud (an industrial waste from alumina production) as dopants. Two types of red mud were used: one from a Bayer process and another from a sintering process. Different techniques (wet chemical, magnetic, SEM-EDS, FTIR, XPS and XRD analyses) were adopted to characterize the synthesized red mud-biochar composites, along with the pristine biochar. The composites were superior to the pristine biochar in terms of acid neutralizing capacity, specific surface area, and degree of magnetization. Two laboratory simulation experiments were conducted to assess the improved efficacy of the composites on the treatment of acidic mine water and mine water-contaminated soils. In general, application of the composites resulted in a significantly higher removal rate of mine water-borne trace elements compared to the pristine biochar treatment. The composites also had better effects on immobilizing the soil-borne trace elements and weakening the uptake of trace elements by the test vegetable plant species grown in the composite-treated soils, as compared to the pristine biochar-treated soil. By comparison, the sintering red mud-biochar composite had a generally better performance compared to the Bayer red mud-biochar composite.

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).

An Ex-Situ Immobilization Experiment with Zn, Pb, and Cu in Dredged Marine Sediments from Bohai Bay, China

The remediation of dredged marine sediments contaminated by metals has drawn increasing attention globally. Immobilization was regarded as a promising method for reducing adverse impacts on marine ecosystems. In this study, kaolinite and limestone were used as amendments to immobilize Zn, Pb, and Cu in dredged marine sediments, which were collected from the coastal zone adjacent to Tianjin Port in Bohai Bay. The sequential extraction procedure was applied to identify the mobility of metals and, further, to evaluate the immobilization effect of the amendments. The physical–chemical properties of the sediments, such as the pH, electrical conductivity (EC), salinity, and total organic carbon (TOC), were also measured to better understand their influence on the three metals’ mobility. The results of the sequential extraction procedure indicated that the mobile fractions of the metals were converted into relatively stable fractions because of the two amendments. In addition, the EC, salinity, and TOC decreased moderately, while no obvious variations in the pH of the sediments were observed with the addition of kaolinite and limestone. It was confirmed that both kaolinite and limestone can effectively reduce the mobility and bioavailability of metals, particularly Zn, and limestone generally has a better immobilization effect, compared with kaolinite.

A review on the potential uses of red mud as amendment for pollution control in environmental media

Red mud is a solid waste of bauxite processing by Bayer process which involves caustic digestion of Al-containing mineral for alumina production. The global inventory of red mud waste reached an estimated amount of 4 billion tons in 2015, increasing at an approximate rate of 120 million tons per year. Therefore, its management is becoming a global environmental issue for the protection of environment, and the need for awareness in this regard is becoming crucial. Although red mud is not considered as a hazardous material in many countries, its high alkalinity and fine particle size may pose significant environmental threat, and it is found to be an interesting material for environmental remediation purposes due to rich iron content. This paper provides a review of possible remedial applications of red mud in various environmental compartments. Modification of red mud creates novel opportunities for cost-effective and efficient removal of metal ions, inorganic anions, dyes, and phenols from wastewater and acid mine drainage. Re-vegetation of red mud disposal sites, treatment of metal-contaminated acidic soils presents the usefulness of this material but less research has been done so far to investigate its use in the stabilization of polluted sediments. On the other hand, leaching and eco-toxicological tests have also revealed that red mud does not pose high toxicity to the environment making it suitable for the treatment of contaminated media. Nevertheless, neutralization of red mud is recommended for its safe disposal and secure application in any environmental media.

Biomineralisation performance of bacteria isolated from a landfill in China

We report an investigation of microbially induced carbonate precipitation by seven indigenous bacteria isolated from a landfill in China. Bacterial strains were cultured in a medium supplemented with 25 mmol/L calcium chloride and 333 mmol/L urea. The experiments were carried out at 30 °C for 7 days with agitation by a shaking table at 130 r/min. Scanning electron microscopic and X-ray diffraction analyses showed variations in calcium carbonate polymorphs and mineral composition induced by all bacterial strains. The amount of carbonate precipitation was quantified by titration. The amount of carbonate precipitated in the medium varied among isolates, with the lowest being Bacillus aerius rawirorabr15 (LC092833) precipitating around 1.5 times more carbonate per unit volume than the abiotic (blank) solution. Pseudomonas nitroreducens szh_asesj15 (LC090854) was found to be the most efficient, precipitating 3.2 times more carbonate than the abiotic solution. Our results indicate that bacterial carbonate precipitation occurred through ureolysis and suggest that variations in carbonate crystal polymorphs and rates of precipitation were driven by strain-specific differences in urease expression and response to the alkaline environment. These results and the method applied provide benchmarking and screening data for assessing the bioremediation potential of indigenous bacteria for containment of contaminants in landfills.

Analysis of bauxite residue components responsible for copper removal and related reaction products

Bauxite residue is a solid waste produced during alumina production process, and the storage of that in China reached 0.6 billion tons with an increase of more than 70 million annually. Bauxite residue can be used to remove heavy metals from water. This study analyzed components of bauxite residue responsible for copper removal, removal process and accompanying reaction products. Calcite (CaCO₃), hematite (Fe₂O₃) and sulfur-Fe are main components contributing to copper removal. Sulfur in bauxite residue works with iron to remove copper. All these components reacted with copper immediately as bauxite residue was added. Reaction time of sulfur-Fe and carbonate was 5 min and 1 h, respectively. And hematite reacted until complete removal of copper (>2 h). Sulfur quickly reacted with coexisting iron to remove copper, producing chalcopyrite (CuFeS₂), cubanite (CuFe₂S₃) and bornite (Cu₅FeS₄). Carbonate in bauxite residue reacted with copper, producing tenorite (CuO), copper hydroxide (Cu(OH)₂), malachite (Cu₂(OH)₂CO₃), carbonate cyanotrichite (Cu₄Al₂(CO₃,SO₄)(OH)₁₂·2H₂O), chalconatronite (Na₂Cu(CO₃)₂·3H₂O), nakauriite (Cu₈(SO₄)₄(CO₃)(OH)₆·48H₂O) and callaghanite (Cu₂Mg₂(CO₃)(OH)₆·2H₂O). Copper precipitated through reaction with hematite to produce delafossite (CuFeO₂). After removal reaction, the existing forms of copper in bauxite residue comprised carbonate-bound (73.6%-85.7%), iron oxide-bound (5.6%-23.8%), organic matter/sulfide-bound (0.5%-9.0%) and residual forms (0.9%-2.0%). In conclusion, removal of copper using bauxite residue features a more complex reaction than adsorption.

Adsorption of heavy metals on conventional and nanostructured materials for wastewater treatment purposes: A review

The problem of water pollution is of a great concern. Adsorption is one of the most efficient techniques for removing noxious heavy metals from the solvent phase. This paper presents a detailed information and review on the adsorption of noxious heavy metal ions from wastewater effluents using various adsorbents - i.e., conventional (activated carbons, zeolites, clays, biosorbents, and industrial by-products) and nanostructured (fullerenes, carbon nanotubes, graphenes). In addition to this, the efficiency of developed materials for adsorption of the heavy metals is discussed in detail along with the comparison of their maximum adsorption capacity in tabular form. A special focus is made on the perspectives of further wider applications of nanostructured adsorbents (especially, carbon nanotubes and graphenes) in wastewater treatment.

Cr(VI) Adsorption on Red Mud Modified by Lanthanum: Performance, Kinetics and Mechanisms

Water pollution caused by the highly toxic metal hexavalent chromium (Cr(VI)) creates significant human health and ecological risks. In this study, a novel adsorbent was used to treat Cr(VI)-containing wastewater; the adsorbent was prepared using red mud (RM) generated from the alumina production industry and the rare earth element lanthanum. This study explored adsorption performance, kinetics, and mechanisms. Results showed that the adsorption kinetics of the RM modified by lanthanum (La-RM), followed the pseudo-second-order model, with a rapid adsorption rate. Cr(VI) adsorption was positively associated with the absorbent dose, pH, temperature, and initial Cr(VI) concentration; coexisting anions had little impact. The maximum Cr(VI) adsorption capacity was 17.35 mg/g. Cr(VI) adsorption on La-RM was a mono-layer adsorption pattern, following the Langmuir isotherm model. Thermodynamic parameters showed the adsorption was spontaneous and endothermic. The adsorption of Cr(VI) on La-RM occurred as a result of LaOCl formation on the RM surface, which in turn further reacted with Cr(VI) in the wastewater. This study highlighted a method for converting industrial waste into a valuable material for wastewater treatment. The novel absorbent could be used as a potential adsorbent for treating Cr(VI)-contaminating wastewater, due to its cost-effectiveness and high adsorption capability.

Use of neutralized industrial residue to stabilize trace elements (Cu, Cd, Zn, As, Mo, and Cr) in marine dredged sediment from South-East of France

Management of marine dredged sediments polluted with trace elements is prime issue in the French Mediterranean coast. The polluted sediments possess ecological threats to surrounding environment on land disposal. Therefore, stabilization of contaminants in multi-contaminated marine dredged sediment is a promising technique. Present study aimed to assess the effect of gypsum neutralized bauxaline(®) (bauxite residue) to decrease the availability of pollutants and inherent toxicity of marine dredged sediment. Bauxaline(®), (alumia industry waste) contains high content of iron oxide but its high alkalinity makes it not suitable for the stabilization of all trace elements from multi-contaminated dredged sediments. In this study, neutralized bauxaline(®) was prepared by mixing bauxaline(®) with 5% of plaster. Experiments were carried out for 3 months to study the effect of 5% and 20% amendment rate on the availability of Cu, Cd, Zn, As, Mo, and Cr. Trace elements concentration, pH, EC and dissolved organic carbon were measured in all leachates. Toxicity of leachates was assessed against marine rotifers Brachionus plicatilis. The Results showed that both treatments have immobilization capacity against different pollutants. Significant stabilization of contaminants (Cu, Cd, Zn) was achieved with 20% application rate whereas As, Mo, and Cr were slightly stabilized. Toxicity results revealed that leachates collected from treated sediment were less toxic than the control sediment. These results suggest that application of neutralized bauxaline(®) to dredged sediment is an effective approach to manage large quantities of dredged sediments as well as bauxite residue itself.

Formations of calcium carbonate minerals by bacteria and its multiple applications

Biomineralization is a naturally occurring process in living organisms. In this review, we discuss microbially induced calcium carbonate precipitation (MICP) in detail. In the MICP process, urease plays a major role in urea hydrolysis by a wide variety of microorganisms capable of producing high levels of urease. We also elaborate on the different polymorphs and the role of calcium in the formation of calcite crystal structures using various calcium sources. Additionally, the environmental factors affecting the production of urease and carbonate precipitation are discussed. This MICP is a promising, eco-friendly alternative approach to conventional and current remediation technologies to solve environmental problems in multidisciplinary fields. Multiple applications of MICP such as removal of heavy metals and radionuclides, improve the quality of construction materials and sequestration of atmospheric CO₂ are discussed. In addition, we discuss other applications such as removal of calcium ions, PCBs and use of filler in rubber and plastics and fluorescent particles in stationary ink and stationary markers. MICP technology has become an efficient aspect of multidisciplinary fields. This report not only highlights the major strengths of MICP, but also discusses the limitations to application of this technology on a commercial scale.

Study of novel mechano-chemical activation process of red mud to optimize nitrate removal from water

Red mud (RM) is the industrial waste of alumina production and causes serious environmental risks. In this paper, a novel activation procedure for RM (mechano-chemical processing) is proposed in order to improve the nitrate adsorption from water. High-energy milling and acidification were selected as mechanical and chemical activation methods, respectively. Synthesized samples of adsorbent were produced considering two parameters of activation: acid concentrations and acidification time in two selected milling times. Optimization of the activation process was based on nitrate removal from a stock solution. Experimental data were analyzed with two-way analysis of variance and Kruskal-Wallis methods to verify and discover the accuracy and probable errors. Best conditions (acceptable removal percentage > 75) were 17.6% w/w for acid concentrate and 19.9 minutes for acidification time in 8 hours for milling time. A direct relationship between increase in nitrate removal and increasing the acid concentration and acidification time was observed. The adsorption isotherms were studied and compared with other nitrate adsorbents. Characterization tests (X-ray fluorescence, X-ray diffraction, Fourier transform infrared spectrophotometry, dynamic light scattering, surface area analysis and scanning electron microscopy) were conducted for both raw and activated adsorbents. Results showed noticeable superiority in characteristics after activation: higher specific area and porosity, lower particle size and lower agglomeration in structure.

Iron and aluminium oxides containing industrial wastes as adsorbents of heavy metals: Application possibilities and limitations

Industrial wastes with a high iron or aluminium oxide content are produced in huge quantities as by-products of water treatment (water treatment residuals), bauxite processing (red mud) and hard and brown coal burning in power plants (fly ash). Although they vary in their composition, the wastes have one thing in common--a high content of amorphous iron and/or aluminium oxides with a large specific surface area, whereby this group of wastes shows very good adsorbability towards heavy metals, arsenates, selenates, etc. But their physical form makes their utilisation quite difficult, since it is not easy to separate the spent sorbent from the solution and high bed hydraulic resistances occur in dynamic regime processes. Nevertheless, because of the potential benefits of utilising the wastes in industrial effluent treatment, this issue attracts much attention today. This study describes in detail the waste generation processes, the chemical structure of the wastes, their physicochemical properties, and the mechanisms of fixing heavy metals and semimetals on the surface of iron and aluminium oxides. Typical compositions of wastes generated in selected industrial plants are given. A detailed survey of the literature on the adsorption applications of the wastes, including methods of their thermal and chemical activation, as well as regeneration of the spent sorbents, is presented. The existing and potential ways of modifying the physical form of the discussed group of wastes, making it possible to overcome the basic limitation on their practical use, are discussed.

Application of red mud as a basic catalyst for biodiesel production

Red mud was investigated in triglyceride transesterification with a view to determine its viability as a basic catalyst for use in biodiesel synthesis. The effect of calcination temperature on the structure and activity of red mud catalysts was investigated. It was found that highly active catalyst was obtained by simply drying red mud at 200 degrees C. Utilization of red mud as a catalyst for biodiesel production not only provides a cost-effective and environmentally friendly way of recycling this solid red mud waste, significantly reducing its environmental effects, but also reduces the price of biodiesel to make biodiesel competitive with petroleum diesel.

Comparison of Copper Scavenging Capacity between Two Different Red Mud Types

A batch experiment was conducted to compare the Cu scavenging capacity between two different red mud types: the first one was a highly basic red mud derived from a combined sintering and Bayer process, and the second one was a seawater-neutralized red mud derived from the Bayer process. The first red mud contained substantial amounts of CaCO₃, which, in combination with the high OH⁻ activity, favored the immobilization of water-borne Cu through massive formation of atacamite. In comparison, the seawater-neutralized red mud had a lower pH and was dominated by boehmite, which was likely to play a significant role in Cu adsorption. Overall, it appears that Cu was more tightly retained by the CaCO₃-dominated red mud than the boehmite-dominated red mud. It is concluded that the heterogeneity of red mud has marked influences on its capacity to immobilize water-borne Cu and maintain the long-term stability of the immobilized Cu species. The research findings obtained from this study have implications for the development of Cu immobilization technology by using appropriate waste materials generated from the aluminium industry.

Electroacoustic isoelectric point determinations of bauxite refinery residues: different neutralization techniques and minor mineral effects

Bauxite refinery residue (BRR) is a highly caustic, iron hydroxide-rich byproduct from alumina production. Some chemical treatments of BRR reduce soluble alkalinity and lower residue pH (to values <10) and generate a modified BRR (MBRR). MBRR has excellent acid neutralizing (ANC) and trace-metal adsorption capacities, making it particularly useful in environmental remediation. However, soluble ANC makes standard acid-base isoelectric point (IEP) determination difficult. Consequently, the IEP of a BRR and five MBRR derivatives (sulfuric acid-, carbon dioxide-, seawater-, a hybrid neutralization, i.e, partial CO(2) neutralization followed by seawater, and an activated-seawater-neutralized MBRR) were determined using electroacoustic techniques. Residues showed three significantly different groups of IEPs (p < 0.05) based around the neutralization used. Where the primary mineral assemblage is effectively unchanged, the IEPs were not significantly different from BRR (pH 6.6-6.9). However, neutralizations generating neoformational minerals (alkalinity precipitation) significantly increased the IEP to pH 8.1, whereas activation (a removal of some primary mineralogy) significantly lowered the IEP to pH 6.2. Moreover, surface charging curves show that surfaces remain in the ±30 mV surface charge instability range, which provides an explanation as to why MBRRs remove trace metals and oxyanions over a broad pH range, often simultaneously. Importantly, this work shows that minor mineral components in complex mineral systems may have a disproportionate effect on the observable bulk IEP. Furthermore, this work shows the appropriateness of electroacoustic techniques in investigating samples with significant soluble mineral components (e.g., ANC).

Effect of self-glazing on reducing the radioactivity levels of red mud based ceramic materials

Self-glazing red mud based ceramic materials (RMCM) were produced by normal pressure sintering process using the main raw materials of red mud. The properties of the RMCM samples were investigated by the measurements of mechanical properties, radiation measurement, X-ray diffraction (XRD) and scanning electron microscopy (SEM). The results show that the self-glazing RMCM have good mechanical properties (water absorption and apparent porosity approached zero; bulk density, 2.94 g/cm(3); compressive strength, 78.12 MPa). The radiation level has clear change regularity that the radioactivity levels of red mud (6360 Bq) is obvious declined, and can be reduced to that of the natural radioactive background of Guilin Karst landform, China (3600 Bq). It will not only consume large quantities of red mud, but also decrease the production cost of self-glazing RMCM. And the statement of this paper will offer effective ways to reduce the radioactivity level of red mud.