Alkalinity conversion of bauxite refinery residues by neutralization

Synergistic utilization, critical mechanisms, and environmental suitability of bauxite residue (red mud) based multi-solid wastes cementitious materials and special concrete

The energy consumption and carbon emissions in the construction field, coupled with the accumulation of various industrial solid wastes, particularly bauxite residue (red mud), represent formidable barriers to sustainable development. The synergistic utilization of bauxite residue (red mud) in cementitious materials and special concrete is widely considered one of the most practical approaches for these issues. In this comprehensive review, characteristics and composition of red mud worldwide were investigated. By comparing and reviewing the latest research, the current achievements in applying red mud with various solid wastes in cementitious materials and special concrete were discussed. In addition, critical mechanisms and environmental suitability issues are emphasized. In conclusion, the present work culminates in identifying the challenges faced and opportunities for progressing in synergizing red mud and multi-solid wastes, which will contribute to the international research community for sustainable development in the industry.

Enhanced NOx absorption in flue gas by wet oxidation of red mud and phosphorus sludge

The environmental problem caused by industrial emissions of NOx has been studied in the past dacades. In this study, red mud coupling with phosphorus sludge were used to enhance the solution to absorb NOx from the flue gas. Firstly, red mud reacted with the binder silicic acid in the phosphorus sludge, destroying the emulsion structure of the phosphorus sludge. Then, the P4 in the phosphorus sludge is completely released, and the P4 reacted with O2 in the flue gas to produce O3 and O. NO and NO2 contained in the flue gas reacted with the active O and O3 to produce high-valent NOx, such as NO3, N2O5. At last, the mixed slurry of red mud and phosphorus sludge absorbed the high-valent NOx, resulting in the formation of Ca5(PO4)3F along with HNO3. Using phosphorus sludge to produce O3 in the reaction process can reduce the production cost of O3 and achieve waste utilization. Meanwhile, the interaction between red mud and phosphorus sludge can promote phosphorus sludge to produce O3 and remove F- from phosphorus sludge, as well as avoid the problem of secondary pollution. This study should be helpful for red mud and phosphorus sludge utilization and flue gas denitration.

Assessing the potential of red mud and dehydrated mineral mud mixtures as soil matrix for revegetation

The disposal of red mud (RM) and dehydrated mineral mud (DM) presents a significant challenge for the global alumina industry. This study proposes a novel disposal method for RM and DM, which uses mixtures of RM and DM as a soil matrix for revegetation in the mining area. RM mixed with DM effectively alleviated its salinity and alkalinity. X-ray diffraction analysis indicated that reduction of salinity and alkalinity may be due to the release of chemical alkali from sodalite and cancrinite. Applications of ferric chloride (FeCl3), gypsum, and organic fertilizer (OF) improved the physicochemical properties of the RM-DM mixtures. FeCl3 significantly reduced available Cd, As, Cr, and Pb content in the RM-DM, while OF significantly increased the cation exchange capacity, microbial carbon and nitrogen, and aggregate stability (p < 0.05). Micro-computed tomography and nuclear magnetic resonance analysis showed that amendment with OF and FeCl3 increased the porosity, pore diameter, and hydraulic conductivity in the RM-DM mixture. The RM-DM mixtures had low leaching of toxic elements, indicating low environmental risk. Ryegrass grew well in the RM-DM mixture at a ratio of 1:3. OF and FeCl3 significantly increased the ryegrass biomass (p < 0.05). These results suggested that RM-DM amended with OF and FeCl3 has a potential application in the revegetation of areas after bauxite mining.

Efficient dealkalization of red mud and recovery of valuable metals by a sulfur-oxidizing bacterium

Red mud (RM) is a highly alkaline polymetallic waste generated via the Bayer process during alumina production. It contains metals that are critical for a sustainable development of modern society. Due to a shortage of global resources of many metals, efficient large-scale processing of RM has been receiving increasing attention from both researchers and industry. This study investigated the solubilization of metals from RM, together with RM dealkalization, via sulfur (S0) oxidation catalyzed by the moderately thermophilic bacterium Sulfobacillus thermosulfidooxidans. Optimization of the bioleaching process was conducted in shake flasks and 5-L bioreactors, with varying S0:RM mass ratios and aeration rates. The ICP analysis was used to monitor the concentrations of dissolved elements from RM, and solid residues were analyzed for surface morphology, phase composition, and Na distribution using the SEM, XRD, and STXM techniques, respectively. The results show that highest metal recoveries (89% of Al, 84% of Ce, and 91% of Y) were achieved with the S0:RM mass ratio of 2:1 and aeration rate of 1 L/min. Additionally, effective dealkalization of RM was achieved under the above conditions, based on the high rates (&gt;95%) of Na, K, and Ca dissolution. This study proves the feasibility of using bacterially catalyzed S0 oxidation to simultaneously dealkalize RM and efficiently extract valuable metals from the amassing industrial waste.

A review on ex situ mineral carbonation

The increased CO₂ quantities in the environment have led to many harmful effects. Therefore, it is very important to decrease the CO₂ levels in the environment. CO₂ capture along with safe and permanent storage using mineral CO₂ sequestration method can play an important role to reduce carbon emissions into the environment. Mineral sequestration is a stable storage method that provides long-term storage and an appropriate substitute for the more popular geological storage method. The process is most suited for places where there is a lack of underground cavities for underground geological storage. Minerals rich in Ca and Mg are used predominantly in carbonation reactions. In addition, those alkaline wastes that are rich in Mg and Ca such as cement waste, steel slag and many process ashes can also be employed in CO₂ sequestration. Mineral carbonation could be used for the sequestration of billions of tonnes of CO₂ every year. However, various drawbacks related to mineral carbonation still need to be addressed, such as resolving the slow rate of reactions, necessity of large amounts of feedstock, decreasing the high overall cost of CO₂ sequestration and reducing the huge energy requirements to accelerate the carbonation reaction. This study explores a number of carbonation methods, parameters that control the process and future potential applications of carbonated products.

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.

The use of rapid, small-scale column tests to determine the efficiency of bauxite residue as a low-cost adsorbent in the removal of dissolved reactive phosphorus from agricultural waters

Bauxite residue, the by-product produced in the alumina industry, is a potential low-cost adsorbent in the removal of phosphorus (P) from aqueous solution, due to its high composition of residual iron oxides such as hematite. Several studies have investigated the performance of bauxite residue in removing P; however, the majority have involved the use of laboratory "batch" tests, which may not accurately estimate its actual performance in filter systems. This study investigated the use of rapid, small-scale column tests to predict the dissolved reactive phosphorus (DRP) removal capacity of bauxite residue when treating two agricultural waters of low (forest run-off) and high (dairy soiled water) phosphorus content. Bauxite residue was successful in the removal of DRP from both waters, but was more efficient in treating the forest run-off. The estimated service time of the column media, based on the largest column studied, was 1.08 min g^-1 media for the forest run-off and 0.28 min g^-1 media for the dairy soiled water, before initial breakthrough time, which was taken to be when the column effluent reached approximately 5% of the influent concentration, occurred. Metal(loid) leaching from the bauxite residue, examined using ICP-OES, indicated that aluminium and iron were the dominant metals present in the treated effluent, both of which were above the EPA parametric values (0.2 mg L^-1 for both Al and Fe) for drinking water.

Recovery of Alkali from Bayer Red Mud Using CaO and/or MgO

Recovering alkali from Bayer red mud is crucial for storage security, resource utilization and environmental protection. In this study, the addition of MgO and/or CaO was conducted to recover alkali from red mud with a hydrothermal method for the first time. A synergistic result with a residual Na2O/SiO2 weight ratio of 0.03 was obtained by adding the blend of CaO and MgO at an appropriate temperature. MgO was found to be more temperature-dependent than CaO when substituting Na2O from red mud due to their different hydration processes. The alkali recovery was controlled by a reaction at a temperature of <200 °C and by internal diffusion at a higher temperature for MgO, but controlled by internal diffusion for CaO in the whole temperature range studied. The formation of hydrotalcite-like compounds with a loose structure was verified with the help of XRD, FTIR, and SEM-EDS. It was proved that both the reaction kinetics and the characteristics of solid products have a significant influence on the recovery of alkali.

Phosphogypsum stabilization of bauxite residue: Conversion of its alkaline characteristics

Reduction of the high alkalinity of bauxite residue is a key problem to solve to make it suitable for plant growth and comprehensive utilization. In this study, phosphogypsum, a waste product from the phosphate fertilizer industry, was used to drive the alkaline transformation of the bauxite residue. Under optimal water washing conditions (liquid/solid ratio of 2 mL/g, 30°C, 24 hr), the impact of quantity added, reaction time and reaction mechanism during phosphogypsum application were investigated. Phosphogypsum addition effectively lowered pH levels and reduced the soluble alkalinity by 92.2%. It was found that the concentration of soluble Na and Ca ions in the supernatant increased gradually, whilst the exchangeable Na⁺ and Ca²⁺ in solid phase changed 112 mg/kg and 259 mg/kg, respectively. Ca²⁺ became the dominant element in the solid phase (phosphogypsum addition of 2%, liquid/solid ratio of 2 mL/g, 30°C, 12 hr). X-ray diffraction data indicated that cancrinite and hydrogarnet were the primary alkaline minerals. SEM images suggested that phosphogypsum could promote the formation of stable macro-aggregates, whilst the content of Ca²⁺ increased from 5.6% to 18.2% and Na reduced from 6.8% to 2.4%. Treatment with phosphogypsum could significantly promote the transformation of alkalinity cations by neutralization, precipitation and replacement reactions. This research provided a feasible method to promote soil formation of bauxite residue by phosphogypsum amendment.

Improved bauxite residue dealkalization by combination of aerated washing and electrodialysis

Bauxite residue, a major by-product of the alumina-producing Bayer process, is a serious environmental pollutant due to its high alkalinity. Here, we reported an operation system designed in our laboratory that included washing and electrodialysis dealkalization systems with aeration pipes. Washing with aeration releases a substantial amount of free alkali and attached alkali into water and increases the dealkalization efficiency. The washing liquid was treated with five steps of batch-mode electrodialysis. The average removal of total dissolved solids (TDS) after the aeration and non-aeration electrodialysis processes were 61.30% and 39.61%, respectively. The average removal of OH^- under aeration conditions was 76.62%, a value that was greater than the value produced under non-aeration conditions (68.48%). This efficiency was also higher than that of some other reports (64.90-68.50%). Aeration decreased the energy consumption to a greater extent than the non-aeration condition. NaOH was recovered in terms of the concentration chamber, and the NaAl(OH)₄ present in the dilution chamber was separated for the electrodialysis treatment. Membrane scaling was generated to a lesser amount under aeration conditions than that of non-aeration conditions, which would improve the dealkalization efficiency. The high repeatability of the experiments was indicated by the intraclass correlation coefficient (P < 0.05).

Acid Mine Drainage Treatment Using Bayer Precipitates Obtained from Seawater Neutralization of Bayer Liquor

Bayer precipitates from the seawater neutralization of Bayer liquor waste from the alumina industry are shown to be a prospective solution for the remediation of acid mine drainage (AMD) water. Precipitates are varied in composition, albeit they are generally comprised of hydrotalcite (Mg6Al2(OH)16CO3∙xH2O), calcite (CaCO3), aragonite (CaCO3), mixed metal hydroxides (Mg2Al(OH)7), and halite (NaCl). Brucite (Mg(OH)2) is detected for lower Bayer liquor concentrations (1-3 g L-1 Al2O3) when the concentrations of aluminum and hydroxyl species are insufficient to promote hydrotalcite formation. The neutralizing capacity of the precipitates also varies with Bayer liquor composition. Treatment of AMD water with Bayer precipitates met discharge pH guidelines. The dissolution of hydrotalcite and brucite (1-3 g L-1 Bayer precipitates only) is responsible for the Bayer precipitate's neutralizing capacity, while calcium carbonate has a buffering affect at around pH 7. Manganese ions are the most challenging species to remove because high pH values are required (pH > 9), which is not possible with all precipitates tested. One caveat is that increasing the degree of manganese removal generates issues with excessive dissolved aluminum which exceeds discharge limits. Future research should address this latter problem and facilitate implementation of this approach to AMD remediation.

The potential for constructed wetland mechanisms to treat alkaline bauxite residue leachate: carbonation and precipitate characterisation

Leachates emanating from bauxite residue disposal areas are alkaline and require neutralisation prior to discharge. The use of passive technologies such as constructed wetlands has received increasing interest as possible treatments for alkaline leachates, including bauxite residues. Mechanisms proposed for wetland effectiveness have included calcite precipitation but it is not clear if such a pathway is feasible in the relatively low Ca residue leachates. Carbonation of Ca-spiked residue leachate treatments was conducted to observe rates of pH decrease and precipitate formation. For all treatments, carbonation effectively decreased pH to ca. 10.5 which remained stable following aeration. Decreases in Al content of 83-93% were also observed. Precipitates retrieved from carbonation experiments and from a constructed wetland trial were characterised using XRD, SEM, XPS and EDX. Calcium carbonates formed in Ca-spiked treatments and dawsonite precipitation occur in the absence of Ca. Rinsing of precipitates removes surface calcium indicating soluble forms adsorbed on precipitates. The results demonstrate that carbonation of bauxite residue leachate is an important component of passive treatments and neutralisation.

Accelerated crystallization of magnetic 4A-zeolite synthesized from red mud for application in removal of mixed heavy metal ions

To cope with the increasing environmental issues of red mud, an integrated technological route for its comprehensive utilization was developed through the extraction of valuable components and the synthesis of magnetic 4A-zeolite. To accelerate the crystallization process of the synthesized 4A-zeolite, sodium chloride (NaCl) was innovatively employed under hydrothermal treatment. The effects of various parameters, including mass ratio of red mud/NaOH, alkali fusion temperature, alkali fusion time and molar ratio of NaCl/Al₂O₃, were systematically investigated. The results showed that approximately 81.0% Al, 76.1% Si and 95.8% Fe were utilized from red mud using alkali fusion and acid leaching methods. The optimal conditions of the alkali fusion process were determined as: mass ratio of red mud/NaOH = 1/2, alkali fusion temperature of 800 °C, and time of 90 min. Furthermore, when the molar ratio of NaCl/Al₂O₃ was kept at 1.5, the crystallization time reduced from 240 min to 150 min, and particle size distributions narrowed from 20-100 μm to 1-10 μm. The practical applications in removal of mixed heavy metal ions (Zn²⁺, Cu²⁺, Cd²⁺, Ni²⁺, and Pb²⁺) from wastewater indicated that the as-synthesized magnetic 4A-zeolite is a promising candidate for heavy metals adsorption.

Spatial distribution of heavy metals, salinity and alkalinity in soils around bauxite residue disposal area

The existence of bauxite residue disposal area (BRDA) is a serious problem in China owing to the huge quantity as well as toxicity and high alkalinity of bauxite residue. To assess the impact of uncontrolled release of bauxite residue on soil, 80 surface soil samples from areas nearby the BRDA in China, were tested to obtain the levels of heavy metals, as well as exchangeable sodium percentage, pH, electrical conductivity (EC), and total alkalinity (TA). High levels of total concentrations of Cd, V, Pb, and Mo were detected in the study area, along with high pH and exchangeable Na, K, Ca, and Mg. Spatial distribution generated by Kriging interpolation of data on surface soils indicated variabilities in the concentrations of heavy metals, alkalinity, and salinity. Factor analyses confirmed the spatial distribution variance and the influence of prevailing winds. The enrichment factors of soil showed extreme enrichment of Mo, moderate enrichment of Cd and V; and high synthesis scores for soil salinization degree were noted from the eastern to southeastern region of the BRDA. This study provides a range of strategies with significant effort in planning, implementation, and monitoring activities to ensure effective dust control in BRDA management.

Bauxite residue neutralization with simultaneous mineral carbonation using atmospheric CO2

Simultaneous carbon mineralization during neutralization of bauxite residue, a caustic alkaline by-product of alumina refining, was tested using laboratory batch and a field pilot study in contact with atmospheric CO₂. Since CO₂ sequestration is limited by the Ca concentration in the bauxite residue, extra Ca sources were added in a semi-soluble mineral and salt form (flue gas desulfurization gypsum or CaCl₂) to verify whether this Ca addition accelerated and enlarged the CO₂ sequestration obtained as a consequence of neutralization. The results of 55 days of batch and longer-term field tests were in good agreement, and the neutralization rate was accelerated through the addition of both Ca sources. Without the addition of the extra Ca source, atmospheric CO₂ contributed to neutralization of pore water alkalinity alone, while Ca addition induced further neutralization through mineral carbonation of atmospheric CO₂ to CaCO₃. This simple addition of environmentally benign Ca to bauxite residue may provide a feasible bauxite residue management practice that is cost-effective and easy to apply in the field.

Acid transformation of bauxite residue: Conversion of its alkaline characteristics

Bauxite residue (BR) is a highly alkaline solid hazardous waste produced from bauxite processing for alumina production. Alkaline transformation appears to reduce the environmental risk of bauxite residue disposal areas (BRDAs) whilst potentially providing opportunities for the sustainable reuse and on-going management of BR. Mineral acids, a novel citric acid and a hybrid combination of acid-gypsum treatments were investigated for their potential to reduce residue pH and total alkalinity and transform the alkaline mineral phase. XRD results revealed that with the exception of andradite, the primary alkaline solid phases of cancrinite, grossular and calcite were transformed into discriminative products based on the transformation used. Supernatants separated from BR and transformed bauxite residue (TBR) displayed distinct changes in soluble Na, Ca and Al, and a reduction in pH and total alkalinity. SEM images suggest that mineral acid transformations promote macro-aggregate formation, and the positive promotion of citric acid, confirming the removal or reduction in soluble and exchangeable Na. NEXAFS analysis of Na K-edge revealed that the chemical speciation of Na in TBRs was consistent with BR. Three acid treatments and gypsum combination had no effect on Na speciation, which affects the distribution of Na revealed by sodium STXM imaging.

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.

Evaluation of aggregate microstructures following natural regeneration in bauxite residue as characterized by synchrotron-based X-ray micro-computed tomography

Bauxite residue often has poor physical conditions which impede plant growth. Native plant encroachment on a bauxite residue disposal area in Central China reveals that natural regeneration may improve its physicochemical properties. Residue samples collected from three different disposal ages were assessed to evaluate residue micromorphology and three-dimensional (3D) aggregate microstructure under natural regeneration. The residue aggregates in different disposal ages were divided in two sections: macro-aggregate (2-1mm) and micro-aggregate (0.25-0.05mm). Residue aggregate micromorphology was determined by scanning electron microscope and energy dispersive X-ray spectroscopy, and the residue aggregate microstructure was determined by synchrotron-based X-ray micro-computed tomography (SR-μCT) and image analysis techniques. Natural regeneration may improve residue aggregate stability and form a stable aggregate structure. Calcium content increased whilst sodium content decreased significantly on the surface of residue aggregates. Under natural soil-forming processes bauxite residue porosity, specific surface area, average length of paths, and average tortuosity of paths all significantly increased. This demonstrated that natural regeneration may stimulate the formation of stable aggregate structure in residues. Further understanding should focus on particle interaction forces and agglomeration mechanisms with the addition of external ameliorations.

Proposal for management and alkalinity transformation of bauxite residue in China

Bauxite residue is a hazardous solid waste produced during the production of alumina. Its high alkalinity is a potential threat to the environment which may disrupt the surrounding ecological balance of its disposal areas. China is one of the major global producers of alumina and bauxite residue, but differences in alkalinity and associated chemistry exist between residues from China and those from other countries. A detailed understanding of the chemistry of bauxite residue remains the key to improving its management, both in terms of minimizing environmental impacts and reducing its alkaline properties. The nature of bauxite residue and the chemistry required for its transformation are still poorly understood. This review focuses on various transformation processes generated from the Bayer process, sintering process, and combined Bayer-sintering process in China. Problems associated with transformation mechanisms, technical methods, and relative merits of these technologies are reviewed, while current knowledge gaps and research priorities are recommended. Future research should focus on transformation chemistry and its associated mechanisms and for the development of a clear and economic process to reduce alkalinity and soda in bauxite residue.

Novel predictors of soil genesis following natural weathering processes of bauxite residues

Bauxite residue often has chemical and physical limitations to support plant growth, and improving its matrix properties is crucial to support sustainable vegetation in the long term. Spontaneous vegetation colonization on deposits in Central China, over a period of 20 years, has revealed that natural weathering processes may convert bauxite residue to a soil-like medium. Residue samples from different stacking ages were collected to determine the effect of natural processes on matrix properties over time. It was demonstrated that natural processes decreased pH (10.98 to 9.45), electrical conductivity (EC) (3.73 to 0.36 mS/cm), and exchangeable sodium percentage (ESP) (72.51 to 28.99 %), while increasing bulk density (1.91 to 1.39 g/cm(3)), improving the mean weight diameter (MWD) of water-stable aggregates (0.24 to 0.52 mm), and the proportion of >0.25-mm water-stable aggregates (19.91 to 50.73 %). The accumulation of organic carbon and the reduction of ESP and exchangeable Na had positive effects on soil aggregate formation, while exchangeable Ca and Mg were significantly beneficial to aggregation of water-stable aggregates. Climate, stacking time, and biological factors appear to improve the structure of bauxite residue. Our findings demonstrate soil genesis occurring following natural weathering processes of bauxite residues over time.

Application of red mud as both neutralizer and catalyst in supercritical water oxidation (SCWO) disposal of sewage sludge

Red mud was used in the supercritical water oxidation (SCWO) disposal of sewage sludge, not only as a neutralizer for acidic substances produced in situ, but also as a catalyst for decomposition of pollutants.

Enabling safe dry cake disposal of bauxite residue by deliquoring and washing with a membrane filter press

Dry cake disposal is the preferred technique for the disposal of bauxite residue, when considering environmental issues together with possible future utilisation of the solids. In order to perform dry cake disposal in an economical way, the deliquoring of the residue must be carried out efficiently, and it is also important to wash the obtained solids well to minimise the amount of soluble soda within the solids. The study presented in this article aims at detecting the most important variables influencing the deliquoring and washing of bauxite residue, performed with a horizontal membrane filter press and by determining the optimal washing conditions. The results obtained from pilot-scale experiments are evaluated by considering the properties of the solids, for instance, the residual alkali and aluminium content, as well as the consumption of wash liquid. Two different cake washing techniques, namely classic washing and channel washing, are also used and their performances compared. The results show that cake washing can be performed successfully in a horizontal membrane filter press, and significant improvements in the recovery of alkali and aluminium can be achieved compared with pressure filtration carried out without washing, or especially compared with the more traditionally used vacuum filtration.

A review of mineral carbonation technologies to sequester CO2

Mineral carbonation is a promising and at the same time challenging option for the sequestration of anthropogenic CO₂.

CO2 mitigation potential of mineral carbonation with industrial alkalinity sources in the United States

The availability of industrial alkalinity sources is investigated to determine their potential for the simultaneous capture and sequestration of CO2 from point-source emissions in the United States. Industrial alkalinity sources investigated include fly ash, cement kiln dust, and iron and steel slag. Their feasibility for mineral carbonation is determined by their relative abundance for CO2 reactivity and their proximity to point-source CO2 emissions. In addition, the available aggregate markets are investigated as possible sinks for mineral carbonation products. We show that in the U.S., industrial alkaline byproducts have the potential to mitigate approximately 7.6 Mt CO2/yr, of which 7.0 Mt CO2/yr are CO2 captured through mineral carbonation and 0.6 Mt CO2/yr are CO2 emissions avoided through reuse as synthetic aggregate (replacing sand and gravel). The emission reductions represent a small share (i.e., 0.1%) of total U.S. CO2 emissions; however, industrial byproducts may represent comparatively low-cost methods for the advancement of mineral carbonation technologies, which may be extended to more abundant yet expensive natural alkalinity sources.

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).

Contaminant mobility and carbon sequestration downstream of the Ajka (Hungary) red mud spill: The effects of gypsum dosing

A number of emergency pollution management measures were enacted after the accidental release of caustic bauxite processing residue that occurred in Ajka, western Hungary in October, 2010. These centred on acid and gypsum dosing to reduce pH and minimise mobility of oxyanion contaminants mobile at high pH. This study assessed the effectiveness of gypsum dosing on contaminant mobility and carbon sequestration through assessment of red mud and gypsum-affected fluvial sediments via elemental analysis and stable isotope analysis. There was a modest uptake of contaminants (notably As, Cr, and Mn) on secondary carbonate-dominated deposits in reaches subjected to gypsum dosing. C and O stable isotope ratios of carbonate precipitates formed as a result of gypsum dosing were used to quantify the importance of the neutralisation process in sequestering atmospheric carbon dioxide. This process was particularly pronounced at sites most affected by gypsum addition, where up to 36% of carbonate-C appears to be derived from atmospheric in-gassing of CO(2). The site is discussed as a large scale analogue for potential remedial approaches and carbon sequestration technologies that could be applied to red mud slurries and other hyperalkaline wastes. The results of this work have substantial implications for the aluminium production industry in which 3-4% of the direct CO(2) emissions may be offset by carbonate precipitation. Furthermore, carbonation by gypsum addition may be important for contaminant remediation, also providing a physical stabilisation strategy for the numerous historic stockpiles of red mud.

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.

Removal of radium from groundwater using a modified bauxite refinery residue

Radium (Ra) removal by an unconventional sorbent, a modified bauxite refinery residue (MBRR), is investigated for a groundwater extracted in Missouri, USA. The MBRR treatment causes substantial reductions of both gross α and combined Ra activities from 0.955 ± 0.005 and 0.66 ± 0.005 Bq L to below detection limits (0.037 Bq L or 1 pCi L). Column breakthrough occurs at 0.555 Bq L for gross α and 0.185 Bq L for combined Ra (15 and 5 pCi L; USEPA's maximum contaminant levels) after 54 and 40 d run time, respectively. At 84 d the MBRR media continues to remove 24.3% of raw water gross α and 39.7% of the combined Ra. The treatment effluent has an initial pH of 10.9, outside the USEPA guides (6.5-8.5); this may be readily mitigated by posttreatment acid injection, or by raw water blending. The MBRR simultaneously removes other potentially hazardous trace elements (e.g., Cu, Zn, and Fe) to extremely low concentrations. In addition, toxicity characteristic leaching procedure testing of spent MBRR suggests that metals are bound tightly, such that it is nonhazardous, permitting cost-effective disposal to landfill without special confinement or storage. Consequently, MBRR may be utilized as an alternative adsorbent for treating Ra-contaminated groundwater.

The red mud accident in Ajka (Hungary): characterization and potential health effects of fugitive dust

As a result of a tragic industrial accident, a highly alkaline red mud sludge inundated settlements and agricultural areas near Ajka, Hungary on October 4, 2010. One of the major concerns about the aftermaths of the accident is the potential health effects of vast amounts of fugitive dust from red mud sediment. Thus, we studied the chemical and physical properties of particles of red mud and its respirable fugitive dust, and performed toxicity measurements. Under unfavorable meteorological conditions dry red mud sediment could emit very high amounts of respirable alkaline particles into the air. The number size distribution of fugitive dust peaks above 1 μm aerodynamic diameter; therefore, its inhalation is unlikely to affect the deep regions of the lungs. No significant mineralogical or elemental fractionation was observed between the sediment and dust, with the major minerals being hematite, cancrinite, calcite, and hydrogarnet. Although the high resuspension potential and alkalinity might pose some problems such as the irritation of the upper respiratory tract and eyes, based on its size distribution and composition red mud dust appears to be less hazardous to human health than urban particulate matter.