A perspective of stepwise utilisation of Bayer red mud: Step two--Extracting and recovering Ti from Ti-enriched tailing with acid leaching and precipitate flotation

Gallium recovery from red mud: Integration of solvent extraction and siderophore assisted technologies

Gallium (Ga) recovery from the red mud, though important has never been successful due to several technical and economic reasons such as contaminant interference and the high cost of membranes due to their faster saturation resulting in the clogging of membranes with contaminants. This study demonstrated the recovery of Ga by a combination of HCl-based leaching, Fe/Al/Ti separation, and recovery of Ga using Cyphos IL 104-based solvent extraction and complexation of Ga with desferrioxamine B as a proof-of-principle of the GaLIophore technology. The main leaching parameters such as concentrations of acids, time and temperature of the reaction, and solid-to-liquid ratio have been systematically investigated. The optimal leaching conditions were determined as 4 mol/L HCl, 2 h time, 80 °C temperature, and solid-to-liquid ratio 1:20 (g/mL) attaining a more than 90% leaching of Ga. Subsequently, more than 99% Ga was extracted from the leachate using 0.05 mol/L Cyphos IL 104 at A:O ratio 1 and stripped by 0.01 mol/L H2SO4 at O:A ratio 1 from the organic phase. Desferrioxamine B (DFOB) demonstrated selectivity by complexing with more than 90% Ga in a stripped solution. The interaction between extractable species of Ga and Cyphos IL 104 was studied by Density Functional Theory (DFT) calculations and infrared spectroscopy. The whole process demonstrated the recovery of Ga by more than 80% present in the red mud. Further, the preliminary economic analysis suggests that the process can be profitable when Fe, Al, Sc, and Ga are recovered at a minimum rate of 50, 50, 75, and 75%.

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

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

Study on the effect of sodium removal from citric acid pretreated red mud on the physical properties of red mud

Red mud is a highly alkaline solid waste discharged from the alumina industry, and its high sodium content is the key factor limiting its wide utilization. Therefore, effective control of the "frosting" phenomenon during the application of red mud has received significant attention. In this study, the changes of particle size, phase, morphology, and pore size of red mud after sodium removal with different amounts of citric acid pretreatment were investigated. The single-factor experiment shows that the Na+ leaching rate is 86.33% under a citric acid dosage of 15%, liquid-to-solid ratio of 7 mL/g, leaching temperature of 80 °C, stirring speed of 300 rpm, and leaching time of 10 min. The leachate is characterized through X-ray diffraction (XRD), scanning electron microscopy (SEM), and Brunauer-Emmett-Teller (BET) surface area analysis. The results reveal that Na+ mainly exists in a combined state in the form of cancrinite. With the increase of citric acid dosage, red mud agglomerates, calcite, and cancrinite are dissolved, and new phases such as calcium oxalate and magnesium aluminum hydroxide are formed. The specific surface area, pore volume, and pore diameter show irregular changes with the increase in the citric acid dosage. Citric acid pretreatment can effectively reduce the sodium content in red mud, the treatment cost of leaching solution is low, and the leaching residue is neutral, which is helpful to promote the practical application of red mud.

Application and development of foam extraction technology in wastewater treatment: A review

With the advancement of technology, wastewater treatment has become a significant challenge limiting the clean and sustainable development of chemical and metallurgical industries. Foam extraction, based on interfacial separation and mineral flotation, has garnered considerable attention as a wastewater treatment technology due to its unique physicochemical properties. Although considerable excellent accomplishments were reported, there still lacks a comprehensive summary of process features and contaminant removal mechanisms via foam extraction. According to the latest research progresses, the principles and characteristics of foam extraction technology, the classification and application of flotation reagents are systematically summarized in this work. Then comprehensively commented on the application fields and prospects of iterative flotation technology such as ion flotation, adsorption flotation and floating-extraction. The shortcomings and limitations of the current foam extraction technologies were discussed, and the feasible process intensification techniques were highlighted. This review aims to enchance the understanding of the foam extraction mechanism, and provides guidance for the selection appropriate reagents and foam extraction technologies in wastewater treatment.

Applying Red Mud in Cadmium Contamination Remediation: A Scoping Review

Red mud is an industrial solid waste rarely utilized and often disposed of in landfills, resulting in resource waste and environmental pollution. However, due to its high pH and abundance of iron and aluminum oxides and hydroxides, red mud has excellent adsorption properties which can effectively remove heavy metals through ion exchange, adsorption, and precipitation. Therefore, red mud is a valuable resource rather than a waste byproduct. In recent years, red mud has been increasingly studied for its potential in wastewater treatment and soil improvement. Red mud can effectively reduce the migration and impact of heavy metals in soils and water bodies. This paper reviews the research results from using red mud to mitigate cadmium pollution in water bodies and soils, discusses the environmental risks of red mud, and proposes key research directions for the future management of red mud in cadmium-contaminated environments.

Recovery of valuable metals from red mud: A comprehensive review

As a bulk solid waste with high alkalinity, red mud (RM) not only occupies a large amount of land and requires high maintenance costs, but also unavoidably generates serious hazards to the surrounding ecological environment. The comprehensive treatment of RM has become an enormous challenge for the green, low-carbon and high-quality development of the global alumina industry. To minimize the RM destruction to the ecology and the waste of secondary resources, the sustainable utilization of RM was widely investigated in the past decades, especially for the recovery of valuable metals. This paper systematically summarized the research status of recycling valuable metals (Al, Fe, Na, Ti, Sc, Ga, V and RE) from RM in recent years. The recycling technology mainly includes physical beneficiation, hydrometallurgy, pyrometallurgy and electrodialysis. The technical principles and characteristics as well as the current problems of various recovery processes from RM were comprehensively introduced, and the future development directions of sustainable utilization were also prospected. The advantages and disadvantages based on the different aspects of recovery efficiency, energy consumption and environmental impact were also discussed. The proposal of new technologies for the harmless, high-value and full utilization of RM is beneficial to the future research on the comprehensive utilization of bulk industrial solid wastes.

Efficient utilization of red mud waste via stepwise leaching to obtain α-hematite and mesoporous γ-alumina

Utilizing the red mud sustainably is now a challenging issue. Red mud due to its wide production, presence of some radioactive elements, high alkalinity, and salinity, has a dramatic potential to contaminate soil and groundwater. Notwithstanding its drawbacks, Red mud consists several elements, including Ca, Al, Ti, Si, and Fe, in various mineral forms. In this study, stepwise leaching was applied as a proper method to separate and purify the main valuable elements using available and affordable HCl. The pre-leaching step under optimized conditions using HCl (0.2 M) at room temperature for 2 h removed 89% of the calcium content from red mud. To selectively remove the solid silica, the residue was treated with concentrated HCl (3.0 M, L/S of 20 mL/g) at 95 °C, resulting in the dissolution of iron and aluminum content with up to 90% efficiency. After precipitation of the Fe³⁺ and Al³⁺, they were characterized using FT-IR, BET, EDS, XRD, SEM and TEM monographs, confirming the formation of nanosized hematite (α-Fe₂O₃) and mesoporous gamma alumina (γ-Al₂O₃). Consequently, inexpensive red mud was converted into highly valuable nano-sized metal oxides using simple, sustainable techniques and cheap reagents. Moreover, this technique generates the lowest amounts of waste during the leaching process and all reagents can be recycled for further uses, making this method a sustainable utilization.

High-Iron Bauxite Residue (Red Mud) Valorization Using Hydrochemical Conversion of Goethite to Magnetite

Bauxite residue (BR), also known as red mud, is a byproduct of the alumina production using the Bayer process. This material is not used to make iron or other iron-containing products worldwide, owing to its high content of sodium oxide and other impurities. In this study, we investigated the hydrochemical conversion of goethite (FeOOH) to magnetite (Fe₃O₄) in high-iron BR from the Friguia alumina refinery (Guinea) by Fe²⁺ ions in highly concentrated alkaline media. The simultaneous extraction of Al and Na made it possible to obtain a product containing more than 96% Fe₃O₄. The results show that the magnetization of Al-goethite and Al-hematite accelerates the dissolution of the Al from the iron mineral solid matrix and from the desilication product (DSP). After ferrous sulfate (FeSO₄·7H₂O) was added directly at an FeO:Fe₂O₃ molar ratio of 1:1 at 120 °C for 150 min in solution with the 360 g L^-1 Na₂O concentration, the alumina extraction ratio reached 96.27% for the coarse bauxite residue size fraction (Sands) and 87.06% for fine BR obtained from red mud. The grade of iron (total iron in the form of iron elements) in the residue can be increased to 69.55% for sands and 58.31% for BR. The solid residues obtained after leaching were studied by XRD, XRF, TG-DTA, VSM, Mössbauer spectroscopy, and SEM to evaluate the conversion and leaching mechanisms, as well as the recovery ratio of Al from various minerals. The iron-rich residues can be used in the steel industry or as a pigment.

A review of comprehensive utilization of red mud

Red mud (RM) is a solid waste generated during the process of alumina production. RM has already posed a serious environmental threat with the development of the alumina refining industry. The comprehensive utilization of RM has attracted much attention due to its large-scale generation and harmful nature. This paper introduces the characteristics and state of RM and summarizes the relevant research on the comprehensive utilization of RM. The results show that comprehensive utilization of RM is mainly focused on the preparation of building materials, the extraction of valuable metals, catalyst synthesis and environmental protection. Besides, the article discusses the existing problems while utilizing RM. Prospects and suggestions for different utilization methods of RM are proposed.

Effect of Carbide Slag on Removal of Na+/K+ from Red Mud Based on Water Leaching

Red mud (RM) is a hazardous solid waste discharged from the alumina production process. The stock of RM is very large, and it has strong alkalinity and certain radioactivity, which makes it have a very serious adverse effect on the environment. Many scholars have carried out extensive experimental investigations on the minimization, hazard-free treatment, and reutilization of RM, and encouraging results have been obtained. However, reutilization of RM has been restricted mainly due to its complex composition and strong alkalinity. In this study, carbide slag, a byproduct of acetylene production, was utilized to remove alkalis (Na⁺ and K⁺) from RM by calcium ion replacement. The effects of the temperature, liquid-to-solid ratio, carbide slag dose, and leaching time on dealkalization of RM by carbide slag were studied. The leaching mechanism of sodium was investigated and analyzed using inductively coupled plasma-atomic emission spectrometry, X-ray diffraction, and scanning electron microscopy with energy-dispersive spectrometry. Under the optimal conditions, the residual Na₂O and K₂O amount in the RM after dealkalization using the carbide slag diminished to less than 0.93 and 0.45 wt %. More than 78.80% of Na₂O and 58.84% of K₂O could be dissolved under the optimal conditions. The cancrinite structure in the initial RM was destroyed, and soluble sodium salts formed in the suspension can be easily replaced by carbide slag reducing Na⁺. The dealkalization process of RM by using carbide slag was controlled by chemical reaction of shrinking core model, where the apparent activation energy was 4.92 kJ/mol.

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.

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.

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.

An efficient separation for metal-ions from wastewater by ion precipitate flotation: Probing formation and growth evolution of metal-reagent flocs

Hazardous metal pollution became a severe environmental issue in China. An efficient precipitation-flotation process was developed to achieve fast removal for metal-ions from wastewater. Structure and strength of precipitate particles/flocs significantly influence the flotation removal of metal-ions. Formation and growth-evolution of precipitate flocs in precipitate flotation were studied by stage analysis of precipitate particles-formation, flocs-regulation and flotation separation. The results demonstrate that early formed precipitates MHA(humics-metal complexing particles) have small particle size, high fractal dimension, low strength and recovery factor. The addition of Fe³⁺ and CTAB(cetyl trimethyl ammonium bromide) reagents make the precipitate particles aggregated to flocs(MHA-Fe, MHA-Fe-CTAB) much more large, loose, coarse, and small-density. The final generated MHA-Fe-CTAB flocs are hard to be broken up, easy to be recovered and efficient to be separated by flotation process. The flotation removal of MHA-Fe-CTAB flocs is clearly higher than that of MHA or MHA-Fe. The flotation results of MHA-Fe-CTAB are as follows: flotation removal of 98.7 ± 0.40%-99.9 ± 0.10%, residual TOC of 0.96 ± 0.38-1.35 ± 0.41 mg/L and turbidity of 0.44 ± 0.09-0.63 ± 0.16 NTU. Introducing Fe³⁺ and CTAB reagents into flotation solution contributes to the growth-evolution of precipitate flocs, which could intensify the metal-ions removal via precipitate flotation process and result in more ideal purification indexes for metal-containing wastewater.

Variation on leaching behavior of caustic compounds in bauxite residue during dealkalization process

Bauxite residue, a byproduct of alumina manufacture, is a serious environmental pollutant due to its high leaching contents of metals and caustic compounds. Four typical anions of CO₃^2-, HCO₃^-, Al(OH)₄^- and OH^- (represented caustic compounds) and metal ions (As, B, Mo and V) were selected to assess their leaching behavior under dealkalization process with different conditions including liquid/solid ratio (L/S ratio), temperature and leaching time. The results revealed that washing process could remove the soluble composition in bauxite residue effectively. The leaching concentrations of typical anions in bauxite residue decreased as follows: c(CO₃^2-) > c(HCO₃^-) > c[Al(OH)₄^-] > c(OH^-). L/S ratio had a more significant effect on leaching behavior of OH^-, whilst the leaching concentration of Al(OH)₄^- varied larger underleaching temperature and time treatment. Under the optimal leaching, the total alkaline, soluble Na concentrations, exchangeable Ca concentrations were 79.52, 68.93, and 136.0 mmol/L, respectively, whilst the soluble and exchangeable content of As, B, Mo and V in bauxite residue changed slightly. However, it should be noted that water leaching has released metal ions such as As, B, Mo and V in bauxite residue to the surrounding environment. The semiquantitative analysis of XRD revealed that water leaching increased the content of gismondine from 2.4% to 6.4%. The SEM images demonstrated the dissolution of caustic compounds on bauxite residue surface. The correlation analysis indicated that CO₃^2- and HCO₃^- could effectively reflect the alkalinity of bauxite residue, and may be regarded as critical dealkalization indicators to evaluate alkalinity removal in bauxite residue.

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.

Selective recovery of vanadium and scandium by ion exchange with D201 and solvent extraction using P507 from hydrochloric acid leaching solution of red mud

D201 resin and P507 extractant diluted with sulfonated kerosene were used to respectively separate vanadium and scandium, and impurity ions from hydrochloric acid leaching solution of red mud. More than 99% of vanadium was selectively adsorbed from the hydrochloric acid leaching solution under the conditions of pH value of 1.8, volume ratio of leaching solution to resin of 10, and flow rate of 3.33 mL/min. Maximum extraction and separation of scandium was observed from the acid leaching solution at an aqueous pH value of 0.2. More than 99% of scandium can be selectively extracted using 15% P507, 5% TBP at the aqueous solution/organic phase (A/O) ratio of 10:1 for 6 min. The loaded organic phase was washed with 0.3 mol/L sulfuric acid, wherein most impurities were removed. After the process of desorption or stripping, precipitation, and roasting, high-purity V₂O₅ and Sc₂O₃ were obtained. Finally, a conceptual flow sheet was established to separate and recover vanadium and scandium from red mud hydrochloric acid leaching solution.

The recycle of red mud as excellent SCR catalyst for removal of NOx

The red mud is reused as catalyst with excellent DeNO_x efficiency at high temperature by milling and neutralization method.

Probing acid/base chemistry and adsorption mechanisms of hydrolysable Al(iii) species with a clay system in aqueous solution

The acid/base chemistry of hydrolysable Al(iii) species with a clay (bentonite and kaolin) system was investigated at 35 °C in the expanded solution pH range from 1 to 9.