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

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.

Conversion of alkaline characteristics of bauxite residue by mechanical activated pretreatment: Implications for its dealkalization

Following the strict environmental policies of various countries, the strong alkalinity of bauxite residue (BR) has become a worldwide problem limiting the sustainable development of the global alumina industry. Continuous conversion of solid-phase alkalinity to free alkali is a major challenge for BR dealkalization to reduce its environmental impact. This work aimed to investigate the effect of mechanical grinding pretreatment on the transformation mechanisms of alkaline solids to free alkali at the BR interface under acids leaching, by monitoring the morphology, phase, and speciation transformations of Al and Si using primarily cross-section scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS) elemental mapping, X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS). The results indicated that particle grinding wrapped some of the alkaline minerals inside the particles to inhibit its release process. The leaching kinetics revealed the order of the buffering effect of minerals against acids leaching is firstly dissolved by minerals containing Na and Ca via the ion-exchange process, followed by Si and Al through the hydrolysis of the desilicated products. The mineral dissemination characteristics and surface compositions further confirmed the undissolved minerals block the interface reaction between embedded alkaline solids and acids to result in the difficult reaction dissolution of alkaline minerals, which is induced by ball milling. This novel approach provides new insight into the efficient dealkalization of BR on a large scale in the industry.

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.

Phosphate recovery with granular acid-activated neutralized red mud: Fixed-bed column performance and breakthrough curve modelling

Granular acid-activated neutralized red mud (AaN-RM) has been successfully prepared with good chemical stability and physical strength. However, its potential for industrial application remains unknown. Therefore, the performance of granular AaN-RM for phosphate recovery in a fixed-bed column was investigated. The results demonstrated that the phosphate adsorption performance of granular AaN-RM in a fixed-bed column was affected by various operational parameters, such as the bed depth, flow rate, initial solution pH and initial phosphate concentration. With the optimal empty-bed contact time (EBCT) of 24.27 min, the number of processed bed volumes and the phosphate adsorption capacity reached 496.95 and 84.80 mg/g, respectively. Then, the saturated fixed-bed column could be effectively regenerated with a 0.5 mol/L HCl solution. The desorption efficiency remained as high as 83.45% with a low weight loss of 3.57% in the fifth regeneration cycle. In addition, breakthrough curve modelling showed that a 5-9-1 feed-forward artificial neural network (ANN) could be effectively applied for the optimization of the fixed-bed adsorption system; the coefficient of determination (R²) and the root mean square error (RMSE) evaluated on the validation-testing data were 0.9987 and 0.0183, respectively. Therefore, granular AaN-RM fixed-bed adsorption exhibits promising potential for phosphate removal and recovery from polluted water.

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.

Enhancing sludge methanogenesis with improved redox activity of extracellular polymeric substances by hematite in red mud

Different conductive materials have been employed to stimulate direct interspecies electron transfer (DIET) during methanogenesis, but few studies have been concerned with the interaction between conductive materials and extracellular polymeric substances (EPS) such as the effect on sludge aggregation and redox activity of EPS. This study aims to systematically investigate the role of red mud with 45.46 wt% hematite on methanogenesis during the anaerobic digestion of waste activated sludge. The results showed that the multivalent cations from hematite effectively promoted the formation of large and compact aggregates, which might contribute to the rapid direct electron exchange during the DIET process. Meanwhile, more redox-active mediators including c-type cytochromes (c-Cyts) and humic substances, particularly in tight-bound EPS (TB-EPS), and more redox-active metals such as Fe introduced by red mud could take part in the interspecies electron transfer process between syntrophic bacteria and methanogenic archaea, which also promoted methane production (35.52 ± 2.64% increase compared with the control). This study provided initial scientific evidence to comprehensively assess the role of conductive materials during methanogenesis, with important implications for the biogeochemical redox processes of conductive minerals in natural and engineered environments.

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.

Effect of experimental variables onto Co(2+) and Sr(2+) sorption behavior in red mud-water suspensions

The prospects of rinsed red mud (alumina production residue) utilization for liquid radioactive waste treatment have been investigated, with Co(2+) and Sr(2+) as model cations of radioactive elements. To evaluate the sorption effectiveness and corresponding binding mechanisms, the process was analyzed in batch conditions, by varying experimental conditions (pH, Co(2+) and Sr(2+) concentrations in single solutions and binary mixtures, contact time, and the concentration of competing cations and ligands common in liquid radioactive waste). Comparison of the Co(2+) and Sr(2+) sorption pH edges with the red mud isoelectric point has revealed that Co(2+) removal took place at both positive and negative red mud surface, while Sr(2+) sorption abruptly increased when the surface became negatively charged. The increase of initial cation content and pH resulted in increased equilibrium times and sorption capacity and decreased rate constants. From single metal solutions and various binary mixtures, Co(2+) was sorbed more efficiently and selectively than Sr(2+). While Sr(2+) sorption was reduced by coexisting cations in the order Al(3+) ≥ Ca(2+) >Na(+) ≥Cs(+), removal of Co(2+) was affected by Al(3+) species and complexing agents (EDTA and citrate). Desorption of Co(2+) was negligible in Ca(2+) and Sr(2+) containing media and in solutions with initial pH 4-7. Sr(2+) desorption was generally more pronounced, especially at low pH and in the presence of Co(2+). Collected macroscopic data signify that Co(2+) sorption by red mud minerals occurred via strong chemical bonds, while Sr(2+) was retained mainly by weaker ion-exchange or electrostatic interactions. Results indicate that the rinsed red mud represent an efficient, low-cost sorbent for Co(2+) and Sr(2+) immobilization.

Application of acid-activated Bauxsol for wastewater treatment with high phosphate concentration: Characterization, adsorption optimization, and desorption behaviors

Acid-activated Bauxsol was applied to treat wastewater with high phosphate concentration in a batch adsorption system in this paper. The effect of acid activation on the change of Bauxsol structure was systematically investigated. The mineralogical inhomogeneity and intensity of Bauxsol decreased after acid activation, and FeCl3·2H2O and Al(OH)3 became the dominant phases of acid-activated Bauxsol adsorption. Moreover, the BET surface area and total pore volume of Bauxsol increased after acid activation. Interaction of initial solution pH and adsorption temperature on phosphate adsorption onto acid-activated Bauxsol was investigated by using response surface methodology with central composite design. The maximum phosphate adsorption capacity of 192.94 mg g(-1) was achieved with an initial solution pH of 4.19 and an adsorption temperature of 52.18 °C, which increased by 7.61 times compared with that of Bauxsol (22.40 mg g(-1)), and was higher than other adsorbents. Furthermore, the desorption studies demonstrated that the acid-activated Bauxsol was successfully regenerated with 0.5 mol L(-1) HCl solution. The adsorption capacity and desorption efficiency of acid-activated Bauxsol maintained at 80.48% and 93.02% in the fifth adsorption-desorption cycle, respectively, suggesting that the acid-activated Bauxsol could be repeatedly used in wastewater treatment with high phosphate concentration.

Atom-efficient route for converting incineration ashes into heavy metal sorbents

Bottom ashes produced from municipal solid-waste incineration are suitable for sorbent synthesis because of their inherent composition, high alkalinity, metastable mineralogy, and residual heat. This work shows that bottom ashes can be atom-efficiently converted into valuable sorbents without the need for costly and hazardous chemicals. The ashes were hydrothermally treated in rotary autoclaves at autogenic pH conditions to promote the conversion of precursor mineral phases into zeolites and layered silicate hydrates. Two main mineral phases were formed: katoite and sodium aluminum phosphate silicate hydrate. These mineral alterations are accompanied by a tenfold increase in specific surface area and a twofold reduction in average particle size. Performance evaluation of the new sorbents for Cd(2+), Zn(2+), and Pb(2+) adsorption at pH5 indicates sorption capacities of 0.06, 0.08, and 0.22 mmol g(-1), respectively, which are similar to those of natural adsorbents and synthetic materials obtained from more demanding synthesis conditions.