Applications of bauxite residue: A mini-review

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.

5-year leaching experiments to evaluate a modified bauxite residue: remediation of sulfidic mine tailings

The ALTEO company produces approximately 300,000 tons per year of bauxite residue after alumina extraction, which is washed and dried in a press filter to produce Bauxaline®. In this study, different ways for recovering and reusing this residue were explored, namely transformation into a vegetated soil, use in acid mine drainage depollution, and application in sulfide-mine tailings remediation. The Bauxaline® was therefore transformed into modified bauxite residue (MBR), resulting in reduced alkalinity, salinity, and sodicity. To counterbalance the net acid generation potential of two sulfidic mine tailings with 1 mol H+ kg-1 (1.5% sulfide) and 3.3 mol H+ kg-1 (5.3% sulfide), respectively, various treatments were applied. These treatments included the addition of 10% MBR or 10% MBR plus limestone, or by limestone only, within 40-l lysimeters. Six lysimeters were monitored over a 5-year period to assess the long-term emissions from treated materials. Vegetation was tested under various conditions, and its impact on emission was evaluated. The emissions of mine tailings treated with MBR and limestone were very low. The mine tailings with limestone showed intermittent peaks of emission, probably due to the coating of calcite grain by ferric oxide, hindering contact with percolating water. Vegetation successfully grew in the treated tailings. This study demonstrated that the alkalinity of limestone can temporarily immobilize elements in sulfidic mine tailings, with a reduction factor of emissions of 300 and 40 for the two mine tailings, respectively. For long-term immobilization, the alkalinity provided by both limestone and MBR and the Al and Fe oxides of MBR are more effective and necessary for long-term immobilization, with a reduction factor of 300 and 900, respectively.

Alkaliphiles for comprehensive utilization of red mud (bauxite residue)-an alkaline waste from the alumina refinery

The mining industry has powered the human endeavor to make life more innovative, flexible, and comfortable. However, it has also led to concerns due to the increasing amount of mining and associated industrial waste. Special attention is highly desired for its proper management and safe disposal in the environment. The problem has only augmented with the increase in the mining costs because of the investments needed for ecological remediation after the mining operation. It is pertinent that the targeted technologies need to be developed to utilize mining and associated industrial waste as a secondary resource to ensure sustainable mining operations. Every perceived waste is a valuable resource that is needed to be utilized to create additional value. In this review, the case of alkaline bauxite residue (red mud)-alumina refinery waste has been discussed at length. The highlight of the proposed work is to understand the importance of alkaliphile-assisted biomining-a sustainable alternative to conventional metal recovery processes. Along with the recovery of metals, pH reduction of red mud is possible through biomining, which ultimately paves the way for its complete utilization. The unique adaptation strategies of alkaliphiles make them more suitable for biomining of red mud through bioleaching, biosorption, and bioaccumulation, which have been discussed here. Furthermore, we have focused on the potential of the indigenous microflora of red mud for metal recovery in addition to its neutralization. The study of indigenous alkaliphiles from red mud, including its isolation and propagation, is crucial for the industrial-scale application of alkaliphile-based technology and has been emphasized.

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

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

Alkalinity neutralization and structure upgrade of bauxite residue waste via synergistic pyrolysis with biomass

Bauxite residues, a large volume solid waste, are in urgent need of effective disposal and management. Especially, strategies to alleviate the high alkalinity of bauxite residue remain a big challenge. Here, we developed a synergistic pyrolysis to neutralize the alkalinity of bauxite residue and upgrade the structure of biomass simultaneously. By cooperating the catalytic feature from bauxite residue, rice straw, a cellulose-enriched biomass, could prefer to produce acidic components under a hypothermal pyrolysis temperature (below 250 °C) and partial oxygen-contained atmosphere as evidenced by the synchronous TGA-FTIR analysis. In return, these in-situ produced acidic components neutralized the bauxite residue profoundly (pH decreased from 11.5 to 7.2) to obtain a neutral product with long-term water leaching stability. Also, a higher pyrolysis temperature led to neutral biochar-based products with well-defined carbonization characteristics. Thus, the biomass-driven pyrolysis strategy provides a potential to dispose the alkalinity issue of bauxite residue and further opportunities for the sustainable reuse and continuing management of bauxite residue.

Physicochemical and Microstructural Properties of Red Muds under Acidic and Alkaline Conditions

The main purpose of this study was to characterize the mineral and chemical composition of typical red muds in China. Changes in the physicochemical and microstructural properties of red muds collected from the Shanxi and Shandong provinces were investigated after they were immersed in an alkaline NaOH or an acidic HCl solution for 7, 28, and 120 days. The results showed that red mud has a high cation exchange capacity and active physicochemical properties, which can be closely related to its extremely high alkalinity and complex microstructure. The neutralization of red mud with the HCl solution results in the release of Na+ from the red mud particles into the leachate and can effectively decrease the pH value of the filtrate. The neutralization process can result in a significant decrease in the liquid limit, plastic limit and plasticity index, whereas the opposite was observed for the different parameters after the addition of the NaOH solution. In this sense, acid neutralization can significantly improve the cementation property of the red mud. This result will increase the water permeability of the acid-treated soil layer and improve the growth ability of plants. The specific surface area of red mud immersed in the NaOH solution decreased, whereas the specific surface area of red mud immersed in the HCl solution increased. This study contributes to our understanding of red mud properties after the red mud has been subjected to acidic and alkaline treatments, and the results can provide insights into the safe disposal of red mud.

Mineralogical and Geochemical Constraints of the REE Accumulation in the Almásfüzitő Red Mud Depository in Northwest Hungary

Detailed mineralogical and geochemical study of red mud samples from Hungary suggests geological and geochemical processes that determine the spatial distribution of certain elements inside the red mud pitfalls. The major processes are the following: (1) Heavy mineral grains (anatase, rutile, titanomagnetite, etc.) tend to subside due to gravitational differentiation and at present accumulate in the deepest horizons of the pitfalls. (2) Kaolinite reacts to cancrinite under hyperalkaline conditions. (3) Due to diagenetic processes, goethite-cancrinite aggregates form in situ. (4) Light mineral grains (e.g., cancrinite) move upward. (5) Cancrinite transforms to calcite at the shallowest horizons, due probably to the reaction with atmospheric CO2. All these processes have a significant role in accumulation tendencies of different groups of elements inside the pitfalls. The behaviour of chalcophile elements and the HFSE elements follow common geochemical rules and remind features of the host bauxite or even its precursor igneous or metamorphic lithologies. The REEs and Sc are possibly adsorbed on goethite and in the channels of cancrinite. Based on linear mixing model calculations, the major container of these elements is cancrinite. The proportion of the REEs and Sc in the Ti-phases, carbonates, phosphates, zircon, etc. is subordinate relative to the amount accumulated by goethite and cancrinite.