Iron Recovery from Bauxite Tailings Red Mud by Thermal Reduction with Blast Furnace Sludge

The Waelz Slag from Electric Arc Furnace Dust Processing: Characterization and Magnetic Separation Studies

The Waelz slag generated during electric arc furnace dust processing is an iron-rich product with significant amounts of iron, zinc and copper. About 600-800 kg of the Waelz slag is generated per ton of the dust processed. The Waelz slag samples from two different plants were thoroughly characterized using inductively coupled plasma optical emission spectroscopy (ICP-AES), X-ray diffraction analysis (XRD), chemical phase analysis, Mössbauer spectroscopy and other supporting methods. The phase distribution of iron, zinc and copper was determined in the Waelz slag samples. Low-intensity wet magnetic separation was tested for the iron recovery from the Waelz slag samples. It was found that the Waelz slag samples have complex chemical and mineralogical compositions, which can impede the selective recovery of valuable elements. The obtained results indicate that the chemical and mineralogical composition of the Waelz slag samples has a considerable effect on the magnetic separation indexes. The experiments showed that the iron concentrates with Fe contents of 73% and 46.8% with the metallization degrees of 87.2% and 57.5% and the iron recovery degree of 54.8% and 52.9% were obtained at optimal conditions for two different samples, respectively, without selective segregation of Cu and Zn in the magnetic or non-magnetic fraction.

A selective hydrometallurgical method for scandium recovery from a real red mud leachate: A comparative study

The aim of this study was to recover Sc as the main product and Fe as a by-product from Hungarian bauxite residue/red mud (RM) waste material by solvent extraction (SX). Moreover, a new technique was developed for the selective separation of Sc and Fe from real RM leachates. The presence of high Fe content (∼38%) in RM makes it difficult to recover Sc because of the similarity of their physicochemical properties. Pyrometallurgical and hydrometallurgical methods were applied to remove the Fe prior to SX. Two protocols based on organophosphorus compounds (OPCs) were proposed, and the main extractants were evaluated: bis(2-ethylhexyl) phosphoric acid (D2EHPA/P204) and tributyl phosphate (TBP). The results showed that SX using diethyl ether and tri-n-octylamine (N₂₃₅) was efficient in extracting Fe(III) from the HCl leachate as HFeC1₄. Over 97% of Sc was extracted by D2EHPA extractant under the following conditions; 0.05 mol/L of D2EHPA concentration, A/O phase ratio of 3:1, pH 0-1, 10 min of shaking time, and a temperature of 25 °C. Sc(OH)₃ as a precipitate was efficiently obtained by stripping from the D2EHPA organic phase by 2.5 mol/L of NaOH with a stripping efficiency of 95%. In the TBP system, 99% of Sc was extracted under the following conditions: 12.5% vol of TBP, an A/O phase ratio of 3:1, 10 min of shaking time, and a temperature of 25 °C. The Sc contained in the TBP organic phase could be efficiently stripped by 1 mol/L of HCl with a stripping efficiency of 92.85%.

Preparation of Battery-Grade FePO4·2H2O Using the Stripping Solution Generated from Resource Recycling of Bauxite Residue

A novel process for the high-value-use of iron from bauxite residue was proposed in this work. The process was trying to use the iron-containing stripping solution generated during resource recycling of bauxite residue to produce battery-grade FePO₄·2H₂O product. Thermodynamics calculation indicates that Fe and P in the stripping solution mainly existed in the form of FeHPO₄⁺, and the theoretical pH for the conversion reaction from FePO₄·2H₂O to Fe(OH)₃ was 1.72. The optimal condition for the synthesis of FePO₄·2H₂O using the stripping solution was determined as: reaction pH of 0.8, reaction temperature of 90°C, Fe/P ratio of 1, and reaction time of 24 h. XRD result showed that the synthesized FePO₄·2H₂O was well-crystallized and perfectly matched with the characteristic peaks of FePO₄·2H₂O. Moreover, all the parameters of the synthesized iron phosphate meet the quality requirements of battery precursor.

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.

An Overview of Thermal Plasma Arc Systems for Treatment of Various Wastes in Recovery of Metals

Thermal plasma systems are being used for the recovery of metals from complex waste and minerals. The latter contain multiphase metals in various forms that are extremely tedious to separate. Thermal plasma arc melts the waste and minerals for qualitative plasma products for powder industries. In this overview, we briefly report a description of the various thermal plasma systems and their uses in recovering metal from metal-containing materials in the form of waste or minerals. Various plasma arc systems, such as transferred, nontransferred, and extended arc, have enabled the development of an efficient and environmentally friendly way to recover valuable metals from industrial wastes such as red mud and minerals such as ilmenite.

Chemoselective decarboxylation of ceiba oil to diesel-range alkanes over a red mud based catalyst under H2-free conditions

Concerns over global greenhouse gas emissions such as CO_x and NO_x as well as the depletion of petroleum fossil resources have motivated humankind to seek an alternative energy source known as green diesel. In this study, green diesel was produced via a deoxygenation (DO) reaction of ceiba oil under a H₂-free atmosphere over Ni modified red mud-based catalysts, which have been synthesized via a precipitation – deep-deposition assisted autoclave method. The obtained catalyst was further characterized by XRF, XRD, BET, FTIR, TPD-NH₃, FESEM, and TGA. Based on the catalytic activity test, all Ni/RMO_x catalysts facilitated greater DO activity by yielding 83–86% hydrocarbon yield and 70–85% saturated diesel n-(C₁₅ + C₁₇) selectivity. Ni/RMO₃ was the best catalyst for deoxygenizing the ceiba oil owing to the existence of a high acidic strength (12717.3 μmol g⁻¹) and synergistic interaction between Fe–O and Ni–O species, thereby producing the highest hydrocarbon yield (86%) and n-(C₁₅ + C₁₇) selectivity (85%). According to the reusability study, the Ni/RMO₃ could be reused for up to six consecutive runs with hydrocarbon yields ranging from 53% to 83% and n-(C₁₅ + C₁₇) selectivity ranging from 62% to 83%.

Concerns over global greenhouse gas emissions such as CO_x and NO_x as well as the depletion of petroleum fossil resources have motivated humankind to seek an alternative energy source known as green diesel.

Extraction of Valuable Elements from Red Mud with a Focus on Using Liquid Media—A Review

Bauxite residue, known as red mud, is a by-product of alumina production using the Bayer process. Currently, its total global storage amounts to over 4.6 billion tons, including about 600 million tons in Russia. The total global storage of red mud occupies large areas, leading to environmental damage and increasing environmental risks. Moreover, it contains a significant amount of sodium, which is easily soluble in subsoil water; therefore, a sustainable approach for comprehensive recycling of red mud is necessary. The bauxite residue contains valuable elements, such as aluminum, titanium, and scandium, which can be recovered using liquid media. In recent years, many methods of recovery of these elements from this waste have been proposed. This paper provides a critical review of hydrometallurgical, solvometallurgical, and complex methods for the recovery of valuable components from red mud, namely, aluminum, titanium, sodium, and rare and rare-earth elements. These methods include leaching using alkaline or acid solutions, ionic liquids, and biological organisms, in addition to red mud leaching solutions by extraction and sorption methods. Advantages and disadvantages of these processes in terms of their environmental impact are discussed.

Experimental Evaluation of PM Emission from Red Mud Basins Exposed to Wind Erosion

The disposal of industrial and mineral processing residues represents a major concern for human health and the environment as a whole. In order to reduce the impact on soil and groundwater due to the waste leachability, the implementation of environmental regulations worldwide has favored the conversion of the disposal techniques from wet to dry (i.e., dry stacking or dry disposal). Such a change in the storage practice may cause the increase of particulate matter (PM) emission from the dry surfaces of the tailings exposed to wind erosion. Considering the significance of the environmental issue on a global scale and the increasingly stricter orientation of environmental policies, the need for modeling tools capable of estimating the contribution of tailing basins to air pollution becomes apparent. The paper deals with the disposal of red mud resulting from the bauxite processing in the alumina industry. An experimental research was carried with an environmental wind tunnel to estimate the Emission Factor (EF) of the basin surfaces as a function of the main affecting variables (i.e., residue water content and wind velocity). The article reports the results of the experimental test carried out on the red mud from a major basin located in Sardinia (Italy).

Research on High-Pressure Hydrochloric Acid Leaching of Scandium, Aluminum and Other Valuable Components from the Non-Magnetic Tailings Obtained from Red Mud after Iron Removal

Red mud is a hazardous waste of the alumina industry that contains high amounts of iron, aluminum, titanium and rare-earth elements (REEs). One of the promising methods for the extraction of iron from red mud is carbothermic reduction with the addition of sodium salts. This research focuses on the process of hydrochloric high-pressure acid leaching using 10 to 20% HCl of two samples of non-magnetic tailings obtained by 60 min carbothermic roasting of red mud at 1300 °C and the mixture of 84.6 wt.% of red mud and 15.4 wt.% Na2SO4 at 1150 °C, respectively, with subsequent magnetic separation of metallic iron. The influence of temperature, leaching duration, solid-to-liquid-ratio and acid concentration on the dissolution behavior of Al, Ti, Mg, Ca, Si, Fe, Na, La, Ce, Pr, Nd, Sc, Zr was studied. Based on the investigation of the obtained residues, a mechanism for passing valuable elements into the solution was proposed. It has shown that 90% Al, 91% Sc and above 80% of other REEs can be dissolved under optimal conditions; Ti can be extracted into the solution or the residue depending on the leaching temperature and acid concentration. Based on the research results, novel flowsheets for red mud treatment were developed.

Ammonium and organic carbon co-removal under feammox-coupled-with-heterotrophy condition as an efficient approach for nitrogen treatment

Nitrification is the rate limiting step in the nitrogen removal processes since nitrifiers have high oxygen demand, but poorly compete with aerobic heterotrophs. In a laboratory-scaled system, we investigated a process of ammonium oxidation under ferric-iron reducing condition (feammox) in the presence of organic carbon using influents with high NH₄⁺ and COD contents, and ferrihydrite as the only electron acceptor. Batch incubations testing influents with different NH₄⁺ and COD concentrations revealed that the [COD]/[NH₄⁺] ratio of 1.4 and the influent redox potential ranging from - 20 to + 20 mV led to the highest removal efficiencies, i.e. 98.3% for NH₄⁺ and 58.8% for COD. N₂ was detected as the only product of NH₄⁺ conversion, whereas NO₂^- and NO₃^- were not detected. While operating continuously with influent having a [COD]/[NH₄⁺] ratio of 1.4, the system efficiently removed NH₄⁺ (> 91%) and COD (> 54%) within 6 day retention time. Fluorescence in situ hybridization analyses using Cy3-labeled 16S rRNA oligonucleotide probes revealed that gamma-proteobacteria dominated in the microbial community attaching to the matrix bed of the system. The iron-reduction dependent NH₄⁺ and COD co-removal with a thorough conversion of NH₄⁺ to N₂ demonstrated in this study would be a novel approach for nitrogen treatment.

Waste to Catalyst: Synthesis of Catalysts from Sewage Sludge of the Mining, Steel, and Petroleum Industries

The generation of sewage sludge presents a problem for several manufacturing companies as it results from industrial processes or effluent treatment systems. The treatment of this type of waste requires high economic investment, for this reason, it is necessary to find alternatives to recover the valuable materials of the sludges. In this study, metal catalysts were synthesized using waste sludge from the steel, mining, and hydrocarbon industries. The waste sludge was subjected to thermal treatments for the removal of organic content and the reduction of metals with hydrogen current to activate their catalytic properties. The sludge and synthesized catalysts were analyzed to determine their physical, chemical, thermoenergetic, and catalytic properties. Catalytic activity was evaluated using CO chemisorption and by thermal–catalytic decomposition of crude oil. The best conditions for synthesizing the catalysts were a calcination temperature between 300 and 500 °C and a reduction temperature between 300 and 900 °C. The catalysts presented a specific surface between 2.33 and 16.78 m2/g. The catalytic material had a heat capacity between 0.7 and 1.2 kJ/kg∙K. The synthesized materials presented catalytic activity comparable to that of commercial catalysts. With this recovery technique, the industrial waste can be valorized, obtaining catalyst derived from the sludges and promoting the circular economy of manufacturing companies.