Red Mud from the Aluminium Industry: Production, Characteristics, and Alternative Applications in Construction Materials—A Review

Properties of Red-Mud-Modified Basic Magnesium Sulfate Cement

This study aimed to decipher the influence of red mud on the mechanical properties, pore structure, and microstructure of basic magnesium sulfate cements (BMSCs). The results showed that BMSC prepared with an appropriate addition of red mud exhibited improved mechanical properties and yielded the highest compressive strength of 94.54 MPa after curing for 28 days. Adding red mud reduced the total porosity and optimized the pore structure of BMSC. The microstructure and hydration products of the specimens were examined using X-ray diffraction, scanning electron microscopy, and energy-dispersive spectroscopy. The results illustrate that the addition of 50% red mud did not affect the amount of the main strength phase 5-1-7 produced in BMSC. It could also reduce the residual amount of MgO and the generation of Mg(OH)2. The red mud and the M-S-H gel generated by the reaction between active SiO2 and α-MgO in the red mud together filled the pore structure of BMSC, making its microstructure denser and higher-strength. This study aims to improve the comprehensive use of red mud, and the results show that red mud can improve the mechanical properties of BMSCs, protecting the environment and simultaneously reducing BMSC production costs to create good economic benefits.

Green steel from red mud through climate-neutral hydrogen plasma reduction

Red mud is the waste of bauxite refinement into alumina, the feedstock for aluminium production1. With about 180 million tonnes produced per year1, red mud has amassed to one of the largest environmentally hazardous waste products, with the staggering amount of 4 billion tonnes accumulated on a global scale1. Here we present how this red mud can be turned into valuable and sustainable feedstock for ironmaking using fossil-free hydrogen-plasma-based reduction, thus mitigating a part of the steel-related carbon dioxide emissions by making it available for the production of several hundred million tonnes of green steel. The process proceeds through rapid liquid-state reduction, chemical partitioning, as well as density-driven and viscosity-driven separation between metal and oxides. We show the underlying chemical reactions, pH-neutralization processes and phase transformations during this surprisingly simple and fast reduction method. The approach establishes a sustainable toxic-waste treatment from aluminium production through using red mud as feedstock to mitigate greenhouse gas emissions from steelmaking.

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.

Environmentally Friendly New Catalyst Using Waste Alkaline Solution from Aluminum Production for the Synthesis of Biodiesel in Aqueous Medium

Red mud (RM) is composed of a waste alkaline solution (pH = 13.3) obtained from the production of alumina. It contains high concentrations of hematite (Fe₂O₃), goethite (FeOOH), gibbsite [Al(OH)₃], a boehmite (AlOOH), anatase (Tetragonal-TiO₂), rutile (Ditetragonal dipyramidal-TiO₂), hydrogarnets [Ca₃Al₂(SiO₄)_3-x(OH)_4x], quartz (SiO₂), and perovskite (CaTiO₃). It was shown to be an excellent catalytic mixture for biodiesel production. To demonstrate the value of RM, an environmentally friendly process of transesterification in aqueous medium using waste cooking oil (WCO), MeOH, and waste alkaline solution (WAS) obtained from aluminum production was proposed. Triglycerides of WCO reacted with MeOH at 60 °C to yield mixtures of fatty acid methyl esters (FAMEs) in the presence of 0.019% (w/w) WAS/WCO using the WAS (0.204 mol L^-1, predetermined by potentiometric titration) from aluminum production by the Bayer process. The use of the new catalyst (WAS) resulted in a high yield of the products (greater than 99% yield).

The Materials Science behind Sustainable Metals and Alloys

Production of metals stands for 40% of all industrial greenhouse gas emissions, 10% of the global energy consumption, 3.2 billion tonnes of minerals mined, and several billion tonnes of by-products every year. Therefore, metals must become more sustainable. A circular economy model does not work, because market demand exceeds the available scrap currently by about two-thirds. Even under optimal conditions, at least one-third of the metals will also in the future come from primary production, creating huge emissions. Although the influence of metals on global warming has been discussed with respect to mitigation strategies and socio-economic factors, the fundamental materials science to make the metallurgical sector more sustainable has been less addressed. This may be attributed to the fact that the field of sustainable metals describes a global challenge, but not yet a homogeneous research field. However, the sheer magnitude of this challenge and its huge environmental effects, caused by more than 2 billion tonnes of metals produced every year, make its sustainability an essential research topic not only from a technological point of view but also from a basic materials research perspective. Therefore, this paper aims to identify and discuss the most pressing scientific bottleneck questions and key mechanisms, considering metal synthesis from primary (minerals), secondary (scrap), and tertiary (re-mined) sources as well as the energy-intensive downstream processing. Focus is placed on materials science aspects, particularly on those that help reduce CO₂ emissions, and less on process engineering or economy. The paper does not describe the devastating influence of metal-related greenhouse gas emissions on climate, but scientific approaches how to solve this problem, through research that can render metallurgy fossil-free. The content is considering only direct measures to metallurgical sustainability (production) and not indirect measures that materials leverage through their properties (strength, weight, longevity, functionality).

Fixed-bed column study for the remediation of the bauxite-liquid residue using acid-activated clays and natural clays

Large amounts of bauxite-liquid residue are generated during the production of aluminium, which has detrimental effects on human and environmental health. Currently, the primary goal of every alumina industry is to improve the wet disposal of bauxite-liquid residues into the environment using eco-friendly and cost-effective methods. Therefore, this study investigated the possibility of treating bauxite-liquid residue with natural clays (NCs) and acid-activated clays (AACs) using a fixed-bed column adsorption study. The chemical compositions and functional groups of clays and bauxite were studied using X-ray diffractometry (XRD), X-ray fluorescence (XRF), and Fourier transform infrared spectroscopy (FTIR) techniques. For iron adsorption, breakthrough curves were plotted by varying the adsorbent type in the fixed-bed column. The Bohart-Adams, Thomas, and Yoon-Nelson models were successfully fitted with the breakthrough curves. Two regeneration cycles revealed high regeneration efficiencies for both natural and acid-activated clays. Overall, the study found that AACs were the best candidates for treating bauxite-liquid residue when compared to NCs. For instance, the pH, temperature, electrical conductivity, total suspended solids, total dissolved solids, biochemical oxygen demand, turbidity, and total alkalinity of the bauxite-liquid residue were all significantly decreased below tolerance levels by using AACs. The AACs removed 92% of the iron in the bauxite-liquid residue. Lastly, our research shows that AACs can be used as an adsorbent to treat bauxite-liquid residue, making it less hazardous when it is disposed of into the environment.

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.

Scandium Recovery from Aqueous Solution by Adsorption Processes in Low-Temperature-Activated Alumina Products

In this paper, we studied the scandium adsorption from aqueous solutions on the surface of low-temperature-activated alumina products (GDAH). The GDAH samples are industrially manufactured, coming from the Bayer production cycle of the Sierra Leone bauxite as aluminium hydroxide, and further, by drying, milling, classifying and thermally treating up to dehydroxilated alumina products at low temperature. All experiments related to hydroxide aluminium activation were conducted at temperature values of 260, 300 and 400 °C on samples having the following particle sizes: <10 µm, 20 µm, <45 µm and <150 µm, respectively. The low-temperature-activated alumina products were characterised, and the results were published in our previous papers. In this paper, we studied the scandium adsorption process on the above materials and related thermodynamic and kinetic studies.

Waste to Hydrogen: Elaboration of Hydroreactive Materials from Magnesium-Aluminum Scrap

Ball-milled hydroreactive powders of Mg-Al scrap with 20 wt.% additive (Wood’s alloy, KCl, and their mixture) and with no additives were manufactured. Their hydrogen yields and reaction rates in a 3.5 wt.% NaCl aqueous solution at 15–35 °С were compared. In the beginning of the reaction, samples with KCl (20 wt.%) and Wood’s alloy (10 wt.%) with KCl (10 wt.%) provided the highest and second-highest reaction rates, respectively. However, their hydrogen yields after 4 h were correspondingly the lowest and second-lowest percentages—(45.6 ± 4.4)% and (56.0 ± 1.2)% at 35 °С. At the same temperature, samples with 20 wt.% Wood’s alloy and with no additives demonstrated the highest hydrogen yields of (73.5 ± 10.0)% and (70.6 ± 2.5)%, correspondingly, while their respective maximum reaction rates were the lowest and second-lowest. The variations in reaction kinetics for the powders can be explained by the difference in their particle sizes (apparently affecting specific surface area), the crystal lattice defects accumulated during ball milling, favoring pitting corrosion, the morphology of the solid reaction product covering the particles, and the contradicting effects from the potential formation of reaction-enhancing microgalvanic cells intended to induce anodic dissolution of Mg in conductive media and reaction-hindering crystal-grain-screening compounds of the alloy and metal scrap components.