Red Mud Research Articles

Red Mud: From Industrial Waste to a Flux for Manufacturing Sustainable Iron/Steel

Red Mud: From Industrial Waste to a Flux for Manufacturing Sustainable Iron/Steel

Pozzolanic activity of FCC catalyst waste slag (CWS) for cement and geopolymer production

Catalyst waste slag (CWS) is generated in large amounts when fabricating the catalyst required in the fluid cracking catalyst (FCC) process used for oil refining. Currently, CWS is landfilled. This paper characterizes the CWS and measures its pozzolanic activity. It determines whether the CWS can be used as partial Portland cement (PC) replacement for the first time in the literature. CWS is primarily composed of Al2O3 and CaO. It contains a negligible quantity of heavy metals that can be immobilised in a matrix. The raw CWS is totally amorphous and extremely reactive which results in flash set. Calcination is an effective method to control the reactivity of CWS. Reactivity increased when CWS was calcined between 300 and 600 °C and it peaked at 500 °C, but this caused flash set. Calcination at 800 °C lowers reactivity (as the highly disordered aluminium phases achieve a greater order) which allows for proper handling. Temperatures over 800 °C caused partial crystallization significantly lowering reactivity.The 800°C-calcined CWS reached high mechanical index (6.25), comparable to other pozzolans such as fly ash and red mud, and greater than alum sludge. CWS combines lime profusely and develops more abundant cementing hydrates than similar pozzolans such as calcined alum sludge. The pozzolanic reaction of the 800°C-calcined CWS provides abundant cementing minerals including AFt and AFm phases, calcium aluminium carbonate hydrates and calcium aluminium hydrates.The high reactivity of CWS and its prolific production of cementing phases in pozzolanic reactions indicate that it can be used as a supplementary cementitious material in PC and lime systems; and that it can be used as a precursor to produce low-carbon and geopolymer cements. CWS constitutes a reactive aluminium source which, in a PC system, participates in hydration reactions and can enhance the properties of the resultant materials.

Preparation and property studies of ferric sulfoaluminate cement based on Bayer red mud and phosphogypsum.

The Bayer red mud (RM) and phosphogypsum (PG) accumulation have caused significant environmental contamination. However, practical and effective resource utilization technologies are still lacking currently. This work aims to develop ferric sulfoaluminate cement (FSAC) employing low-cost materials including Bayer red mud, phosphogypsum, and other materials. This method effectively improves the utilization rate of Bayer red mud and phosphogypsum. Under the premise of ensuring the performance of FSAC, the utilization rate of solid waste can reach up to 48.56%. The effects of different red mud dosages on cement mineral formation, workability, and mechanical properties are investigated. Then, untreated phosphogypsum is adopted as a retarder for FSAC, and the hydration process, working properties, mechanical properties, types of hydration products, and morphology of FSAC are explored. The results suggest that the crystal transformation of Ye'elemite is promoted with the increase of Bayer red mud content. Cubic crystal system Ye'elemite with higher hydration activity is generated, which increases the early strength of cement but greatly reduces the setting time, hindering the later strength growth. Untreated phosphogypsum can effectively delay the early hydration process of FSAC, prolong the setting time of cement, and increase the strength of FSAC in the later stage. When the dosage of Bayer red mud and phosphogypsum is 17.64% and 9.21%, respectively, with phosphogypsum dosage of 20%, the prepared FSAC has satisfactory mechanical properties, and the 3-day and 90-day compressive strengths are 34.6 MPa and 57.1 MPa, respectively. In addition, the study of heavy metal leaching indicates that the FSAC prepared by Bayer red mud, phosphogypsum, and other raw materials will generate no environment pollution, and the solidification of heavy metal elements in the cement slurry is superior.

Study on the Characteristics and Evolution Laws of Seepage Damage in Red Mud Tailings Dams

Seepage damage is a significant factor leading to red mud tailings dam failures. Laboratory tests on seepage damage were conducted to investigate the damage characteristics and distribution laws of red mud tailings dams, including soil pressure, infiltration line, pore water pressure, dam displacement, and crack evolution. The findings revealed the seepage damage mechanisms of red mud slopes, offering insights for the safe operation and seepage damage prevention of red mud tailings dams. The results showed that the higher the water level is in the red mud tailings dam, the higher position the infiltration line is when it reaches the slope face. At the highest infiltration line point of the slope surface, the increase of pore water pressure is the highest and the change of horizontal soil pressure is the highest. Consequently, increased pore water pressure leads to decreased effective stress and shear strength, increasing the susceptibility to damage. Cracks resulting from seepage damage predominantly form below the infiltration line; the higher the infiltration lines is on the slope surface, the higher the position of the main crack formations is. The displacement of the dam body primarily occurs due to the continuous expansion of major cracks; the higher the infiltration lines are on the slope surface, the larger the displacement of the dam body is.

Experimental Study on Bio-cementation of Red Mud Through Microbially Induced Calcite Precipitation

Experimental Study on Bio-cementation of Red Mud Through Microbially Induced Calcite Precipitation

Activation Behavior and Mechanism of Sodium Sulfate for Iron Recovery from Red Mud through Magnetization Roasting–Magnetic Separation

Activation Behavior and Mechanism of Sodium Sulfate for Iron Recovery from Red Mud through Magnetization Roasting–Magnetic Separation

Salt distribution and alkalinity characterization in bauxite residue disposal areas from the spatial scale range

Bauxite residue (red mud) has high alkalinity and salinity, which seriously restricts its reuse. It is crucial to understand the salt distribution pattern and alkalinity characteristics in the bauxite residue disposal area (BRDA), which can provide a theoretical basis for realizing the salinity and alkalinity regulation and reuse of bauxite residue. In this paper, samples from different locations and depths of the BRDA were used for the determination of soluble salts content, pH, and electrical conductivity (EC), and the correlation between the indicators was analyzed. The results show that bauxite residue has a high content of soluble salts, and the spatial distribution of soluble salts in the BRDA is relatively complex, with moderate variability, but does not show an obvious regularity. The major cations are Na+, K+ and the major anions are CO32−, HCO3−. Through cluster analysis, the soluble ions in bauxite residue can be divided into two main groups, one is Na+, CO32−, HCO3−, and the other is Ca2+, Mg2+, K+, Cl− and SO42−. PH has a significant positive correlation with Na+, K+, CO32− and HCO3−, and a negative correlation with Ca2+. And its alkalinity depends to a large extent on carbonate and bicarbonate, and the Na+ content can be predicted from EC, thus reflecting the concentration of alkaline residues in the bauxite residue.

Enhancement of nitrogen on core taxa recruitment by Penicillium oxalicum stimulated microbially-driven soil formation in bauxite residue

Microbially-driven soil formation process is an emerging technology for the ecological rehabilitation of alkaline tailings. However, the dominant microorganisms and their specific roles in soil formation processes remain unknown. Herein, a 1-year field-scale experiment was applied to demonstrate the effect of nitrogen input on the structure and function of the microbiome in alkaline bauxite residue. Results showed that the contents of nutrient components were increased with Penicillium oxalicum (P. oxalicum) incorporation, as indicated by the increasing of carbon and nitrogen mineralization and enzyme metabolic efficiency. Specifically, the increasing enzyme metabolic efficiency was associated with nitrogen input, which shaped the microbial nutrient acquisition strategy. Subsequently, we evidenced that P. oxalicum played a significant role in shaping the assemblages of core bacterial taxa and influencing ecological functioning through intra- and cross-kingdom network analysis. Furthermore, a recruitment experiment indicated that nitrogen enhanced the enrichment of core microbiota (Nitrosomonas, Bacillus, Pseudomonas, and Saccharomyces) and may provide benefits to fungal community bio-diversity and microbial network stability. Collectively, these results demonstrated nitrogen-based coexistence patterns among P. oxalicum and microbiome and revealed P. oxalicum-mediated nutrient dynamics and ecophysiological adaptations in alkaline microhabitats. It will aid in promoting soil formation and ecological rehabilitation of bauxite residue. Environment implicationBauxite residue is a highly alkaline solid waste generated during the Bayer process for producing alumina. Attempting to transform bauxite residue into a stable soil-like substrate using low-cost microbial resources is a highly promising engineering. However, the dominant microorganisms and their specific roles in soil formation processes remain unknown. In this study, we evidenced the nitrogen-based coexistence patterns among Penicillium oxalicum and microbiome and revealed Penicillium oxalicum-mediated nutrient dynamics and ecophysiological adaptations in alkaline microhabitats. This study can improve the understanding of core microbes’ assemblies that affect the microbiome physiological traits in soil formation processes.

A Review on Utilization of Plastic Waste as Aggregate in Construction Materials

In a construction material in a modern construction if we look the major component includes concrete and steel reinforcement. However, in recent studies it showed the replacement of steel bars by the different material like bamboo etc. and in concrete there is fiber, red mud and fly ash is been deployed as the replacement for the binding material say cement.In today’s scenario the utilization of plastic in day-to-day life is showed the substantial growth but the associated problem with the plastic is their environmental impact as they cannot get easily decomposed. So, if we utilize this plastic waste in a construction works as a construction materialmay lead to the significant reduction in its waste foot print. In recent literature, significant strides have been made in the development of concrete mixtures that integrate plastic waste as a partial substitute for traditional aggregates during the concrete manufacturing process. Some recent studies show that it can be used construction industry due to some of its properties like inert behaviour, resistance to degradation etc. Also, use of waste plastic can help in reducing plastic waste. This emerging trend reflects a broader commitment to sustainability, aiming to mitigate plastic pollution while fostering environmentally conscious construction practices.

Engineering Properties and Microstructure of Soils Stabilized by Red-Mud-Based Cementitious Material.

Red mud (RM) is an industrial waste generated in the process of aluminum refinement. The recycling and reusing of RM have become urgent problems to be solved. To explore the feasibility of using RM in geotechnical engineering, this study combined magnesium oxide (MgO) (or calcium oxide (CaO)) with RM as an RM-based binder, which was then used to stabilize the soil. The physical, mechanical, and micro-structural properties of the stabilized soil were investigated. As the content of MgO or CaO in the mixture increased, the unconfined compressive strength (UCS) of the RM-based cementitious materials first increased and then decreased. For the soils stabilized with RM-MgO or RM-CaO, the UCS increased and then decreased, reaching a maximum at RM:MgO = 5:5 or RM:CaO = 8:2. The addition of sodium hydroxide (NaOH) promoted the hydration reaction. The UCS enhancement ranged from 8.09% to 66.67% for the RM-MgO stabilized soils and 204.6% to 346.6% for the RM-CaO stabilized soils. The optimum ratio of the RM-MgO stabilized soil (with NaOH) was 2:8, while that of the RM-CaO stabilized soil (with NaOH) was 4:6. Freeze-thaw cycles reduced the UCS of the stabilized soil, but the resistance of the stabilized soil to freeze-thaw erosion was significantly improved by the addition of RM-MgO or RM-CaO, and the soil stabilized with RM-MgO had better freeze-thaw resistance than that with RM-CaO. The hydrated magnesium silicate generated by the RM-MgO stabilized soil and the hydrated calcium silicate generated by the RM-CaO stabilized soil helped to improve the UCS of the stabilized soil. The freeze-thaw cycles did not weaken the formation of hydration products in the stabilized soil but could result in physical damage to the stabilized soils. The decrease in the UCS of the stabilized soil was mainly due to physical damage.

Enhancing biomass gasification: A comparative study of catalyst applications in updraft and modifiable-downdraft fixed bed reactors

This study aims to investigate the effects of different catalysts on biomass gasification. Therefore, red mud (RM) and Aluminum–Nickel alloy were used as catalysts with biomass mixture (BM) for the lab-scale gasification studies by using an updraft and a modifiable-downdraft fixed bed reactor. The maximum volumetric percentage of H2, ranging from 51% to 65%, was achieved at 900 °C in both gasifiers. Al–Ni catalyst significantly boosted H2 content, reaching 65% in the updraft gasifier at 900 °C with 0.05 L/min dry air. H2/CO ratio varied from 2 to 4 for BM, while catalyst use expanded the range to 1.6–7 with the Al–Ni catalyst demonstrating the most effective performance. In general, it was seen that RM increased the H2 component in the syngas between 1 and 7 vol% at 900 °C in updraft gasifier. In the modifiable-downdraft reactor, on the contrary, H2 concentration in the syngas decreased by 2–6% with the addition of RM.

Novel magnetic N-doped biochar derived from sugarcane bagasse and red mud for effective adsorption of tetracycline hydrochloride

In this work, with sugarcane bagasse (SB) and red mud (RM) as raw materials, magnetic nitrogen (N)-doped biochar (MNSB) was synthesized by a facile one-pot pyrolysis method and then applied as an efficient adsorbent to remove tetracycline hydrochloride (TC-HCl) from wastewater. The results of SEM, EDS, VSM, BET, FT-IR, and XPS demonstrated that the synthesized MNSB adsorbent had a large specific surface area, excellent superparamagnetic properties, and rich mesopore pore structures. The batch adsorption experiments revealed that the TC-HCl could be removed 96.3% with the optimal adsorption conditions: MNSB dosage of 0.25 g/L, initial pH of 6.58, TC-HCl initial concentration of 20 mg/L, and adsorption temperature of 30 °C. The analysis of adsorption kinetics and isotherms showed that the adsorption process was mainly controlled by chemisorption, and the theoretical maximum adsorption capacity of TC-HCl on MNSB was 143.9 mg/g. Mechanistic analysis revealed that the excellent adsorption process of MNSB for TC-HCl was mainly contributed by pore filling, π–π interaction, hydrogen bonding, and electrostatic attraction. The recycling and settlement experiments demonstrated that MNSB had good stability and settleability. This study successfully opened new prospects that utilizing RM and SB to prepare a low-cost adsorbent to remove TC-HCl from water.

Development of an environmentally foamed concrete incorporating red mud.

In this work, an efficient utilization method for red mud (RM) is provided through recycling RM as a mineral admixture for the preparation of foamed concrete (FC). Specifically, FC with different RM contents was prepared and investigated in terms of workability, mechanical properties, and hydration products. Results show that adding RM can significantly shorten the setting time, while it inevitably weakens the mechanical properties and fluidity of FC. However, the compressive strength of FC can still meet the strength predicted by the specification requirements when the RM replaces cement with 60% content (3d > 1.6MPa). Most importantly, the heavy metals leaching from RM-based FC under the action of rain is still unclear, so a device for simulating stormwater runoff was designed to test the heavy metal leaching risk of RM-based FC. The findings indicate that the solidification of cement and the high basicity of the matrix can effectively reduce the leaching risk of heavy metals from RM in FC. Although the pore structure analysis demonstrates that the porosity and connected pores of FC will be deteriorated as RM concentration increases. The results are of great significance for the recycling of waste and the sustainable development of building materials.

Synergistic CO2 mineralization using coal fly ash and red mud as a composite system

CO2 mineralization plays a critical role in the storage and utilization of CO2. Coal fly ash (CFA) and red mud (RM) are widely utilized as CO2 mineralizers. However, the inert calcium species in CFA limit its carbonation capacity, meanwhile the substantial Ca2+ releasing of RM is hindered by a covering layer of calcium carbonate. In this study, CO2 mineralization in a composite system of CFA and RM was investigated to enhance the carbonation capacity. Multiple analyzers were employed to characterize the raw materials and resulting mineralization products. The results demonstrated that a synergistic effect existed in the composite system of CFA and RM, resulting in improving CO2 mineralization rate and efficiency. The produced calcium carbonate was ectopically attached the surface of CFA in the composite system, thus slowing down its coverage on the surface of RM. This phenomenon facilitated further releasing Ca2+ from the internal RM, thereby enhancing CO2 mineralization efficiency. Meanwhile, the inclusion of RM significantly improved the alkalinity of the composite system, which not only promoted the dissolution of Ca2+ of the inert CaSO4(H2O)2 in CFA, but also accelerated CO2 mineralization rate. The investigation would be beneficial to CO2 mineralization using industrial solid wastes.

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.

Experimental Study on the Strength and Microstructure of Red Mud-Based Silty Sand Modified with Lime–Fly Ash

This study aimed to assess the viability of utilizing lime–fly ash (LF) and red mud (RM) in the modification of silty soil (LF-RMS) for subgrade filling. The primary objective of this research was to analyze the mechanical characteristics and examine the curing mechanisms associated with said modified materials. Different curing times were utilized in the analysis of mechanical properties (e.g., via unconfined compression testing), microstructure (via scanning electron microscopy, X-ray diffraction, and thermogravimetric-differential thermal analysis), and environmental indices (via assessment of corrosivity, heavy metal concentration, and radioactivity) with various dosages of red mud (DRM) and Lime–fly ash (DLF). Analyses of the curing mechanisms, failure modes, microstructures, and degrees of environmental impact associated with LF-RMS were also undertaken. The tests indicated that the unconfined compressive strength (UCS) exhibited an initial increase followed by a decrease as the DRM and DLF levels increased. Additionally, the strength of LF-RMS increased with an increase in curing time. It is worth noting that the specimen composed of 20% LF and 23% RM (D20%LF+23%RM) demonstrated a maximum UCS value of 4.72 MPa after 90 days of curing, which indicates that it has the strongest ability to resist deformation. The strength of the specimen cured for 90 days was 1.4 times higher than that of the specimen cured for 7 days (1.97 MPa). Furthermore, the toxic concentration and radionuclide index of LF-RMS were significantly reduced compared to those of pure RM. The overall concentration of heavy metals in the D20%LF+23%RM specimen decreased by more than 60% after curing for 28 days. The internal irradiation index and the external irradiation index decreased by 1.63 and 1.69, respectively. The hydration products in LF-RMS play a key role in the solidification of heavy metals, and the alkaline environment provided by RM also contributes to the precipitation and replacement of heavy metals. In this study, red mud, fly ash and lime were used to modify silty soil. The central tenets of sustainable development may be achieved through the reuse of RM as a road filler.

Experimental Study on the Evolutionary Law of Transient Saturation Zones in a Red Mud Dam under Rainfall Conditions

Utilizing a laboratory model test, this study seeks to evaluate the distribution patterns of volumetric moisture content, soil pressure, and pore water pressure within the body of a red mud dam, given varying initial conditions of slope types and ratios, during continuous heavy rainfall. The objective is to investigate the failure mechanisms of a red mud dam under distinct operational conditions during rainfall, thereby offering insights for landslide prevention and ensuring dam construction quality. The results suggest that a stepped red mud dam acts as a buffer platform, altering the seepage direction within the dam and minimizing the water seepage path. When the slope ratio is 1:1, the transient saturated zone is located on the slope face of the dam’s body, near the top of the slope, with the saturation time at the first monitoring point occurring 300 s earlier than in a dam with a slope ratio of 1:2. Rainfall affects the distribution of internal forces in the red mud dam body. After rainfall, in the transient saturated zone of the stepped dam body, vertical soil pressure decreases 25% and horizontal soil pressure decreases 6.5%; in the transient saturated zone of the dam with a slope ratio of 1:1, vertical soil pressure decreases 14.8% and horizontal earth pressure decreases 29%; in the transient saturated zone of a dam with a slope ratio of 1:3, the change in soil pressure is small.

Optimal Red Mud Replacement Level Evaluation in Conventional Concrete Based on Fresh and Hardened Concrete Characteristics

Optimal Red Mud Replacement Level Evaluation in Conventional Concrete Based on Fresh and Hardened Concrete Characteristics

Efficient Separation of Iron and Alumina in Red Mud Using Reduction Roasting and Magnetic Separation

Efficient Separation of Iron and Alumina in Red Mud Using Reduction Roasting and Magnetic Separation

Red mud: Characteristics, utilization, and environmental remediation strategies in the aluminium industry

Aluminium plants generate a substance identified as red mud, which is an alkaline atrophy product. As the aluminium industry expands, the accumulation of red mud has become a more pressing concern. Various atrophy treatment technologies have been developed to utilize red mud as a material for environmental remediation. These substances, also identified as Red Mud Ecological Rehabilitation Ingredients (RM-ERMs), are created by stimulating red mud, fusing it in a complementary manner with additional compounds, or removing useful components from it. RM-ERMs find application in three main areas: purifying wastewater, treating atrophy gases, and remediating soil. The extremely alkaline nature of red mud is harnessed in the making of RM-ERMs, offering a window to perk up the environment through purification methods. The utility of RM-ERMs has shown promise as a potential method for simultaneously addressing various types of waste. This review provides an introduction to the physical and chemical characteristics of red mud, and summarizes the active mechanism of RM-ERMs in addressing specific contaminants in wastewater, atrophy gases, and soil. Additionally, a review of current challenges in the field of RM-ERMs offers crucial insights and recommendations for future research in this area.