Industrial By-products Research Articles

Aflatoxin B1-associated oxidative stress along with toxicopathological and immunological alterations is efficiently counteracted by dietary supplementation of distillery yeast sludge in broilers.

Aflatoxin B1 (AFB1) is among the most potent genotoxic and carcinogenic mycotoxins and is a major source of distress for the growing poultry sector. On the other hand, distillery yeast sludge or distillery sludge (DS) is a byproduct of molasses-based industries. It is often treated as a waste despite containing abundant nutrients particularly protein, basic amino acids, and vitamins along with other macro and micronutrients. This study was designed to investigate the oxidative stress and immunological alterations induced by AFB1 and their amelioration by dietary supplementation with DS. For this purpose, 360 newly hatched broiler chicks were randomly divided into twelve groups (30 birds each) and fed different combinations of AFB1 (100, 200, or 600µg/kg) and DS (5 or 10g/kg) for 42days. The parameters under consideration were body weight, feed conversion ratio (FCR), relative organ weights, histopathological examination of different visceral organs, total antioxidant capacity, antibody response to intravenous injection of sheep red blood cells, in situ lymphoproliferative response to phytohemagglutinin-P, and phagocytic potential through a carbon clearance assay system. The results of this study established that DS supplementation ameliorated AFB1-associated oxidative stress and ameliorated toxicopathological and immunological anomalies in groups given AFB1 at 100µg/kg and 200µg/kg; however, little to no relief was observed in birds fed AFB1 at 600µg/kg. The determination of the actual ratio of the AFB1 to the DS for substantiating the ameliorating effects requires further investigation.

Effect of anionic polyacrylamide amendment on the climatic durability of solidified waste rock fine

In order to improve the climatic durability of solidified waste rock fine (WRF), anionic polyacrylamide (APAM) was innovatively introduced to amend solidified WRF in this study. The effects of APAM content, freeze-thaw (F-T), and wet-dry (W-D) cycles on the mechanical behaviors of solidified WRF were explored. After that, zeta potential, fourier transform infrared (FTIR) spectroscopy, and scanning electron microscope (SEM) tests were initiated to understand the behavioral mechanisms of APAM. The results show that APAM can significantly improve the mechanical properties and durability of solidified WRF, and there exist a threshold content of APAM (0.3%~0.8% in this study), beyond which the strength will decrease. The microscopic test shows that the bridging effect and the filming effect induced by APAM are considered to be the two decisive factors affecting the mechanical behavior of S-WRF. On the one hand, the linear APAM long chain enables the cohesion between particles to be stronger through ion bridging, on the other hand, the long chains cross-link with each other to form a network interwoven inside the structure, thus playing a microfabric reinforcement role and enhancing the crack resistance of the solidified matrix. In addition, life cycle assessment (LCA) further confirmed the advantages of using industrial by-products combined with APAM to amend solidified-WRF. These results provide a theoretical basis for using APAM as trace additives to mitigate climatic durability-related issues.

Anticorrosive pigment for smart and green protective coatings: An alkyd resin coating incorporating lanthanum-loaded hydroxyapatite, derived from a phosphate mining industry by-product

Intelligent anti-corrosive coatings have gained considerable interest as a method to protect metals. This approach offers an effective strategy for mitigating corrosion by providing advanced control over the process. In this research, lanthanum-loaded hydroxyapatite pigment (La-HAp) was successfully synthesized using phosphate sludge (PS) waste. The pigment was incorporated into an alkyd resin coating to provide smart corrosion protection for mild steel exposed to a saline solution. The synthesized pigments were characterized using various analytical techniques, including FTIR, XRD, and SEM−EDS. The inhibitory performance of La-HAp on mild steel submerged in a 3% NaCl solution was evaluated using linear polarization and EIS techniques. The findings demonstrated substantial inhibitory effectiveness, achieving 82% inhibition efficiency. Further investigation compared the protective capabilities of modified (C-La-HAp) and reference (C-Ref) alkyd coatings on carbon steel using EIS. The results indicated significant corrosion protection enhancement with 5% La-HAp, showing a polarization resistance of 19.7 MΩ·cm2 after four weeks of immersion in the aggressive solution. This corrosion resistance is primarily attributed to the formation of a barrier against the corrosive environment and the trapping of Cl- ions by the HAp, accompanied by the release of La, phosphate, and calcium ions. La ions react with OH- ions produced in the cathodic zones to form a uniform protective layer of Lahydroxides, while iron orthophosphates provide additional protection at anodic sites. This synergistic blend of mechanisms imparts intelligent corrosion-inhibiting properties to the alkyd resin, effectively guarding against the damaging effects of corrosive agents.

Greener lightweight foam concrete using seaweed industrial by-product to replace natural sand with inorganic salt as a stabilizer

In recent years, the seaweed industry has expanded, resulting in higher volumes of seaweed industrial by-products (SWB). People commonly dispose SWB on land, which raises environmental concerns due to its hazardous chemical content. The use of waste materials as alternatives to natural sand has gained attention due to its potential to reduce environmental impact. Therefore, this study aimed to develop a greener lightweight foam concrete (LFC) by incorporating 0-30% SWB as a replacement for natural sand in fine aggregates and evaluate its performance. Furthermore, the study investigated the inclusion of inorganic salt concentrations ranging from 0 to 15% into the concrete mixture to improve performance. The production, sampling, and testing procedures followed the SNI 8640:2018 standards. Properties like density, water absorption, drying shrinkage, and compressive strength were analyzed for SWB percentage (0-30%), salt concentration (0-15%), foaming pressure (0.20, 0.39, and 0.59 MPa), and curing duration (7, 14, and 28 days). Viable specimens were further examined for microstructure, energy intensity, CO2 emission, and production cost. Specimen FS5 met standards with a density of 707.1 kg/m3, compressive strength of 2.12 MPa, water absorption of 25.45% (v/v), and drying shrinkage of 0.13%. The energy intensity, CO2 emission, and total cost of greener LFC were calculated to be 159.88 MJ/m3, 188.98 kg of CO2/m3, and IDR 682,130/m3, respectively. Ultimately, this work greatly contributes to the field of green manufacturing and environmental sustainability by successfully decreasing energy intensity, CO2 emissions, and environmental harm in LFC production processes.

Mechanical Properties Evaluation of Fly Ash Bricks in Masonry Construction

Abstract: In the context of sustainable construction practices, the utilization of industrial by-products like fly ash in brick manufacturing is gaining popularity. This study aims to evaluate the mechanical properties of fly ash bricks, such as compressive strength, water absorption, flexural (rupture) strength, density, and efflorescence, and compares them to traditional burnt clay bricks commonly used in Pakistan. Experimental results show that fly ash bricks exhibit higher compressive and rupture strength and lower water absorption compared to conventional clay bricks. However, moderate levels of efflorescence in fly ash bricks suggest room for improvement in certain applications. The percent difference between fly ash and clay bricks has been calculated to quantify their suitability for masonry construction in Pakistan. This research contributes to the understanding of how fly ash bricks could serve as an alternative in construction materials with a lower environmental footprint.

PURIFICATION OF BETA-GLUCOSIDASE FROM APRICOT SEEDS TO REDUCE THE TOTAL VICINE –CONVICINE CONTENT IN FABA BEANS (VICIA FABA L.)

This research was aimed to purified beta-glucosidase from apricot seeds using ammonium sulfate precipitation, followed by gel filtration chromatography, then ion exchange chromatography. Ion exchange chromatography resulted in the enzyme sample with a specific activity of 41.3 U/mg with a purification fold of 15 and a yield of 30.3%. The apricot beta-glucosidase had an optimum pH of 4 with good stability between pH 3 and 6. The optimum temperature was 60°C and there was good stability between 5 and 40°C. Faba beans treated at pH 5.5 containing beta-glucosidase showed higher total vicine removal than with only water at pH 5.5 after 4 h. Additionally, treatment at 40°C showed higher total vicine removal that treatments at 25°C. However, treating faba beans at pH 5.5 with and without beta-glucosidase resulted in a lower total vicine content for the enzyme treatment before cooking but the total vicine content after cooking was the same for the water treated compared to the enzyme treated. As an industrial by-product, apricot seeds are a rich source of beta-glucosidase that may be used to treat faba beans to increase their nutritional composition.

Stabilization strategy of normal and chrome tanning effluent mixed subsoil: a novelty to enhance the soil characteristics

Soil stabilisation is a unique method to effectively and accurately find a solution to the issues caused by loose subsoil. This research investigates the problems of uncontrolled industrial effluent disposal, mainly from tannery enterprises, which presents severe environmental problems in emerging nations due to soil properties changing and large regions being unfit for cultivation and human habitation. The study uses Atterberg's limits, sieve analysis, and direct shear testing to examine the effects of untreated tannery effluents on soil parameters. The findings show that the soil's shear strength, moisture content, and flexibility have all significantly decreased. Lime and waste stone powder were added to lessen these impacts, and this improved soil stability was shown by an increase in the values of all the variables. For efficient soil remediation, the study suggests using waste stone powder and lime in the following proportions: 0%, 3%, 6%, and 9%. Combining lime stabilisation methods with industrial by-products like slag and fly ash opens up new possibilities for enhancing the geotechnical characteristics of polluted soils. This study emphasises how important it is to use customised geotechnical design techniques to handle soil contamination issues in infrastructure and foundation projects, especially in areas where the leather industry predominates.

Leveraging Spruce Bark Particle Morphology for Enhanced Internal Bonding in Particleboard Production

The continuous rise in global demand for wood products has led to an increase in prices and a surge in research into alternative resources. As a byproduct of the timber industry, bark has emerged as a promising supplement in particleboard (PB) production. However, its anatomical structure, the presence of extractives, and its inferior mechanical properties complicate the production process, which have not yet been fully overcome at a commercial scale. This study proposes a paradigm shift, advocating for separate and specialized bark constituent processing in a wet state. Three bark-based raw materials—namely, outer bark particles, bark fiber clumps, and bark fibers—were investigated under varying wood content scenarios. PBs with a target density of 0.7 g/cm3 and a thickness of 16 mm were produced using mixtures of these bark-based materials and wood particles in different ratios bonded with a urea–formaldehyde adhesive. The results demonstrated that these bark constituents exhibit distinct properties that can be optimized through tailored processing techniques. Compared to bark fibers, outer bark particles displayed about 40% lower water absorption and thickness swelling. However, bark fibers improved the internal bond by about 50% due to their favorable morphology compared to outer bark. These findings highlight the potential of bark as a valuable resource for particleboard production and pave the way for its efficient utilization through specialized processing strategies.

Oat Okara Fermentation: New Insights into the Microbiological and Metabolomic Characterization

The importance of the valorization of industrial by-products has led to increasing research into their reuse. In this research, the innovative by-product okara oat flour, derived from the vegetable beverage industry, was studied. Oat okara sourdough was also produced and evaluated. The microbiological identification and typing involved bacterial and yeast isolates from both flour and sourdough. Untargeted metabolomics allowed the identification of biomarkers of fermented flour, such as phenolic classes, post-fermentation metabolites, fatty acids, and amino acids. The microorganisms most found were Weissella confusa, Enterococcus faecium, Pediococcus pentosaceus, and Pichia kudriavzevii, while Saccharomyces cerevisiae appeared only at the end of the sourdough’s back-slopping. Untargeted metabolomics identified a total of 539 metabolites, including phenolic compounds, lipids, amino acids, and organic acids. An increase in polyphenols released from the food matrix was detected, likely because of the higher bio-accessibility of phenolic metabolites promoted by microbial fermentation. Fermentation led to an increase in isoferulic acid, p-coumaric acid, sinapic acid, and a decrease in amino acids, which can be attributed to the metabolism of lactic acid bacteria. Some key markers of the fermentation process of both lactic acid bacteria and yeast were also measured, including organic acids (lactate, succinate, and propionate derivatives) and flavor compounds (e.g., diacetyl). Two bioactive compounds, such as gamma-aminobutyric acid and 3-phenyl-lactic acid had accumulated at the end of fermentation. Taken together, our findings showed that oat okara flour can be considered an excellent raw material for formulating more sustainable and functional foods due to fermentation promoted by autochthonous microbiota.

Influence of Soilless Growing Media Comprising Industrial By-products on Growth of Foliage Plants Epipremnum aureum and Dracaena sp.

Experiments were conducted during August, 2020 to April, 2021 at the ICAR-Directorate of Floricultural Research, Pune, Maharashtra, India to assess the suitability of industrial by-products fly ash and press mud as growing media component for foliage plants Epipremnum aureum and Dracaena sp. Different growing media compositions comprising of fly ash, press mud, cocopeat and vermicompost were evaluated in varying proportions. Foliage plants growth was monitored for nine months duration. Initial pH and electrical conductivity of growing media compositions were determined and leaf samples were analyzed for macro and micronutrients content at the end of the experiment. pH of growing media compositions ranged from near neutral to slightly alkaline pH and electrical conductivity of all media compositions was less than 1.0 dS m-1. Results indicated that growing media composition Fly ash+Vermicompost+Cocopeat (20:30:50) was the most suited growing media to grow Epipremnum aureum under 50% shade condition. Media compositions Cocopeat+Vermiculite+Perlite (33.3:33.3:33.3) and Fly ash+Vermicompost+Cocopeat (20:30:50) were observed to be more suited for growth of Dracaena sp. under 50% shade condition. Maximum plant height, number of leaves, leaf size and petiole length were recorded in Epipremnum aureum and Dracaena sp. plants grown in above media compositions respectively. Results inferred that fly ash along with vermicompost and cocopeat can be used as a growing media component for production of foliage plants Epipremnum aureum and Dracaena sp.

A Review of the Sustainability of Helium: An Assessment of Its Past, Present and a Zero-Carbon Future

Helium, as a by-product of the natural gas industry, will be impacted by the decline in consumption of fossil fuels as the world moves towards net-zero carbon emissions. In September 2022, all assets relating to the US government’s previous helium industry were sold. In the US, helium is now only available from private suppliers. In June 2022, Russia banned the export of helium to “unfriendly” countries, highlighting the geopolitical issues surrounding the industry. In the past, helium was popularized, and the industry was supported by its military applications (filling dirigible aircraft, welding fighter jets and purging rocket engines). It also plays an important role in supporting present-day technologies (e.g., MRI machines and spectroscopy) and will also be important for a high-tech future (e.g., in quantum computing, fusion power, and space exploration). Shortages of helium will inevitably cause skyrocketing prices and consequently lead to significant challenges for research and development (as has happened in the past) and technological progress, as well as a slowdown in world economic growth and prosperity. Anticipated declines in natural gas production, associated with moves towards net-zero carbon emissions targets, make helium less accessible. While this is problematic for industry in the short term, it perhaps preserves some low entropy helium within the ground, making it more accessible to future generations. Given anticipated limitations to the future supply of helium, technological developments are currently focused on a few areas: the replacement of helium by other gases in industrial applications, changing technological approaches to not require helium, and reducing the cost of obtaining helium from the atmosphere. This paper explores the past, present and future of helium, focusing on the sustainability of the helium industry.

Valorization of Residue from Aluminum Industries: A Review

Recycling and reusing industrial waste and by-products are topics of great importance across all industries, but they hold particular significance in the metal industry. Aluminum, the most widely used non-ferrous metal globally, generates considerable waste during production, including dross, salt slag, spent carbon cathode and bauxite residue. Extensive research has been conducted to recycle and re-extract the remaining aluminum from these wastes. Given their varied environmental impacts, recycling these materials to maximize residue utilization is crucial. The components of dross, salt slag, and bauxite residue include aluminum and various oxides. Through recycling, alumina can be extracted using processes such as pyrometallurgy and hydrometallurgy, which involve leaching, iron oxide separation, and the production of alumina salt. Initially, the paper will provide a brief introduction to the generation of aluminum residues—namely, dross, salt slag, and bauxite residue—including their environmental impacts, followed by an exploration of their potential applications in sectors such as environmental management, energy, and construction materials.

Shrinkage and Mechanical Resistance of Steel Fiber Reinforced Geopolymer Mortars Containing Industrial By-Product GGBS; Solution to Binder Affect in Oven Curing Condition

Shrinkage and Mechanical Resistance of Steel Fiber Reinforced Geopolymer Mortars Containing Industrial By-Product GGBS; Solution to Binder Affect in Oven Curing Condition

Sustainable Management of Agro-Food Wastes Derived from the Olive Mill and Sugar Industry and Clinoptilolite to Produce Novel Adsorptive Materials

Novel sorbents were produced using sustainable and eco-friendly methods, aimed at minimizing environmental impact while utilizing industrial by-products and natural minerals. Olive stones and molasses derived from olive mill and sugar industries, respectively, and an abundant, natural and low-cost mineral, clinoptilolite, were combined in the following proportions: 80/20 clinoptilolite/stone, 80/10/10 clinoptilolite/stone/molasses, 50/50 stone/molasses, w/w. Then, physical carbonization (CL80OL20C, CL80OL10M10C, OL50M50C) or chemical activation (CL80OL20A, CL80OL10M10A, OL50M50A) took place. The adsorbents were characterized through Raman, FT-IR, BET and SEM-EDS analysis. The CL80OL20A material presents the highest ratio of C/O in EDS analysis and the lowest ID/IG in Raman spectroscopy. The increase in the specific surface area is as follows: OL50M50C < OL50M50A < CL80OL10M10C < CL80OL20C < CL80OL20A < CL80OL10M10A. Three applications were conducted: two with dyes (methylene blue and methyl red) in aqueous means and one in olive mill wastewaters for the removal of total phenols and their addition to rice, increasing the total phenolic content and producing novel foods. The well-fitted application of the pseudo-second order kinetic model to the experimental data has shown that chemisorption is the prevailing mechanism. The adsorbed amount of the recovered phenols to rice ranges from 0.14 to 0.93 mg/g. Consequently, olive and sugar by-products can be used as filters either to adsorb dangerous organic compounds or to recover bioactive compounds from wastewater, preventing their disposal in the environment, which could otherwise lead to severe negative effects on the ecosystems.

Comprehensive Review of Fly Ash: Environmental Impact and Applications

ABSTRACTFly ash (FyA), a byproduct from coal combustion in power plants, has become increasingly valuable due to its pozzolanic properties. Primarily, FyA finds applications in the construction industry, including road and brick construction, forest road building, and the cement industry. When added to concrete, it enhances splitting tensile strength, compressive strength, and workability, while also reducing the environmental impact of cement production. Beyond construction, FyA is utilized for air pollutant removal and serves as an adsorbent for various contaminants. It also plays a role in creating geopolymers and nanocomposites, promoting the development of eco‐friendly construction materials. This review article presents current data on thermal power plants (ThPPs) in India, the challenges in FyA management, and its environmental impact. It also discusses relevant Indian policies and highlights ongoing research aimed at improving the efficiency and expanding the applications of FyA in various industrial sectors, such as battery manufacturing, zeolite synthesis, and cenosphere extraction. These efforts underscore FyA's potential in supporting sustainable practices. The findings of this review address critical issues related to FyA. By reducing the environmental footprint of cement manufacturing, removing air pollutants, and acting as an adsorbent for various contaminants, FyA demonstrates significant potential in pollution mitigation. It also contributes to the development of eco‐friendly construction materials and promotes sustainability in the construction sector. Effective management practices are essential to minimize FyA's negative impact on human health and the environment. The article emphasizes the need for greater awareness and implementation of policies to address these issues comprehensively. By providing a detailed understanding of the benefits and challenges associated with FyA, it aims to pave the way for more effective and sustainable utilization of this industrial byproduct.

CARBON-SILICA COMPOSITE AS ADSORBENT FOR REMOVAL OF CATIONIC DYE (METHYLENE BLUE)

The aim of this research was to synthesize carbon-silica composite (CSC) as an adsorbent for cationic dye removal from wastewater. Molasses, a by-product of the sugar industry, was successfully utilized to prepare CSC by sol-gel method with tetraethoxylsilane (TEOS) as silica source. The physicochemical properties of the composites were studied by N2 adsorption, FTIR and TGA. The highest specific surface areas of CSC was 144 m2/g at a molasses/TEOS ratio of 0.8, with a mesopore volume of 83% and average pore width of 9.71 nm. This optimal CSC was evaluated for methylene blue (MB) adsorption using batch experiments under varying adsorption times and initial MB concentrations. Adsorption equilibrium was reached within 14 h and the pseudo-second order equation provided the adequate fit for the kinetic studies, suggesting that dye adsorption was limited by chemisorption. The equilibrium data were best described by the Sips model with a maximum adsorption capacity of 180.22 mg/g. The CSC derived from molasses is considered a potentially promising adsorbent for cationic dye removal in wastewater.

Tomato Waste as a Sustainable Source of Antioxidants and Pectins: Processing, Pretreatment and Extraction Challenges

Tomato processing waste (TPW), a byproduct of the tomato processing industry, is generated in significant quantities globally, presenting a challenge for sustainable waste management. While traditionally used as animal feed or fertilizer, TPW is increasingly recognized for its potential as a valuable raw material due to its high content of bioactive compounds, such as carotenoids, polyphenols and pectin. These compounds have significant health benefits and are in growing demand in the pharmaceutical and cosmetic industries. Despite this potential, the broader industrial utilization of TPW remains limited. This review explores the influence of various processing, pretreatment and extraction methods on the concentration and stability of the bioactive compounds found in TPW. By analyzing the effects of these methodologies, we provide insights into optimizing processes for maximum recovery and sustainable utilization of TPW. Additionally, we address the major challenges in scaling up these processes for industrial application, including the assessment of their ecological footprint through life cycle analysis (LCA). This comprehensive approach aims to bridge the gap between scientific research and industrial implementation, facilitating the valorization of TPW in line with circular economy principles.

Synthesis of gold nanoparticles using soybean byproducts: applications in catalysis

AbstractThis study demonstrates the feasibility of extracting lecithin from oil industry byproducts in an eco‐friendly manner, with minimal use of water and without harmful chemicals. Liposomes can be generated directly from this extracted lecithin, enhancing the value of these byproducts and enabling the production of catalytic gold nanoparticles (AuNPs). Thin‐layer chromatography of the extracted lecithin revealed a phospholipid composition primarily consisting of phosphatidylethanolamine and phosphatidylcholine, and surface tension studies demonstrated similar behavior between the extracted and commercial lecithin. Liposome formation using sustainable lecithin (LPn) resulted in structures that were stable for at least 10 days, exhibiting a low polydispersity index (0.395) and uniform size (approximately 214 ± 7 nm). Gold nanoparticles were synthesized successfully in LPn loaded with [HAuCl4] by using different photoreduction methods: ultraviolet (UV) lamp, pulsed laser 355 nm, and sunlight irradiation. The AuNPs exhibited characteristic sizes (ranging from 5.03 to 6.78 nm) and optical properties typical of nanoparticles, including a distinct surface plasmon resonance. As a proof of concept, we also demonstrated that the synthesized AuNPs exhibited catalytic activity in UV‐induced cis‐trans isomerization reactions. Overall, the study highlights the potential of sustainable soy lecithin extraction for diverse applications, including nanoparticle synthesis and catalysis.

The effect of copper slag as a precursor on the mechanical properties, shrinkage and pore structure of alkali-activated slag-copper slag mortar

Copper slag, an industrial by-product produced in large quantities during copper smelting and refining, has the potential to be used as an alternative precursor for alkali-activated materials. This approach not only reduces the environmental impact of copper slag but also addresses the growing scarcity of conventional precursors, such as ground granulated blast furnace slag. In this research, copper slag was used as an alternative precursor for alkali-activated slag-copper slag mortars. Sodium hydroxide and water glass served as the activators. The workability, mechanical properties, autogenous shrinkage and drying shrinkage were investigated to evaluate the influence of copper slag content. Furthermore, the reaction products and pore structure of hardened mortar were analysed to gain deeper insights into its performance. The results show that the incorporation of copper slag effectively prolongs the setting time and increases the fluidity. Copper slag reduces the autogenous shrinkage, but it also results in an undesirable increase in drying shrinkage. While copper slag delays strength development and reduces the strength, incorporating copper slag at a 50 % ratio still results in strength comparable to that of mortars utilizing 100 % ground granulated blast furnace slag as the precursor. The incorporation of copper slag alters the composition of calcium aluminosilicate hydrate and promotes the formation of ferro-silicate. Although it reduces the proportion of macropores in the total pore volume, it simultaneously increases the amount of capillary pores. Copper slag alters pore solution, and although heavy metal leaching remains minimal, risks in complex environments require further study.

Applicability of Waste from Al Industry toward Dephosphorization of Hot Metal in Primary Steel Making

Managing industrial waste is a global challenge. Red mud is a byproduct of the aluminum industry posing serious concerns. The presence of FeO and CaO in red mud makes it a potential DeP flux. Red mud has been utilized as a DeP flux in previous studies, but these studies deal with low Si content and no P2O5 content in the red mud. However, certain steel makers have high initial Si content (0.6–0.7 wt%) in the hot metal, and with increasing demand for low P steel, new dephosphorization fluxes need to be explored. Addressing this gap, this study investigates red mud's potential as a flux for dephosphorization in hot metal with elevated Si levels. Conducting slag–metal equilibrium experiments at 1350 °C, using red mud‐based fluxes, the research achieves a 40% dephosphorization degree under optimized conditions of double deslagging and fluxing. Analysis via wet chemical methods and inductively coupled plasma mass spectrometry confirms the effectiveness of the approach. Furthermore, thermodynamic calculations highlight the influence of O2 partial pressure and Si content on dephosphorization efficacy. Through laboratory experiments and theoretical insights, this study provides a valuable roadmap for leveraging red mud as a sustainable flux in hot metal dephosphorization processes, contributing to both waste management and steel production efficiency.