Red mud is an industrial hazardous alkaline solid waste, whereas it is rich in polymetallic components showing a high comprehensive utilization value. Direct materialization of red mud towards zero waste emission is a more reasonable and environmentally friendly strategy. In this work, a novel materialization approach of red mud via converting the polymetallic constituents into functional ferrite material by phase reconstruction with MnO2 was proposed. The mineral phase reconstruction, microstructure evolution, reaction interface observation, electromagnetic property, and the materialization conversion mechanism were investigated. It was found that the complicated phases in red mud were transferred to simple forms including the magnetic ferrites (Ca/Na/Al/Ti-bearing Mn ferrite) and weakly magnetic silicates ((Na,Al,Ca)2SiO3) after phase reconstruction. The reconstructed red mud after sintering at 1200 ℃ for 120min in air atmosphere had satisfactory electromagnetic property. Magnetism study demonstrated the soft magnetic property with maximum saturation magnetization of 34.22emu/g and coercivity of only 7.0Oe. Compared with the original red mud, effective electromagnetic wave absorption with reflection loss (RL) values of the reconstructed red mud below -20 dB were satisfied across a wider frequency bandwidth of 5-18GHz, and the minimum RL value was lower as -32.4dB with a thinner veneer thickness of 15mm, highlighting its excellent electromagnetic wave absorption performance. Moreover, Na solidification behaviors indicated that Na was solidified in the sintered product, which can reduce the possible environmental hazards of red mud alkalinity. The novel materialization treatment with zero waste emission exhibits a favorable application prospect with a large red mud batching ratio about 50wt%.
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