Bulk Utilization of Red Mud in Geopolymer Based Products

Red Mud is the solid residue generated from Alumina refinery during the process of bauxite ore processing through Bayer’s process. Typical generation of red mud is 1.5 tons of red mud per ton of alumina produced. The disposal and storage of red mud has been a concern for the alumina industry since its inception, more than a hundred years ago. With the increase in alumina production, the magnitude of the problem is getting multiplied. Its alkaline nature (Na2O ~ 3-7%) and fine size make red mud unsuitable for many applications; a limited utilization is reported in cement industries as one of the raw mix components for cement. The present work deals with the utilization of red mud in geopolymer based paving blocks. Alumina, silica and alkali are the essential items required for geopolymer preparation. Having all these in red mud, the current study attempted to use the same in geopolymer based products. The focus has been on bulk utilization of red mud; target strength of 20 MPa after 28 days of curing (M20 grade) has been the goal as this strength is sufficient for many applications. The study focused on optimizing the red mud content, alkali concentration, fly ash content, etc. The samples are tested for its compressive strength and leachability. The study reveals that significant amount of red mud incorporation is possible with products conforming to USEPA 1311 norms.

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Effect of red mud addition on the corrosion parameters of reinforced concrete evaluated by electrochemical methods

Revista IBRACON de Estruturas e Materiais ◽

10.1590/s1983-41952012000400004 ◽

2012 ◽

Vol 5 (4) ◽

pp. 451-467 ◽

Cited By ~ 9

Author(s):

D.V. Ribeiro ◽

J.A. Labrincha ◽

M.R. Morelli

Keyword(s):

Electrical Resistivity ◽

Reinforced Concrete ◽

Red Mud ◽

Corrosion Potential ◽

Corrosion Process ◽

Bayer Process ◽

Alumina Production ◽

High Ph ◽

High Electrical Resistivity ◽

Bauxite Ore

Red mud, the main waste generated in aluminum and alumina production from bauxite ore by the Bayer process, is considered "hazardous" due to its high pH. The high pH also provides greater protection of rebars, which is reflected in the low corrosion potential and high electrical resistivity (filler effect) of concrete. The corrosion potential was monitored by electrochemical measurements and the electrical resistivity was evaluated using sensors embedded in concrete test specimens. The results showed that the addition of red mud is beneficial to concrete, reducing its corrosion potential and increasing its electrical resistivity. Red mud proved to be a promising additive for concrete to inhibit the corrosion process.

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Removal of Pb ion from water samples using red mud (bauxite ore processing waste)

E3S Web of Conferences ◽

10.1051/e3sconf/20130141019 ◽

2013 ◽

Vol 1 ◽

pp. 41019 ◽

Cited By ~ 1

Author(s):

A. Ghorbani ◽

M. Nazarfakhari ◽

Y. Pourasad ◽

S. Mesgari Abbasi

Keyword(s):

Water Samples ◽

Red Mud ◽

Processing Waste ◽

Ore Processing ◽

Bauxite Ore

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Synthesis of Amorphous Aluminosilicates from Bintan’s Red Mud as Alumina Source

Indonesian Journal of Chemistry ◽

10.22146/ijc.25184 ◽

2018 ◽

Vol 18 (4) ◽

pp. 580

Author(s):

Futri Wulandari ◽

Eka Putra Ramdhani ◽

Yatim Lailun Ni’mah ◽

Ahmad Anwarud Dawam ◽

Didik Prasetyoko

Keyword(s):

Red Mud ◽

Nitrogen Adsorption ◽

X Ray Diffraction ◽

Structure Directing Agent ◽

Alumina Production ◽

Hydrolysis Method ◽

Alkali Fusion ◽

Silica Source ◽

Bauxite Ore ◽

Adsorption Desorption

Red mud is a generated by-product in alumina production from bauxite ore. In this study, Bintan’s red mud has been used as alumina and silica source to synthesize amorphous mesoporous aluminosilicates material. Alkali fusion method with a NaOH/red mud ratio 0.8; 1.0; 1.2; 1.4 and 1.5 followed by hydrolysis method was used to extract dissolved alumina and silica from red mud. Synthesis of amorphous aluminosilicates by hydrothermal method was conducted at 80 °C for 24 h. Cetyltrimethylammonium bromide (CTABr) was added as the structure directing agent. Aluminosilicate products were characterized using FTIR spectroscopy (Fourier Transform Infra-Red Spectroscopy), XRD (X-ray Diffraction), SEM (Scanning Electron Microscopy), and nitrogen adsorption-desorption. XRD and SEM result shows that the product was amorphous with low uniformity in terms of surface morphology and particle size. Nitrogen adsorption-desorption profile shows that all aluminosilicates products has a meso pore structure, confirmed by the highest pore distribution at 3.05–17.70 nm. The highest surface area and pore volume were obtained in ASM 0.8 (NaOH/red mud ratio = 0.8) i.e. 177.97 m2/g and 1.09 cm3/g, respectively.

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USE OF DUMPED RED MUD OF ALUMINA INDUSTRY AT GRANULATION OF THE MOLTEN SULFUR-CONTAINING BLAST FURNACE SLAG

Periódico Tchê Química ◽

10.52571/ptq.v16.n31.2019.847_periodico31_pgs_837_845.pdf ◽

2019 ◽

Vol 16 (31) ◽

pp. 837-845

Author(s):

Andrey B LEBEDEV ◽

Vladimir A UTKOV ◽

Olga A KAYGORODOVA ◽

Marsel A KADYROV

Keyword(s):

Blast Furnace ◽

Red Mud ◽

Power Plants ◽

Natural Waters ◽

Thermal Power ◽

Alumina Production ◽

Industrial Gases ◽

Red Muds ◽

Alumina Industry ◽

Sulfur Containing

There is a problem of using waste of alumina production from bauxite red mud. Warehousing of it is fraught with ecological catastrophes. Red muds constantly worsen the environment due to dusting and pollution of natural waters. Red mud is a product of bauxite processing. One ton of alumina accounts for 1 to 2.5 tons of red mud. Currently, it is not being processed, despite the availability of 3,000 publications and patents on this topic. One of them is justified by the ambiguity in the economic effectiveness of its use by consumers. In this paper, the options for economic and environmental efficiency of RM use are presented as substitutes for expensive lime and limestone used for purification of industrial gases emitted to the atmosphere in large quantities with toxic sulfur compounds. Laboratory and industrial tests revealed the sorption properties of red muds. When cleaning gases from sulfur emitted into the atmosphere by furnace gases, thermal power plants, sinter machines, and steelmaking furnaces. In addition, the ecological and technological efficiency of purification of sulfur-containing gases released in the areas of granulation of molten blast-furnace slags is shown.

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X-ray Diffraction and Thermal Analysis of Bauxite Ore-Processing Waste (Red Mud) Exchanged with Arsenate and Phosphate

Clays and Clay Minerals ◽

10.1346/ccmn.2011.0590207 ◽

2011 ◽

Vol 59 (2) ◽

pp. 189-199 ◽

Cited By ~ 8

Author(s):

Paola Castaldi ◽

Margherita Silvetti ◽

Stefano Enzo ◽

Salvatore Deiana

Keyword(s):

Thermal Analysis ◽

Red Mud ◽

Processing Waste ◽

X Ray Diffraction ◽

X Ray ◽

Ore Processing ◽

Bauxite Ore

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Influence of Na2CO3 and K2CO3 Addition on Iron Grain Growth during Carbothermic Reduction of Red Mud

Metals ◽

10.3390/met9121313 ◽

2019 ◽

Vol 9 (12) ◽

pp. 1313 ◽

Cited By ~ 2

Author(s):

Dmitry Zinoveev ◽

Pavel Grudinsky ◽

Andrey Zakunov ◽

Artem Semenov ◽

Maria Panova ◽

...

Keyword(s):

Magnetic Separation ◽

Grain Growth ◽

Red Mud ◽

Carbothermic Reduction ◽

Reduction Roasting ◽

Alumina Production ◽

Iron Aluminum ◽

Bauxite Ore ◽

Hsc Chemistry ◽

Sodium And Potassium

Red mud is a by-product of alumina production from bauxite ore by the Bayer method, which contains considerable amounts of valuable components such as iron, aluminum, titanium, and scandium. In this study, an approach was applied to extract iron, i.e., carbothermic reduction roasting of red mud with sodium and potassium carbonates followed by magnetic separation. The thermodynamic analysis of iron and iron-free components’ behavior during carbothermic reduction was carried out by HSC Chemistry 9.98 (Outotec, Pori, Finland) and FactSage 7.1 (Thermfact, Montreal, Canada; GTT-Technologies, Herzogenrath, Germany) software. The effects of the alkaline carbonates’ addition, as well as duration and temperature of roasting on the iron metallization degree, iron grains’ size, and magnetic separation process were investigated experimentally. The best conditions for the reduction roasting were found to be as follows: 22.01% of K2CO3 addition, 1250 °C, and 180 min of duration. As a generalization of the obtained data, the mechanism of alkaline carbonates’ influence on iron grain growth was proposed.

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XRD, FTIR, and Thermal Analysis of Bauxite Ore-Processing Waste (Red Mud) Exchanged with Heavy Metals

Clays and Clay Minerals ◽

10.1346/ccmn.2008.0560407 ◽

2008 ◽

Vol 56 (4) ◽

pp. 461-469 ◽

Cited By ~ 65

Author(s):

Paola Castaldi ◽

Margherita Silvetti ◽

Laura Santona ◽

Stefano Enzo ◽

Pietro Melis

Keyword(s):

Heavy Metals ◽

Thermal Analysis ◽

Red Mud ◽

Processing Waste ◽

Ore Processing ◽

Bauxite Ore

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Removal of Phosphate Using Red Mud: An Environmentally Hazardous Waste By-Product of Alumina Industry

Advances in Physical Chemistry ◽

10.1155/2016/9075206 ◽

2016 ◽

Vol 2016 ◽

pp. 1-9 ◽

Cited By ~ 10

Author(s):

Shivkumar S. Prajapati ◽

P. A. Mohamed Najar ◽

Vijay M. Tangde

Keyword(s):

Aqueous Solutions ◽

Red Mud ◽

Selective Adsorption ◽

Bauxite Residue ◽

Selective Removal ◽

Bet Surface Area ◽

Size Analysis ◽

Alumina Production ◽

Heat Treated ◽

Alumina Industry

The industrial waste, bauxite residue generated in the Bayer chemical process of alumina production, commonly known as red mud (RM) has been used as the adsorbent for selective removal of phosphate in aqueous solutions. RM collected from the storage area of alumina industry was characterized by chemical analysis and physical methods such as BET surface area, Scanning Electron Microscopy (SEM), particle size analysis, and X-ray diffraction (XRD) methods. Among the various red mud samples (0.2–200 μ) studied, the samples treated with 1 M HCl for 2 h were found better for the selective adsorption of phosphate in comparison with untreated and heat treated RM samples. The presence of phosphate in the aqueous samples collected after adsorption studies with red mud was determined by standard spectrophotometric procedure using ammonium molybdate and ascorbic acid in nitrate medium at λmax 880 nm. The studies reported significant adsorption of phosphate on acid treated red mud in comparison with adsorption of phosphate on untreated and heat treated red mud, respectively. The adsorption of phosphate on raw red mud and activated red mud was further investigated with respect to stirring time, pH of the solution, dose of adsorbent, and varying phosphate concentration. Acid treated RM is observed as an efficient and cost-effective adsorbent for selective removal of phosphate in aqueous solutions.

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Current key options for management of industrial alkaline waste of alumina production (red mud)

E3S Web of Conferences ◽

10.1051/e3sconf/202128401003 ◽

2021 ◽

Vol 284 ◽

pp. 01003

Author(s):

Htet Ye Aung ◽

Alexander Boyarintsev ◽

Sergey Stepanov ◽

Andrei Shoustikov

Keyword(s):

Red Mud ◽

Large Scale ◽

Cost Effective ◽

Industrial Wastes ◽

Toxic Waste ◽

Alumina Production ◽

The Sustainable Development ◽

The World ◽

Liquid Products ◽

Bauxite Ore

Due to the ever-increasing demand of the world economy for aluminum, its alloys and compounds, the production of this metal is increasing annually throughout the world. This leads to an increase in the industrial production of alumina, which is obtained from bauxite ore in the Bayer process. After recovering the bulk of the aluminum from the bauxite ore, there remains a residue which is highly alkaline toxic waste, which is also called bauxite residues (tailings) or red mud (RM). About 140-150 million tons of RM are produced annually and almost 4 billion tons have already been accumulated. At the moment, the problem of RM recycling and the development of effective and cost-effective approaches to their reprocessing is extremely urgent. Reducing RM affects economic, environmental, social areas and is a prerequisite for the sustainable development of nature and society. Despite active scientific research and efforts to develop and optimize various methods for RM recycling and reprocessing, the problem of an annual increase in their volumes around the world remains unresolved. Recently, promising and efficient processes have been proposed that allows for the complex reprocessing of RM with the extraction of a number of valuable liquid products that may be in demand in various fields of industry. This allows to focus on large-scale disposal of RM and can be a solution to the problem of handling these industrial wastes. The article considers the main current trends in the field of management of various types of RM with a focus on complex reprocessing and zero waste concepts.

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