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Frontiers of Chemical Science and Engineering

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Front. Chem. Sci. Eng.    2017, Vol. 11 Issue (3) : 483-496    https://doi.org/10.1007/s11705-017-1653-z
REVIEW ARTICLE
Materials sustainability for environment: Red-mud treatment
Brajendra Mishra1(), Sumedh Gostu2
1. Department of Mechanical Engineering, Worcester Polytechnic Institute, Worcester, MA 01609-2280, USA
2. Department of Material Science and Engineering, Worcester Polytechnic Institute, Worcester, MA 01609-2280, USA
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Abstract

Bayer’s process revolutionized the extraction of aluminum from the bauxite ores. However, the hydrothermal extraction of alumina is associated with the generation of a byproduct, red-mud consisting of undissolved solids composed of iron oxides, sodium alumino silicates, titania, silica and rare earth elements. The accumulation of red-mud (or bauxite residue) in the world is 30 billion metric tons produced at a rate of 125 million tons per annum (2013). Utilization of red-mud for constructional purposes, wastewater treatment, metallurgical products, and pigments are listed. Metallurgical processing efforts of red-mud to generate various value added products such as pig iron, direct reduced iron slag wool, magnetite, titania, iron carbides are presented in the article.
Keywords red-mud processing      waste management      sustainability      valorization     
Corresponding Author(s): Brajendra Mishra   
Just Accepted Date: 14 April 2017   Online First Date: 27 June 2017    Issue Date: 23 August 2017
 Cite this article:   
Brajendra Mishra,Sumedh Gostu. Materials sustainability for environment: Red-mud treatment[J]. Front. Chem. Sci. Eng., 2017, 11(3): 483-496.
 URL:  
https://academic.hep.com.cn/fcse/EN/10.1007/s11705-017-1653-z
https://academic.hep.com.cn/fcse/EN/Y2017/V11/I3/483
Source SiO2 TiO2 Al2O3 Fe2O3 CaO MgO H2O (combined) Total
France 0.8 2.8 58.6 26.2 10.9 99.30
France 0.8 3.3 76.4 4.8 14.3 99.8
France 0.29 0.8 60.6 26 10.4 98.09
France 13.3 2.4 63.7 5.5 14.3 99.2
Romania 1.49 3.12 59.66 23.66 11.81 99.74
Romania 0.8 2.8 65.5 21.3 9.96 100.36
Yugoslavia 0.89 51.85 26.82 19.97 99.54
Italy 2.79 1.27 57.6 26.55 11.71 99.92
Italy 7.91 58.85 18.62 0.30 0.37 13.27 99.32
US, Alabama 2.90 3.40 58.21 3.60 31.89 100
US, Arkansas 2 3.5 62.25 1.66 30.31 99.52
US, Arkansas 10.13 55.09 6.08 28.99 100.29
US, Georgia 0.62 1.05 64.91 0.28 33 99.86
British Guiana 2.73 0.1 64.38 0.5 32.29 100
British Guiana 1 1.1 70.90 0.8 26.30 100.10
Tab.1  The compositions (%) of some bauxite ores around the world [4]
Fig.1  Pictorial flowsheet of the Bayer process [5]
Plant, location (country) Fe2O3 Al2O3 TiO2 SiO2 Na2O CaO LOI
Alcoa of Australia (Pinjarra, Australia) 36.2 17.1 3.9 2.8 1.6 3.9 10.4
Alcan, Arvida (Quebec, Canada) 27.4 28.4 9.8 14.3 8.8 1.3 9.9
Hungalu (Ajka, Hungary) 42.1 14.8 5.2 13.5 8.9 6.1 8.2
Alcan Jamaica (Kirkvine, Jamaica) 49.4 13.2 7.3 3.0 9.6 5.7 7.2
Kaiser (Gramercy, Louisiana, USA) 51.5 15.0 6.7 1.7 1.0 7.0 9.3
Alcoa alumino (Pocos, de Caldes, Brazil) 29.6 21.9 4.4 17.5 8.3 2.9 11.5
Indian plants
Hindalco (a) causticised
(Renukoot) (b) uncausticised		 28.1
33.1		 21.9
18.2		 15.6
19.6		 7.5
8.8		 4.5
5.8		 10.2
2.7		 12.2
8.9
Nalco (a) 1995
(Damanjodi) (b) 1991		 54.8
68.5		 14.8
12.5		 3.7
2.8		 6.4
3.0		 4.8
2.5		 2.5
0.1		 9.5
10.2
Balco (Korba) causticised 27.9 19.2 16.4 7.3 3.3 11.8 12.6
Indal (Muri) 24.5 24.3 18.0 6.2 5.3 ? ?
Indal (Belgaum) 44.5 19.2 13.5 7.0 4.0 0.8 10.0
Tab.2  Chemical compositions (wt-%) of various red-mud around the world [6]
Fig.2  Research done by some authors in red mud utilization until date [15]
Fig.3  Process flowsheet for metal extraction from red mud employed by Piga et al. [30]
Fig.4  Process for removal of iron from aluminous iron ores by Kumar et al. [32]
Fig.5  Stepwise reduction, roasting and magnetic separation process for red-mud by Li et al. [38]
Fig.6  Process flowsheet for metal recovery from red mud adopted by Piga et al. [30]
Fig.7  Cryolite production from red-mud by HCl leaching [42]
  
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