Summary of research progress on separation and extraction of valuable metals from Bayer red mud.

Bayer red mud is a strong alkaline solid waste discharged during alumina production. Due to large emissions and strong alkalinity, red mud is now mostly dammed or buried, which not only occupies huge land but also contaminates the surrounding ecosystem, causing the risk of collapse and landslide. In addition to its overall utilization in building materials, agriculture, the environment, and the chemical industry, red mud also contains valuable metals such as sodium, aluminum, iron, titanium, and scandium and is considered to be an important secondary resource. In this paper, the physicochemical properties and hazards of red mud are first introduced, and then, the overall utilization of red mud is summarized. Then, the latest research progress on the separation and extraction of valuable metals from red mud is reviewed in detail and a new comprehensive utilization method is recommended and evaluated. This paper also provides suggestions for the future development direction of the comprehensive utilization technology of red mud.

Research on the Dealkalization Treatment of Bauxite Residue and Deep Extraction of Alumina.

Bauxite residue is the bulk solid waste generated by the alumina industry, and the environmental treatment of bauxite residue has always been a focus of attention. In this study, in the high calcium system, the bauxite residue was intensively digestion by the calcification-carbonation method, and the mole ratio of solution, the mass ratio of CaO/SiO2 of the digestion process were changed, so that the high-efficiency dealkalization of bauxite residue was realized and the aluminum oxide in bauxite residue was deeply extracted. The experimental results showed that the calcification process could achieve the recovery of 17.83% alumina at 260°C, reaction duration of 60 min, liquid-solid ratio = 5:1, the mass ratio of CaO/SiO2 = 3.5, and 200 g/L NaOH solution. The whole process can recover 49.61% of alumina from bauxite residue, and 94.4% of alkali in bauxite residue can be removed.

Study on Iron Extraction from High Iron Bauxite Residue by Pyrite Reduction.

A new method of solid-phase reduction magnetic separation with pyrite as a reducing agent was proposed in order to realize resource utilization of high iron bauxite residue while reducing environmental harm. FeS2 powder and high iron bauxite residue powder were uniformly blended and roasted in a closed environment. A magnetic separator was utilized to separate the magnetic iron concentrate at 2400 GS, and the recovery rates were calculated. Experimental results show that the best iron recovery was 91.5% at 1:6 roasted bauxite: residue at 800℃ for 2 h. The recovery of Fe can be improved by reducing high iron bauxite residue with pyrite, and iron in both pyrite and high iron bauxite residue can be recovered simultaneously, alleviating the pressure of iron ore resources and improving its utilization value.

Extraction and Utilization of Valuable Elements from Bauxite and Bauxite Residue: A Review.

Bauxite is the ideal raw material for the manufacturing of alumina. Aside from the primary constituents of aluminum and silicon, bauxite is frequently coupled with many valuable elements such as gallium (Ga), titanium (Ti), scandium (Sc), and lithium (Li). The bauxite residue and circulating spent liquor in alumina production typically include significant amounts of valuable elements, making them a potential source of polymetallic. The recovery of these essential components can greatly increase alumina manufacturing process efficiency while reducing industrial liability and environmental impact. This study gives a critical analysis of existing technology used to recover valuable elements from bauxite residue and circulating spent liquor to provide insight into the broader usage of bauxite residue as a resource rather than a waste. A comparison of existing process features demonstrates that an integrated process for valuable elements recovery and waste emission reduction is advantageous.

Calcification-Carbonation Method for Bayer Red Mud Treatment: Carbonation Performance of Hydrogarnets.

Hydrogarnets are vital intermediate products in the calcification- carbonation method, which is designed for Bayer red mud treatment. Their carbonation performance greatly depends on SiO2 substitution. In this study, different SiO2-substituted hydrogarnets were synthesized and characterized. Then, batch experiments were performed to evaluate the potential effects of important parameters such as CO2 pressure, and SiO2 substitution degree (x) on the carbonation process. The SiO2 substitution degrees of the hydrogarnets synthesized at 60, 120, 180, and 240°C were 0.27, 0.36, 0.70, and 0.73, respectively. As the SiO2 substitution degree increased, the hydrogarnet carbonation extents gradually declined. With an increase in CO2 pressure, the hydrogarnet carbonation percentages increased gradually and rose from 80.33% to 98.19% within 120 min. The phases detected in the carbonized products were strip-like aragonite as well as some calcite; the Al-rich and Si-rich phases in the carbonized products were amorphous.

Comprehensive Application Technology of Bauxite Residue Treatment in the Ecological Environment: A Review.

The emission of bauxite residue continues to grow with the increase of alumina production capacity, along with the large amounts of bauxite residue currently stored in stockpiles. The exposed problems of high yield, strong alkalinity, low comprehensive utilization rate, and threats to the ecological environment are becoming increasingly prominent. With the strict requirements of environmental protection, improving the comprehensive utilization rate of bauxite residue and bulk consumption of bauxite residue has become an urgent issue to be solved. A large number of researchers have conducted in-depth investigations into the application of bauxite residue over a wide range, and this paper summarizes its application in the environment in recent years, providing guidance for the high value and harmless application of bauxite residue, which can help reduce environmental pollution and human life and health hazards caused by bauxite residue.

Experimental Research on Vortex Melting Reduction of High-Iron Red Mud (Bauxite Residue).

In this study, the advantages of the vortex melting reduction treatment of red mud were verified. Vortex melting reduction can improve the feeding rate, promote the reaction and the directional deposition of iron, which was conducive to the separation of slag and gold. The effects of different adding methods, stirring speed and reaction time on iron recovery were investigated by using red mud, aluminum leached slag and calcified slag as raw materials. According to the experiment, the best reaction conditions were that the raw material put into the furnace by rolling pellets, stirring speed 125 RPM, and reaction time 30 min. The results provided an experimental basis for the harmless and high-value utilization of high-iron red mud treated by vortex melting reduction.

Research on the oxidation characteristics of zinc sulfite in the zinc oxide desulfurization process.

Aiming at the pollution problem of low-content SO2 in non-ferrous metal production industry, the oxidation kinetics of zinc sulfite in the zinc oxide desulfurization process was studied. The concentration change of Zn2+, variation of pH, temperature and apparent activation energy in the oxidation process of two ZnSO3 samples were investigated systematically. The results indicate that the raw material with different crystal water has little effect on the oxidation kinetic of zinc sulfite. The reaction process comprises two stages: the dissolution process and the oxidation process. The zinc ion concentration is linearly rising with the action time during the oxidation process. The pH value rises quickly in the dissolution process and goes down slowly with reaction time in the oxidation process. The process is mainly controlled by a diffusion step and less effected by the temperature. The apparent activation energy Ea obtained for the two samples are 8.662 and 9.645 kJ/mol, respectively. Integrated with the kinetic model, the oxidation rate of zinc sulfite is controlled by the diffusion of HSO3- and O2 to the gas-liquid interface.

Recovery of vanadium from calcification roasted-acid leaching tailing by enhanced acid leaching.

Vanadium contained tailing generated from the typical calcium roasting-acid leaching process is contaminant and waste of resource. Atmospheric and pressurized leaching were conducted and compared to recover the vanadium from the vanadium tailing and improve the tailing's environmental quality. Orthogonal experiments were designed and applied for the atmospheric leaching study. It is shown that the extraction efficiency of V changed from 29.6% to 43.5% while the extraction efficiency of Fe, Cr, Ti, Mg remained stable under 4% with variable atmospheric leaching conditions. In the pressurized leaching experiments, the effects of leaching temperature, H2SO4 concentration, liquid to solid ratio and leaching time on the extraction of V, Fe, and Ti were investigated. Under the optimum conditions (the temperature of 413.15 K, H2SO4 concentration of 300 g/L, liquid to solid ratio of 8:1 mL/g and the reaction time of 100 min), the extraction efficiencies of V, Fe, and Ti reached 91.7%, 60.1% and 46.5% respectively, a leach residue contains only 0.13% of stable vanadium was obtained.

Calcification-carbonation method for red mud processing.

Red mud, the Bayer process residue, is generated from alumina industry and causes environmental problem. In this paper, a novel calcification-carbonation method that utilized a large amount of the Bayer process residue is proposed. Using this method, the red mud was calcified with lime to transform the silicon phase into hydrogarnet, and the alkali in red mud was recovered. Then, the resulting hydrogarnet was decomposed by CO2 carbonation, affording calcium silicate, calcium carbonate, and aluminum hydroxide. Alumina was recovered using an alkaline solution at a low temperature. The effects of the new process were analyzed by thermodynamics analysis and experiments. The extraction efficiency of the alumina and soda obtained from the red mud reached 49.4% and 96.8%, respectively. The new red mud with <0.3% alkali can be used in cement production. Using a combination of this method and cement production, the Bayer process red mud can be completely utilized.