Recycling Red Mud of JSC Ural Aluminum Plant with the Recovery of Iron and Construction Materials

Abstract:

Red mud is a by-product of alumina industry which is currently almost completely stored in landfill sites without further use. It contains considerable amounts of valuable components such as iron, aluminum, titanium and rare-earth metals. The reduction smelting of red mud was carried out in laboratory scale to recover iron and obtain slag suitable for use in the construction industry. It has been shown that it is expedient to obtain pig iron and slag from the unprocessed red mud. Those two are suitable for the subsequent leaching of aluminum, titanium and rare-earth metals. It is practical to process dealkalized red mud, with composition adjustment by CaO and Al₂O₃ addition, in order to obtain pig iron and slag in the form of aluminous clinker.

• Periodical: Key Engineering Materials (Volume 743)
• Pages: 331-337
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.743.331
• Online since: July 2017
• Authors: Dmitry Zinoveev*, Pavel Grudinsky, Vladimir Korneev, Valery Dyubanov, Mark Zheleznyi
• Keywords: Aluminous Cement, Portland Cement, Red Mud, Reduction Smelting

References

[1] R. Zhang, S. Zheng, S. Ma, et al., Recovery of alumina and alkali in Bayer red mud by the formation of andradite-grossular hydrogarnet in hydrothermal process, Journal of Hazardous Materials 189 (2011) 827-835.

DOI: 10.1016/j.jhazmat.2011.03.004

[2] W. Wang, Y. Pranolo, C.Y. Cheng, Recovery of scandium from synthetic red mud leach solutions by solvent extraction with D2EHPA, Separation and Purification Technology 108 (2013) 96-102.

DOI: 10.1016/j.seppur.2013.02.001

[3] M. Gräfe, G. Power, C. Klauber, Bauxite residue issues: III alkalinity and associated chemistry, Hydrometallurgy 108 (2011) 60-79.

DOI: 10.1016/j.hydromet.2011.02.004

[4] K. Binnemans, P.T. Jones, B. Blanpain, et al., Towards zero-waste valorisation of rare-earth-containing industrial process residues: a critical review, Journal of Cleaner Production 99 (2015) 17-38.

DOI: 10.1016/j.jclepro.2015.02.089

[5] C.K. Gupta, N. Krishnamurthy, Extractive metallurgy of rare earths, CRC Press, Boca Raton, (2004).

[6] W. Liu, J. Yang, B. Xiao, Review on treatment and utilization of bauxite residues in China, International Journal of Mineral Processing 93 (2009) 220-231.

DOI: 10.1016/j.minpro.2009.08.005

[7] H. Sutar, S.C. Mishra, S.K. Sahoo, et al., Progress of Red Mud Utilization: An Overview, American Chemical Science Journal 4 (2014) 255-279.

DOI: 10.9734/acsj/2014/7258

[8] G. Power, M. Gräfe, C. Klauber, Bauxite residue issues: II options for residue utilization, Hydrometallurgy 108 (2011) 11-32.

DOI: 10.1016/j.hydromet.2011.02.007

[9] R.K. Paramguru, P.C. Rath, V.N. Misra, Trends in red mud utilization – a review, Mineral Processing and Extractive Metallurgy Review 26 (2004) 1-29.

DOI: 10.1080/08827500490477603

[10] Y. Liu, R. Naidu, Hidden values in bauxite residue (red mud): Recovery of metals, Waste Management 34 (2014) 2662-2673.

DOI: 10.1016/j.wasman.2014.09.003

[11] V. Ya. Miller, A.I. Ivanov, Kharakteristika i puti kompleksnogo ispolzovaniya krasnykh shlamov [Characteristics and ways of integrated use of red mud], in: Trudy Instituta Metallurgii UFAN SSSR [Proceedings of Institute of Metallurgy, Ural Division Academy of Sciences of the USSR], Sverdlovsk, 1958, iss. 2, p.2.

[12] O.A. Arkhipov, Tekhnologicheskaya skhema kompleksnoy pererabotki krasnykh shlamov Uralskogo alyuminievogo zavoda [The technological scheme of complex processing of red mud in Ural aluminum plant], in: Trudy Soveshchaniya po kompleksnomu ispolzovaniyu rudnogo syriya Urala [Proceedings of Conference on the integrated use of Ural ore raw materials], Sverdlovsk, 1964, pp.245-248.

[13] C.R. Borra, B. Blanpain, Y. Pontikes, et al., Smelting of Bauxite Residue (Red Mud) in View of Iron and Selective Rare Earths Recovery, Journal of Sustainable Metallurgy 2 (2016), 28-37.

DOI: 10.1007/s40831-015-0026-4

[14] D.V. Valeev, Y.A. Lainer, A.B. Mikhailova, et. Al., Reaction of Bauxite with Hydrochloric Acid Under Autoclave Conditions, Metallurgist 60 (2016) 204-211.

DOI: 10.1007/s11015-016-0274-y

[15] D.V. Valeev, Y.A. Lainer, V.I. Pak, Autoclave leaching of boehmite-kaolinite bauxites by hydrochloric acid, Inorganic Materials: Applied Research 7 (2016) 272-277.

DOI: 10.1134/s207511331602026x

[16] D.V. Valeev, E.R. Mansurova, V.A. Bychinskii, et. al., Extraction of Alumina from high-silica bauxite by hydrochloric acid leaching using preliminary roasting method, IOP Conference Series: Materials Science and Engineering 110 (2016) 012049.

DOI: 10.1088/1757-899x/110/1/012049

[17] L.I. Leontiev, I.A. Vatolin, S.V. Shavrin, I.S. Shumakov, Pirometallurgicheskaya pererabotka kompleksnykh rud [Pyrometallurgical processing of complex ores], Metallurgiya, Moscow, 1997. (in Russian).

[18] E. Balomnenos, D. Kastritis, D. Panias, et al., The Enexal Bauxite Residue Treatment Process: Industrial Scale Pilot Plant Results, in: J. Grandfield (Ed. ) Light Metals 2014, John Wiley & Sons Inc., Hoboken, New Jersey, 2014, pp.143-147.

DOI: 10.1002/9781118888438.ch25

[19] W. Liu, J. Yang, B. Xiao, et al., Application of Bayer red mud for iron recovery and building material production from alumosilicate residues, Journal of Hazardous Materials 161 (2009) 474-478.

DOI: 10.1016/j.jhazmat.2008.03.122

[20] R.M. Enick, E.J. Beckman, C. Shi, J. Xu, Remediation of metal-bearing aqueous waste streams via direct carbonation, Energy Fuels 15 (2001) 256-262.

DOI: 10.1021/ef000245x

[21] C. Brunori, C. Crmisini, P. Massanisso, V. Pinto, L. Torricelli, Reuse of treated red bauxite waste: studies on environmental compatibility, Journal of Hazardous Materials B117 (2005) 55-63.

DOI: 10.1016/j.jhazmat.2004.09.010

[22] E.V. Shiryaeva, G.S. Podgorodetskii, T. Ya. Malysheva, et al., Effects of adding low-alkali red mud to the sintering batch at OAO Ural'skaya Stal', Steel in Translation 44 (2014) 6-10.

DOI: 10.3103/s0967091214010173

[23] L.Z. Khodak, I.I. Gultiay, G.I. Zhmoydin, G.A. Panasko, Shlakovyy rezhim domennoy plavki vysokoglinozyomistogo syriya [Slag adjustment of blast furnace smelting with high-alumina raw materials], in: Shlakovyy rezhim domennykh pechey [Slag adjustment in blast furnace], Metallurgiya, Moscow, 1967, pp.121-134.

DOI: 10.1007/978-981-19-3288-5_3

[24] G.E. Bye, Portlandcement. Composistion, production and properties, second ed., Thomas Telford, London, (1999).

[25] E. Erçaĝ, R. Apak, Furnace smelting and extractive metallurgy of red mud: Recovery of TiO2, Al2O3 and pig iron, Journal of Chemical Technology and Biotechnology 70 (1997), 241-246.

DOI: 10.1002/(sici)1097-4660(199711)70:3<241::aid-jctb769>3.0.co;2-x

[26] Information on http: /conference2015. redmud. org/wp-content/uploads/2015/10/Frank-KAUSSEN-2-secure. pdf.

[27] D.V. Zinoveev, V.G. Dyubanov, A.V. Shutova, et al., Recycling of Red Muds with the Extraction of Metals and Special Additions to Cement, Russian Metallurgy (Metally) 1 (2015) 19-21.

DOI: 10.1134/s0036029515010164