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<p>Red mud is a highly alkaline bulk solid waste generated during the alumina production process. The accumulation and disposal of red mud not only result in substantial resource wastage but also contribute to significant environmental pollution. Aluminum (Al) and iron (Fe) constitute the primary valuable metallic composition in red mud. Efficient separation of these metallic elements is critical for product preparation and lays the foundation for comprehensively utilizing red mud resources. The study results demonstrated that under optimized conditions of 60°C, 2&#xa0;mol/L H<sub>2</sub>SO<sub>4</sub> concentration, 1.5&#xa0;h reaction duration, and a liquid-to-solid ratio of 10:1, the Al extraction efficiency achieved 43.61%, while Fe recovery remained considerably lower at 3.7%. The kinetic analysis revealed that the apparent activation energies for Al and Fe were 26.67&#xa0;kJ/mol and 52.25&#xa0;kJ/mol, respectively. The leaching process conformed to the shrinking unreacted-core model, achieving selective dissolution of aluminum and silicon components while retaining iron in the solid phase. This demonstrates the selective separation capability of Al and Fe. This study proposes an innovative approach for red mud utilization with demonstrated economic feasibility, accompanied by an economic analysis. The findings offer critical insights that may guide sustainable development strategies in the alumina industry.</p>

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Mechanism and Kinetics of Selective Separation of Al and Fe Species in Bayer Red Mud

  • 期刊论文

  • 发表日期：

    2025年7月16日

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  • Chaojun Fang,
  • Ruixue Lou,
  • Tianrui Cai,
  • Yihong Jia,
  • Jinwen Wu,
  • Le Chen,
  • Guolong Zhong,
  • Xiaowei Deng,
  • Bo Lv

摘要

Red mud is a highly alkaline bulk solid waste generated during the alumina production process. The accumulation and disposal of red mud not only result in substantial resource wastage but also contribute to significant environmental pollution. Aluminum (Al) and iron (Fe) constitute the primary valuable metallic composition in red mud. Efficient separation of these metallic elements is critical for product preparation and lays the foundation for comprehensively utilizing red mud resources. The study results demonstrated that under optimized conditions of 60°C, 2 mol/L H2SO4 concentration, 1.5 h reaction duration, and a liquid-to-solid ratio of 10:1, the Al extraction efficiency achieved 43.61%, while Fe recovery remained considerably lower at 3.7%. The kinetic analysis revealed that the apparent activation energies for Al and Fe were 26.67 kJ/mol and 52.25 kJ/mol, respectively. The leaching process conformed to the shrinking unreacted-core model, achieving selective dissolution of aluminum and silicon components while retaining iron in the solid phase. This demonstrates the selective separation capability of Al and Fe. This study proposes an innovative approach for red mud utilization with demonstrated economic feasibility, accompanied by an economic analysis. The findings offer critical insights that may guide sustainable development strategies in the alumina industry.