Low-cost dealkalization of bauxite residue by gypsum coordinated with industrial iron salt: Mineralogical mechanisms and field practice

The sustained-release of alkalinity in bauxite residue hinders the soil formation and ecological restoration processes in disposal areas. Ferric salts (Fe3+), known for their rapid neutralization reaction process and straightforward operational simplicity, showed a synergistic advantage with gypsum (CaSO4) in the alkaline regulation of bauxite residue. Nevertheless, the mineralogical mechanisms of the reaction between Fe3+ and Ca2+ and alkaline minerals in bauxite residue remained unclear. The present study aimed to elucidate the geochemical stability mechanisms of sodalite and cancrinite, major alkaline minerals in bauxite residue, driven by Fe3+ and Ca2+ from a mineral structural perspective and the integrated restoration effect was demonstrated by the field experiment. Unreacted shrinking core model (USCM) calculations demonstrated that Fe3+ was able to enter the lattice structure of sodalite and cancrinite to replace Na+ and assisted Ca2+ in successfully replacing Na+ in cancrinite. Moreover, Fe3+ and Ca2+ facilitated the formation of insoluble coating layers on their surface. In the lattice structure of sodalite and cancrinite, the replacement reaction for Na+ was influenced by the competition between Fe3+ and Ca2+. The Ca2+ preferentially replaced Na+, while Fe3+ accumulated near the Si-O bonds, balancing the negative charges of the Si-O and Al-O tetrahedra structure and further inhibited alkaline mineral dissolution. The pH and EC of bauxite residue decreased from 10.52 to 7.60 and 712 mu S/cm to 501 mu S/cm, respectively, after a one-year field-scale amelioration by the integration of Fe3+ and Ca2+. These findings highlighted the synergistic roles of Fe3+ and Ca2+ in regulating the alkalinity of bauxite residue and provided a practical strategy for ecological restoration in disposal areas.