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Hydrometallurgy 108 (2011) 46–59

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Hydrometallurgy
j o u r n a l h o m e p a g e : w w w. e l s ev i e r. c o m / l o c a t e / h yd r o m e t

Bauxite residue issues: IV. Old obstacles and new pathways for in situ
residue bioremediation
M. Gräfe, C. Klauber ⁎
CSIRO Process Science and Engineering (Parker CRC), Light Metals National Research Flagship, PO Box 7229, Karawara WA 6152, Australia

a r t i c l e i n f o a b s t r a c t

Article history: Worldwide bauxite residue disposal areas contain an estimated 2.7 billion tonnes of bauxite residue,
Received 20 August 2010 increasing by ~120 million tpa. The future management of this residue is of increasing environmental
Received in revised form 1 February 2011 concern. Ideally it would be utilized as an industrial by-product for other applications (the zero waste
Accepted 14 February 2011
situation), but realistically the drivers for zero waste are not high and there are significant cost and liability
Available online 24 February 2011
barriers to implementation. Any future utilization will most likely be based on contemporary production and
Keywords:
residue currently consigned to long-term storage is unlikely to be recovered, thus the environmental impact
Bauxite residue risk remains. This prompts the question as to whether remediation can be conducted in situ, i.e. changing the
Red mud residue chemistry without specifically re-excavating for conventional processing. In this review the key
Halophytes parameters of residue chemistry and its physical properties are considered in the context of what is required
Alkaliphilic microbes for a remediated residue to support a viable eco-system, i.e. what is required for rehabilitation in terms of a
Bioremediation series of easily understandable goals. Specifically residue characteristics of stable residue solution such that;
Saline–sodic soils pH of 5.5–9.0, sodium adsorption ratio (SAR) of ≤ 7, exchangeable sodium percentage (ESP) of ≤ 9.5, residual
sodium carbonate (RSC) of ≤ 1.25, electrical conductivity (EC) of b4 mS/cm. These goals are a long way from
typical existing residue. Bauxite residue itself is the by-product of an iconic hydrometallurgical process,
namely the Bayer process. While understanding the hydrometallurgical consequences is one key to the
successful implementation of a remediation strategy, it is also clear that the key to in situ remediation is most
likely not conventional hydrometallurgy but a systematic and targeted bioremediation approach.
The most promising pathway for an in situ rehabilitated bauxite residue disposal area would appear to be
bioremediation based on strategies developed for saline–sodic soils using halophyte plants and alkaliphilic
microbes to effectively farm sodium from the system and mitigate pH, respectively. On bauxite residue surfaces
the advantages and similarities should closely parallel saline–sodic agricultural soils. Halophytes provide great
potential to accomplish some of the necessary rehabilitation goals indicated. Practical environmental
rehabilitation attempts to date have been more concerned with BRDA closure in a cosmetic sense. These have
had some limited success and probably reflect the aim of the work to achieve re-vegetation, relying on a limited
understanding of the residue chemistry and lacking detailed information on individual plant responses and
tolerances. It is proposed that research design for bioremediation should commence with a more rigorous plant,
fungi and microbe selection in conjunction with a better understanding of residue chemistry. That is, tackling
both the abiotic and biotic aspects of the problem systematically, especially as the sodium halophyte farming
would initially be progressing into an even more extreme environment. This cannot be an unassisted process;
without intervention BRDA environments would remain sterile for an extended period of time. Amendments
such as applied gypsum can further displace Na+ from the residue exchange complexes and in conjunction with
other divalent cation strategies control pH within halophyte tolerance. Both halophyte produced organic acids
and halophyte promoted microbial populations provide H+ and increase the partial pressure of CO2 in the rooting
zones to further the rehabilitation process. Suitable drainage strategies, along with other additions (organic
waste, sewage sludge, macro and micro-nutrients) will promote plant and microbe survival. Whilst this approach
would not be envisaged to be either capital or operating intensive, it is not a “quick-fix”. Bio-remediation is a
process that would require multiple growing seasons, but well within the typical lifetime of a refinery operation.
This is the final in a series of four related reviews examining bauxite residue issues in detail.
Crown Copyright © 2011 Published by Elsevier B.V. All rights reserved.

1. Introduction

⁎ Corresponding author. Tel.: +61 8 9334 8060; fax: +61 8 9334 8001. The breakthrough hydrometallurgical process patented by Bayer in
E-mail address: craig.klauber@csiro.au (C. Klauber). 1892 enabled alumina to be extracted economically from bauxite ore on

0304-386X/$ – see front matter. Crown Copyright © 2011 Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.hydromet.2011.02.005
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 47

Table 1
Interaction of the residue solution and solids properties and how they impact on the residue's ability to support living organisms. Top-left quadrant summarizes the chemical matrix.
Response arrows indicate an increase (↑) or a decrease (↓) for a property based on the increase of the chemical value in the dark grey cells. Measure of qualitative impact given by the
number of arrows.

a large scale. So successful, the Bayer process became the basis of a major residue is deficient (poses a negative environmental impact) and
new industry that grew exponentially for over 120 years. Bayer himself requires correction. In the main part of this review (Section 2) these
noted that an inevitable consequence of his process was the production physical and chemical deficiencies are discussed in the context of a set
of significant quantities of residue. At the time he recognized the residue of specifically defined rehabilitation goals. The goals are to achieve
itself as a possible source of iron. To date the large-scale utilization of and sustain the following five principal characteristics in order to
bauxite residue, whether for the recovery or iron or for other support the development of ecosystems on closed-down bauxite
applications, has not been realized (Klauber et al., 2011-this issue). At residue disposal areas:
present, bauxite residue disposal areas worldwide have no clear future
1. Stable residue solution pH below 9.0 and above 5.5 (Tisdale et al.,
management vision, so this century old industrial legacy is of great
1993).
concern. Whilst ideally this would be utilized as an industrial by-
2. Sodium adsorption ratio (SAR) of 7 or less (ESP of 9.5 or less), and a
product for other applications, the drivers for the zero waste solution are
residual sodium carbonate (RSC) value of 1.25 or less (McBride,
low and the cost and liability barriers are high (Klauber et al., 2011-this
1994).
issue). Moreover, future residue utilization is most likely to be based on
3. Electrical conductivity of b4 mS/cm1 (McBride, 1994).
contemporary production and residue currently consigned to long-term
4. Na, Al, and heavy and trace metal content in the residue solution
storage is unlikely to be part of any of those processes, so the
below toxic threshold levels to plants and microbes and in part
environmental impact risk remains. This prompts the question as to
described by the ANZECC guidelines (Australian and New Zealand
whether remediation can be conducted in situ, i.e. changing the residue
Environment and Conservation Council, 2000).
chemistry without specifically re-excavating for conventional proces-
5. Bulk density2 (ρ) of less than or equal to 1.6 (Fredlund and
sing. In this review the key parameters of residue chemistry and its
Rahardjo, 1993).
physical properties are considered in the context of what is required for
a remediated residue to support a viable eco-system, i.e. what is In addition to these five primary goals, the provisions of adequate
required for rehabilitation in terms of a series of easily understandable macro- (N, P, K, Ca, and Mg) and micronutrients (Cu, Zn, Mn, Fe, and
goals. For those unfamiliar with the Bayer process and residue related B) consistent with the requirements of the specific plant type and
terminology please refer to the three glossaries at the end of the Part II development stage are essential. While critical, the nutrient issue is
(Klauber et al., 2011-this issue) and III reviews (Gräfe and Klauber, not included in the set of five primary goals as it is species dependent.
2011) and also this review. It is important to note that a plethora of research supports the
importance of all five factors for sustainable plant growth (e.g., Tisdale
1.1. Rehabilitation goals et al., 1993; Doran et al., 1994; McBride, 1994), and as such they
should not be revisited as issues for debate or negotiation by
In this review, in situ rehabilitation is taken to define a final stakeholders. If and when met, residues whose characteristics are
outcome in which bauxite residues, in an impoundment situation, consistent with these five goals will be able to support plants and
exist in an improved state compared to their original state. This is a microbes, which will make a significant improvement to the current
narrow interpretation of the concept of rehabilitation, which would abiotic, barren, and erosion-susceptible states of bauxite residue
normally be a complete restoration to a previous condition, i.e. to have surfaces. The rehabilitated physical and chemical qualities of the
the same impact as the un-mined bauxite. Such a state is not residues and the solutions in contact with them will markedly
technically possible. The pathway by which the required improved
1
state is accomplished is taken as the act of remediation. This is an Conductivity of Siemens per unit length. By comparison sea water (for example)
with an SI conductivity of 4.8 S/m has a cgs value of 48 mS/cm or 4.8 × 104 μS/cm or
important distinction, i.e. rehabilitation is not equal to remediation. “EC units”, i.e. 48,000 EC units.
The interplay between rehabilitation as a final outcome and the 2
This arises from a critical limit for root growth and inter-relates with both void
remedial pathway assumes that the current state of the bauxite ratio and hydraulic conductivity.
48 M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59

improve the residues' micro-, meso- and macro-structural properties Table 2


thus improving hydraulic conductivity, and providing a basis to Selected chemical and physical characteristics of untreated bauxite residues.

remove Na-based salts from the residues on an ongoing basis. The Average std a
max min nb Target
remediated chemical qualities of the residue will furthermore
pH 11.3 1.0 12.8 9.7 44 5.6–8.9
diminish the potential for adverse effects on the integrity of the EC, mS/cm 7.4 6.0 28.4 1.4 46 4
sealants of the bauxite residue disposal area (as far as present) thus [Na+] 101.4 81.6 225.8 8.9 9 see SAR
minimizing the potential of leaking remaining sodic–alkaline plumes SAR 307.2 233.1 673 31.5 10 b7
ESP 68.9 19.6 91 32.1 10 b9.5
potentially loaded with other hazardous chemicals. Table 1 illustrates
ANC (pH = 7.0) 0.94 0.3 1.64 0.68 13 n/a
a qualitative relationship matrix of the key factors that need to be ANC (pH = 5.5) 4.56 – – – 1 n/a
considered for residue rehabilitation. PZC 6.9 1.0 8.25 5.1 11 n/a
Discussion is warranted with regards to the most effective remedial ρ 2.5 0.7 3.5 1.6 13 ≤1.6
pathways. The complexity of rehabilitating bauxite residues is due to the SSA 32.7 12.2 58.0 15.0 30 n/a

inter-dependence of the five principal characteristics; they cannot be [Na+] = concentration of Na+ in solution expressed as mmol of charge per litre
considered in isolation. Furthermore, imbedded in the condition of (mmol+ L− 1).
SAR = sodium adsorption ratio: [mmol Na L− 1]/[(mmol Ca2+ L− 1 + mmol Mg2+ L− 1)1/2].
sustainability is the time dependence of maintaining the five conditions.
ESP = exchangeable sodium percentage: ESP/(ESP + 100) = 0.015 SAR.
Because of the sheer volume of bauxite residues, imparting a buffering ANC (pH = 7.0) is acid neutralization capacity normalized to the weight of the residue
capacity against the recurrence of the current physical and chemical to a pH endpoint of 7.0 using a strong acid.
conditions (alkaline pH, high Na, Al, CO2−
3 contents, cementation, low ANC (pH = 5.5) is acid neutralization capacity normalized to the weight of the residue
permeability, etc.) should be seen as one of the key remediation to a pH endpoint of 5.5 using a strong acid. Only one study is quoted in this table.
Additional studies are discussed in text where the ANC (pH = 5.5) was estimated from
outcomes. Principally, it requires that either an equal amount of graphs.
counter-active substance (e.g., a source of H+) is provided from the PZC = point of zero charge. Measurements include bauxite residues with and without
start or that these counter-active substances are provided over time in flocculant addition.
response to the stimulus arising from the chemical gradients trying to ρ = dry density of the solids, referred to as the bulk density (Fredlund and Rahardjo,
1993).
achieve homeostasis (akin to a titration with fixed endpoint).
SSA = specific surface area with units of m2 g− 1.
Throughout this review we have chosen to default to the units, a
std = standard deviation of the population (n).
concepts and definitions commonly in use for soil science. A number b
n = population size from which the average and std were calculated.
of these are unique to soil science and would not normally be familiar
to hydrometallurgists. A glossary of commonly used terms is therefore
appended.
microbe and plant root membranes, effectively negating the possibil-
ity of water and (thus) nutrient uptake. Matric potential and how it
2. Chemical and physical characteristics of bauxite residues
relates to total soil water potential and the issue of wilting point are
定义 expanded on in the glossary.
Bauxite residues are the slurry by-products generated from the
treatment of bauxite in concentrated NaOH under elevated tempera-
tures and pressure, following, in principle, the Bayer process to produce 2.1. Basic mineralogy and chemical composition of bauxite residues
alumina. Despite washing the solid remnants in counter-current
decantation washer trains, bauxite residues remain strongly sodic– Bauxite residues are solid-solution mixtures ranging in solids content
alkaline at the time of their disposal into purpose-built tailings ponds from 20 to 80 wt.% depending on the disposal method. The elemental
(bauxite residue disposal areas, BRDAs) independent of the disposal abundance in bauxite residues is typically Fe N Si ~ Ti N Al N Ca N Na (see
method (e.g., dry-stacking versus lagooning). Although the Na- Table 3). Bauxite residues consist on average of approximately 70% (by
dominated solution liquor typically has an average electrical conduc- weight) crystalline phases and 30% amorphous materials (Gräfe et al.,
tivity of 7.4 ± 6.0 mS/cm (range: 1.4–28.4 mS/cm, Table 2), this is lower 2009, and references therein). Hematite is ubiquitous (7–29 wt.%),
than expected based on total dissolved solids (TDS). In untreated whereas goethite is abundant in bauxite residues generated from
residues, the counter ions are primarily composed of CO2− 3 and Jamaican and Darling Range bauxites which contain significant amounts
associated OH−, which have a lower actual conductance. As the slurries of goethite in the original ores (Li and Rutherford, 1996; Li, 1998).
dry a structureless, massive, and highly compacted bauxite residue stack Magnetite (Fe3O4) is a transformation product that occurs in bauxite
(ρ = 2.5 ± 0.7, Table 2) develops, which, at its surface will form an residues generated from bauxites sintered with soda to solubilize
evaporation crust with a light-colored, evanescent salt layer (Klauber et boehmite or diasaspore. Boehmite (γ-AlOOH), gibbsite (Al(OH)3),
al., 2008). anatase, rutile (both TiO2), ilmenite (FeTiO3), perovskite (CaTiO3) and
Trace metals can be of concern and may exceed regulatory levels in quartz (SiO2) are the other minerals commonly present in bauxite
certain circumstances (Goldstein and Reimers, 1999; Kutle et al., residues.
2004). Some bauxite residues may emit ionizing radiation above The Bayer process transforms soluble phyllosilicate and tectosilicate
natural background rates due to the presence of naturally occurring clay minerals into sodalite, cancrinite, tri-calcium aluminate (katoite and
radioactive materials (NORMs): 238U and/or 232Th and members of hydrogrossulars), hydro-calumites, calcite/aragonite and Na-carbonates.
their decay chains (Bardossy and Aleva, 1990; Pinnock, 1991; von These minerals contain primarily Si4+, Al3+, Ca2+, Na+, OH− and CO2− 3 .
Philipsborn and Kuhnast, 1992; Wong and Ho, 1993; McPharlin et al., Sodalite is the most common desilication product forming during pre-
1994; Cooper et al., 1995; Somlai et al., 2008). desilication, while cancrinite forms in the presence of excess CO2− 3 , and
The physical and chemical characteristics of the residues make re- at elevated digestion temperatures that are required to dissolve
vegetation particularly challenging, and established floras are difficult boehmitic bauxites. Sodalite concentrations of 16–24% (Castaldi et al.,
to sustain without amendments (Meecham and Bell, 1977a,b; Wong 2008) and up to 50% cancrinite (Garau et al., 2007) have been measured
and Ho, 1991, 1992, 1993, 1994a,b; Wehr et al., 2006; Woodard et al., in bauxite residues from Eurallumina, which processes Weipa bauxites.
2008). Bulk densities commonly encountered in bauxite residues of Perovskite (CaTiO3) and calcite/aragonite (both CaCO3) are common in
fine silty to heavy clay textures do not permit root penetration. In bauxite residues in China due to the addition of lime during the Bayer
addition, the high salt content that rapidly re-dissolves upon wetting process (Liu et al., 2007). Hydrated Ca-silicates, tri-calcium aluminates
the residues lowers the matric potential of the residue pore water and hydrocalumites form from adding slaked lime during digestion and
substantially and causes adverse osmotic potentials across both causticization. The formation of sodium carbonates (e.g., trona or
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 49

Table 3
Elemental and mineralogical composition of bauxite residues. Points of zero charge were taken from Stumm (1992), Hanawa et al. (1998), Hu et al. (2003) and Sparks (2003). Bayer
process characteristic solids (BPCSs) are identified by bold lettering.

Element Content Minerals Unit cell formula PZCc


(n)a
min avg ± stdb max

Hematite α-Fe2O3 8.7–9.8


Fe2O3 (63) 6.8 40.9 ± 15.6 71.9 Goethite α-FeOOH 7.5–8.5
Magnetite Fe3O4 6.8
Boehmite γ-AlOOH 8.2
Al2O3 (62) 2.12 16.3 ± 6.4 33.1 Gibbsite γ-Al(OH)3 5.0
Diaspore α-AlOOH 6.4
Sodalite Na6[Al6Si6O24]·[2NaOH, Na2SO4]d n/d
Cancrinite Na6[Al6Si6O24]·2[CaCO3]·0[H2O]e n/df
SiO2 (63) 0.6 9.6 ± 6.7 23.8 Quartz SiO2 b 2.0
other illite, muscovite
Rutile TiO2 4.6
Anatase TiO2 5.9–6.3
TiO2 (61) 2.5 8.8 ± 4.4 22.6 Perovskite CaTiIVO3 8.1
Ilmenite TiIVFeIIO3 n/d
Calcite CaCO3 8.3
Perovskite CaTiIVO3 8.1
Whewellite CaC2O4g n/d
CaO (76) 0.6 8.6 ± 9.4 47.2 TCA hydro-calumite Ca3Al2(OH)12 Ca4Al2(OH)12·CO3·6H2Oh n/d
Sodalite Na6[Al6Si6O24]·[2NaOH, n/d
Na2O (78) 0.1 4.5 ± 3.3 12.4 Cancrinite Na2SO4]d n/d
Dawsonite Na6[Al6Si6O24]·2[CaCO3]·0[H2O]e n/d
NaAl(OH)2·CO3 n/d
LOI(46) 4.4 10.0 ± 2.8 21.1
a
n = number of samples.
b
avg ± std = average ± standard deviation of the population.
c
PZC = point of zero charge of the corresponding mineral. n/a = not applicable, n/d = not determined.
d
Sodalite has between 0 and 6 waters of hydration (Whittington, 1996; Whittington et al., 1998).
e
Cancrinite has 0 to 2 waters of hydration depending on the ions in the cage (Whittington, 1996): 0 for 2CaCO3, 1 for 2NaOH, and 2 for Na2SO4.
f
Possibly similar to that of feldspar (~ 2–2.4).
g
Calcium oxalate.
h
See Vieillard and Rassineux (1992).

nahcolite) at the surfaces of residues in the drying areas due to substantially by the digestion conditions. Very significantly, both the
evaporation emphasizes that the solution contains a substantial chemical and physical properties of deposited residue will depend on the
concentration of Na+ and CO2− 3 . Other minor mineral constituents deposition management and aging processes. Fig. 1 illustrates a residue
often found in bauxite residues (e.g. ilmenite, FeTiO3) are present profile from field data for a BRDA in Mobile (Alabama, USA) based on the
because they are contained in the parent ore and are not affected work of Fuller et al. (1982).

Fig. 1. Textural distribution of bauxite residues deposited at the BRDA of the Alcoa Mobile plant (Alabama, USA). The textural class influences the chemical properties of the residues
from pH to Na, Ca and Mg and therefore ESP. Figure based on data reported by Fuller et al. (1982).
50 M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59

2.1.1. pH, RSC, SAR and ESP In contrast to the SAR, the ESP value approximates the composition
The pH, the amount of residual sodium carbonate (RSC), the of the cation exchange sites on the residue surface based on the
sodium adsorption ratio (SAR) and exchangeable sodium percentage solution composition of Na, Ca and Mg:
(ESP) in bauxite residue are all closely related to each other in the
context of the Bayer process inputs (NaOH, and Ca(OH)2) and the 1:5 × SAR
ESP = ð3Þ
mineralogy of the residues (see Table 3). Remnant NaOH and Na2CO3 1 + 0:015 × SAR
concentration in solution impart an average solution pH of 11.3 ± 1.0
(Table 2). This average value is lower than one might expect, however, An average ESP value of 68.9 ± 19.6 (Table 2) has been computed
this table includes the pH of aged bauxite residues that have for 10 bauxite residues based on residue solution data. At a pH above
experienced at least partial neutralization by atmospheric CO2 (Liu 9.5, calcium (Ca) and magnesium (Mg) solid phases (primarily as
et al., 2007). Carbonate in solution originates in part due to the carbonate minerals: calcite, aragonite, and dolomite) are sparingly
diffusion of CO2(g) into the liquor, but also due to the decomposition soluble and therefore neither mitigate the SAR nor ESP (Gustafsson,
of organic matter in bauxite under Bayer process conditions into 2006).
water, CO2, and various organics particularly short-chain (low
molecular weight) aliphatic dicarboxylates. The RSC is thus a partial 2.1.2. Electrical conductivity
evaluation of the alkalinity of the residue solution and is quantified Electrical conductivity is related to cation and anion concentra-
by: tions in solution and therefore to ionic strength (IS). Electrical
conductivity is related to total cation and anion concentrations in
solution by approximately a factor of 10 provided that the solution is
h i h i
− 2− 2 + 2 + neither highly acidic nor highly alkaline (McBride, 1994):
RSC = HCO3 + CO3 – Ca + ; Mg ð1Þ
   
−1 −1
Total cations mmolð + Þ L e EC mS cm  10 ð4Þ
where all units are expressed in millimoles of charge (mmol+/−) per
   
litre (L− 1). In bauxite residue solutions with an average pH of 11.3, −1 −1
Total anions mmolð−Þ L e EC mS cm  10 ð5Þ
the RSC is effectively equal to the CO2− 3 concentration as at this pH
the contribution to the RSC from HCO− 3 is negligible, and any Ca
2+
or
Mg2+ will exist as precipitated species (presumably Ca/Mg carbo- In the absence of detailed solution compositional data, electrical
nates). As an illustration, a residue liquor total soda or S, at time of conductivity is the most feasible quantity to measure (to investigate
disposal, of 38 g Na2CO3 per L means that the RSC would be total cation and anion concentrations) and thus to estimate ionic
approximately 717 mmol− L− 1 which is 290 times the upper limit strength. In natural aqueous solutions, Griffin and Jurinak (1973)
for a viable eco-system. determined that:
Removing the alkaline–sodic components from bauxite residues is
ISe0:0127  EC ð6Þ
complicated by the presence of alkaline solids such as sodalite and/or
cancrinite and undissolved Na2CO3, among others, which exist in a
quasi-equilibrium with the residue solution. Thornber and Binet (1999) In addition, the EC is related to the quantity of total dissolved solids
sequentially exchanged bauxite residues with H2O and determined that (TDS, (McBride, 1994)):
while the mass of the solids decreased with sequential washings, neither    
−1 −1
the pH, Na+, Al(OH)− 2−
nor the OH− concentration changed in TDS mg L e EC mS cm  640 ð7Þ
4 , CO3
solution. The buffering properties of the solution with respect to these
ions occurred due to the dissolution of alkaline solids such as The ionic strength of a solution is relevant as it determines the
undissolved Na2CO3, alunite, sodalite and/or cancrinite and may be double-layer thickness of charged particles and therefore in turn
quantified as the acid neutralization capacity (ANC) of the residues. The relates to physical behavior such as dispersion and coagulation of
average ANC (pH 7.0) is 0.94± 0.3 mol H+ kg− 1 residue. Snars et al. particles. In addition, the ionic strength indicates the osmotic
(2004) investigated the buffering capacity of an Alcoa supplied potential of a solution, which, as ion concentration in solution
desilication product and showed that its ANC (pH 7.0) was increases, becomes increasingly negative and therefore suppresses
about 3 mol H+ per kg of DSP. The dissolution behavior and mechanisms the total water potential (or activity). As water will flow from high to
of the major ANC contributing mineral phases thus presents an low potentials, the electrical conductivity of a saturated residue paste
important knowledge base requirement for neutralizing and mitigating helps to define water quality (e.g. in leaching salts from residues to a
against Na+, OH−, Al(OH)− − 2− 2−
4 , H3SiO4 /H2SiO4 and CO3 in solution. This specified target value).
is particularly true for Na bearing solids such as sodalite and cancrinite as It is important to note that Eqs. (4) through (7) will apply when
their dissolution would contribute to the sodium adsorption ratio (SAR) the remediated residue starts to approach target values. Untreated
of residue solutions and the exchangeable sodium percentage (ESP) of residue is so alkaline that the ionic species are not fully dissociated
the cation exchange complex. and the concept of equivalent conductances at infinite dilution has no
The SAR is, like pH and the RSC value, a solution parameter meaning. In particular, how applicable Eqs. (6) and (7) are for bauxite
(McBride, 1994) but it is dependent on the nature of the solid with residues has not been ascertained to date.
which the solution is in contact. In bauxite residues, high EC values are due to high Na+ concentrations
in solution that are replenished from Na-bearing solids. Calcium,
magnesium and other cations do not contribute significantly to the EC
mmolþ Na L1 as their concentrations are negligible in solution at pH above 10. The
SAR = sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 ffi ð2Þ
mmolþ Ca L1 + mmolþ + MgL1 average electrical conductivity (EC) of bauxite residues in deionized
water is 7.4±6.0 mS cm− 1 and ranges from 1.4 to 28.4 mS cm− 1
2
(Table 2, (Fuller et al., 1982; Liu et al., 2007)). In amended residues, the EC
varies from as low as 0.3 (Castaldi et al., 2008) to as high as 60 mS cm− 1
(Woodard et al., 2008). Acid neutralized residues tend to have lower ECs,
SAR values for solutions in contact with untreated bauxite residues whereas seawater-neutralized residues have higher ECs (Meecham and
have an average value of 307.2 ± 233.1 (Table 2). Bell, 1977a; Snars et al., 2004; Castaldi et al., 2008).
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 51

2.1.3. Particle size distribution problematic comparison as many authors fail to specify under what
The particle size distribution of bauxite residues depends on the moisture potentials the bulk densities were measured and conse-
separation of sand size particles after the alumina extraction step. quently any shrink–swell influences on residue volume cannot be
Menzies et al. (2004), for example, show that red sand from Gove has quantified. Consequently, the bulk density values range from 1.6 to
a particle size distribution between 10 and N1000 μm with more than 3.5 g cm− 3, effectively describing the bulk density from a well graded
50% of the particles being larger than 250 μm. In contrast, the fine or sand–silt–clay sized residue matrix (1.6 g cm− 3) all the way to what
mud fraction has a particle size range from less than 0.1 to about would be a highly compacted, non-porous material (3.5 g cm− 3). As
100 μm. Summers et al. (1996) reported sand/silt/clay size distribu- the apparent particle size distribution may be a function of the
tion of 3.6/65.6/30.8% and 4/85/11% for bauxite residues from sampling and disposal methods, the bulk density will vary across a
Suriname and Pinjarra (WA, Australia), respectively, while Newson BRDA, with the finer, clay-sized residues settling out further away
et al. (2006) reported a particle size range for bauxite residues from from the embankment. Chemistry aside, bulk densities exceeding
the UK (likely Burntisland, Scotland) between 1 and 300 μm with 50% 1.7 g cm− 3 in the sandy residue zones, 1.55 g cm− 3 in fine silty zones
of the particles being larger than 5 μm. More recently, Snars and Gilkes and 1.4 in clayey (N45% clay-sized particle content) zones will impede
(2009) reported particle size ranges (b2 μm, 2–20 μm and N20 μm) root penetration and therefore plant establishment.
for bauxite residues from 11 different refineries. On average 31% of the Nikraz et al. (2007) worked with residues that had a ρ of 1.85 prior to
particles were less than 2 μm, 46% were between 2 and 20 μm, and treatment, and treatment with CO2 resulted in a ρ of 1.8 g cm− 3. Bitterns
23% were greater than 20 μm. Approximately the sand and fine treated residues had a bulk density of 1.62 g cm− 3, a level at which root
fraction combined bauxite residues would thus have a particle size of penetration is potentially possible. The void ratio achieved with bitterns
2 to 100 μm with a range of 100 nm to 200 μm and places it into the treatment was 2.84, a 44–81% improvement over untreated and CO2
range between clay loams to fine sand textural class (Gee and Bauder, treated samples (1.57–1.97) and a consequently improved hydraulic
1986). In addition to actual practices at the refinery, Fuller et al. conductivity of 0.4 mm h− 1, up from 0.1–0.2 mm h− 1 for untreated and
(1982) have shown that the texture of the residues is dependent on CO2 treated bauxite residues. The increased ability of bitterns treated
the disposal method. The particle size separation with distance from bauxite residues to conduct and drain water relates to the size and inter-
the embankment (see Fig. 1) suggests that the residue was disposed connectivity of the void spaces or pores. Void space is a function of the
as a wet slurry (lagooned) rather than as a thickened paste discharge ability of individual particles to form stable floccs and aggregates, which
(dry-stacking). The chemical characteristics of the residues and their in turn create (empty) space between aggregates. As indicated above,
solutions including pH, Ca, Mg and Na content and consequently RSC, particle aggregation, flocculation and coagulation are related to electrical
SAR and ESP vary with textural class, suggesting that disposal method conductivity, but more directly, ionic strength and solution composition
and aging strongly influence the physicochemical characteristics of (in particular, Na+ levels in solution) play a critical role. In clay–water
the deposited residues. mixtures, Na+ is associated with clay dispersal, poor aggregate structure,
cementation and dust formation upon drying at the surface (McBride,
2.1.4. Bulk density 1994; Klauber et al., 2008). Its presence in significant quantities at
The average bulk density of bauxite residues is reported as 2.5 ± alkaline pH is a significant inhibitor to the creation of aggregate
0.7 g cm− 3 (Table 2). The cited literature values are however a structure, hydraulic conductivity, and total water potential conducive

Table 4
Guidelines on the investigation levels for soils, drinking water, water for recreational purposes and irrigation.

Metal/metalloid SIL parks SIL industrial WA Class IVA QLD industrial refuse (lined) DW WfRP Irrigation water
(mg/kg) sites (mg/kg)
STC (mg/kg) LCC (mg/L) (mg/L) (mg/L) (μg/L) Plants Livestock
(mg/L) (mg/L)

Aluminium n/d n/d n/d n/d n/d n/d 200 5.0 5.0
Arsenic 200 500 3000 7 0.007 5.0 50 0.1 0.5
Beryllium 40 100 n/d n/d n/d n/d 0.1 0.1
Cadmium 40 100 500 2 0.002 0.5 5.0 0.01 0.01
Chromium (III) 24% 60% 2500 50 n/d 5.0 50 1.0 (total Cr) n/d
Chromium (VI) 200 500 (total Cr) (total Cr) 0.05 (total Cr) (total Cr) 0.1 1.0
Cobalt 200 500 5000 n/d 5.0 0.05 1.0
Copper 2000 5000 10,000 2000 n/d 100 1000 0.2 0.5
Lead 600 1500 30,000 10 0.01 5 50 0.2 0.1
Manganese 3000 7500 n/d n/d 0.5 n/d 100 2.0 n/d
Methyl mercury 20 50 200 1.0 0.001 0.1 1.0 0.002 0.002
Inorganic mercury 30 75 (total Hg) (total Hg) 0.001 (total Hg) (total Hg) (total Hg) (total Hg)
Nickel 600 3000 10,000 20 0.02 5 100 0.02 1.0
Sodium 300 mg/L
TDS 100 mg/L
Uranium n/d n/d n/d n/d 0.02 n/d n/d n/d
Vanadium n/d n/d n/d n/d n/d 5 0.1 0.1
Zinc 14,000 35,000 50,000 n/d n/d 500 2.0 20.0

SIL = soil investigation level (National Environment Protection Council, 1999).


WA Class IVA = The values shown in the table for STC and LCC represent the maximum total concentration allowed in Western Australian wastes classified as “low hazard wastes”. In
making this classification, if either the STC or LCC criteria are exceeded, the waste must be treated or classified as Class V (hazardous waste) (Australian and New Zealand
Environment and Conservation Council, 1999).
QLD Industrial Refuse (lined) (Australian and New Zealand Environment and Conservation Council, 1999).
STC = soil total concentration (Australian and New Zealand Environment and Conservation Council, 1999).
LCC = leachable contaminant concentration (Australian and New Zealand Environment and Conservation Council, 1999).
TDS = total dissolved solids {Anon, 2000 #2194}.
DW = Drinking Water (National Environment Protection Council, 1999).
WfRP = water for recreational purposes (Australian and New Zealand Environment and Conservation Council, 2000).
n/d = not determined.
52 M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59

to plant growth. In addition, the presence of large concentrations of Na+ insofar as it significantly increased biomass production, which was in
elevates the electrical conductivity of the solution beyond tolerable part attributed to the complexation capacity of sewage sludge for Al.
limits for plants. Uptake of Mg, Ca, K, N, and P were all positively correlated to biomass
production highlighting the necessity to provide macro-nutrients to
2.1.5. Trace metals bauxite residues. In line with Fuller's work, Thiyagarajan et al. (2009)
The speciation of trace metals in bauxite residues is virtually showed that micronutrients such as B, Mn, and Zn can significantly
unexplored (Goldstein and Reimers, 1999) however, public concerns limit plant growth even though the overall physical (drainage) and
over the presence and potential bioavailability of trace metals are real chemical properties (SAR/ESP) are improved. In the HCO− 3 pH regime

(Ryle, 2002). Trace metals such as chromium, vanadium and arsenic established with gypsum amendments, Cu and Zn become signifi-
may build up in residue solutions when supernatant liquor from the cantly limited which is consistent with micronutrient management
residue area and the counter-current decantation washer trains is principles (Tisdale et al., 1993). Mn and Fe pools were limited due to
successively recycled within the plant (Kutle et al., 2004). the low solubility of the common Fe and Mn oxide forms. These
As a first step in determining whether trace metals pose a potential studies highlight the necessity of the supplementary rehabilitation
(ecological/human) health risk, measurements of elemental concen- goal of supplying adequate nutrient levels specific to the plants'
trations in residue liquors and solids need to be made. In Australia, requirements.
ANZECC (Australian and New Zealand Environment Conservation Studies by Wong and Ho (1992, 1993, 1994) investigated the
Council) and NEPC (National Environment Protection Council) physicochemical properties (pH, EC and ESP) of bauxite residue from
guideline values (see Table 4) can then be used to assess whether Kwinana (Western Australia) following gypsum and or sewage sludge
the residue is considered a low risk or a high risk hazardous waste.3 applications and their effect on the emergence and development of
However, as total concentrations in solid phases are poor indicators of tall wheat grass (Agropyron elongatum) and Bermuda grass (Cynodon
potential bioavailability, and leach tests (e.g., TCLP or Toxic Charac- dactylon). The initial residue pH (10.2–10.5) was suppressed to 8.7 by
teristic Leach Procedure) are only valid under their operational (and applications of at least 5 wt.% gypsum (8.7) and ESP lowered from
legislative) parameters, solid phase speciation via spectroscopy of 70.4 to less than 12. As a consequence of the decreased pH, water-
trace metals is highly warranted. Changes in the solid phase soluble Al decreased from 1.04 to less than 0.15 mg kg− 1 (solid
speciation of potentially toxic trace metals may occur as a result of solution ratios used in the experiment are unknown). By comparison
the remediation process, and this may render post-remediation leach the addition of sewage sludge to the residues did not suppress the pH,
waters more contaminated or transform the solid phase complex of a however, water-soluble Na concentrations decreased suppressing the
specific metal to be more soluble, i.e., more bioaccessible to plants and ESP to 42–47 and making Na non-exchangeable, i.e., not bioaccessible
microbes. Understanding the chemical dynamics of potentially toxic to either grass. As a consequence to the addition of sewage sludge and
trace metals in bauxite residues provides validation whether the the lack of a pH suppressing effect, Al bound by the sewage sludge was
quality of the rehabilitated bauxite residue is truly improved. Due to released into solution, which had a devastating effect on A. elongatum
the refinery specific operational parameters and the (often unique) dry matter yield consistent with the study by Fuller and Richardson
origin of the bauxite ore, these assessment tests need to be conducted (1986) on desert saltgrass. In the presence of 8 wt.% gypsum,
on a per-refinery/per-bauxite residue basis. These also help in however, the aluminate toxicity effect was suppressed by the lower
defining whether micro-nutrients4 (e.g., Cu, Zn) and toxic metals/ pH regime in which Al precipitates as gibbsite. Similar work carried
metalloids (e.g., As) are potential health risk factors during remedi- out on bauxite residues from Alumine de Grece (AdG) and multiple
ation and in the rehabilitated state. plant species including salt cedar (Tamarix sp.), Chinese cheesewood
(Pittosporum chinense), mastic tree (Pistacia lentiscus), Sea Orach
(Atriplex halimus) and Mediterranean saltbush (Centaurea spinosa)
2.2. Previously attempted remediation strategies and revegetation trials showed the same efficacy of sewage sludge and gypsum on sustaining
plant growth. In addition, these authors identified that adequate P
2.2.1. Laboratory and greenhouse studies nutrition was vital to enhance plant growth. Of the plants investigat-
Meecham and Bell (1977b) showed that Rhodes grass (Chloris ed, salt cedar gave the most promising survival results.
gayana) responded well to improved physical conditions of red sand Polcaro et al. (2000) investigated the physicochemical changes of
(QAL: red sand treated with seawater during transport to BRDA) mixed bauxite residues from Eurallumina as a function of a fresh-water leach
with fly ash (80:20 ratio) as the unconfined compression strength that percolated through gypsum-amended bauxite residues. Residues
(kg cm− 2) was significantly reduced from ~2.5 to 0.9 kg cm− 2 due to from the final thickening filter and seawater-slurried bauxite residue
the fly ash amendment. Under adequate nutrient supply conditions, from the BRDA holding ponds were tested. Gypsum loadings of 5 and
Rhodes grass (C. gayana) had a combined dry matter yield of circa 15 g, 10% are indicated (assumed to be dry weight percentage) and
which improved to over 40 g in the 80:20 red sand–fly ash mixture. An leachate quantities reported as liquid/solid washing ratios (volume
optimal dry matter yield for Rhodes Grass on red sand was determined of water per gram of dried residue). For the filtered residue the pH of
to exist for N application rates of circa 200 kg ha− 1, while supplying at the leachate decreased from 12 to about 10.5 by ~ 30 ml g− 1, while the
least 200 kg P ha− 1. Na+ release (reported in terms of integrated release per unit mass of
Fuller et al. (1982) and Fuller and Richardson (1986) evaluated the residue) in the leachate increased from ~0.5 to more than 8 mg g− 1,
performance of desert saltgrass (Distichlis spicata var. stricta) as a providing evidence for the displacement of Na+ by Ca2+ (the residue
function of dry matter yield and fertilizer applications including liquor only having an intial Na level of 7.4 mg L− 1). In the case of the
sewage sludge. The dry matter yield of desert saltgrass is negatively seawater treated residue the leachate pH increased from 9 to about
correlated to shoot concentrations of Al and Fe. In a separate 10.5 over the experiment, while the Na+ release increased from ~ 5 to
hydroponic experiment, the toxicity of aluminate at pH 9.5 and 10.0 16 mg g− 1. As the pond residue has almost twice the Na level it is not
was suggested by increased uptake of Al in above-ground (shoot) clear whether this has any significance, although the authors appear
tissues. The application of sewage sludge is seen as advantageous to conclude that seawater treatment is a major hindrance to the
extraction of Na+ and more gypsum is required. Importantly though
3
At present the practical hazardous waste classification for residue relates more the gypsum treatment improved particulate agglomeration and
narrowly to its alkalinity rather than trace metal composition or availability.
4
A micro-nutrient applied in excess to tolerance limits of micro-organisms and
permeability. Work by Menzies et al. (2004) similarly showed that the
plants is toxic Tisdale, S. L., Nelson, W. L., Beaton, J. D. & Havlin, J. L. (Eds.) (1993) Soil pH of solutions from 1:1 and 1:2 solid-seawater ratios (Gove, NT)
Fertility and Fertilizers, New York, Macmillan Publishing Co. increased slightly from 10.4 to 10.6 and from 10.7–11.0 over a 26-h period.
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 53

For lower solid-seawater ratios, the solution pH decreased over time to of the otherwise clay-size matrix. This was in part attributable to the
9.7–9.0 with decreasing solid-seawater ratios ranging from 1:5–1:50. solubilization of Ca from the SMC and or CaCO3, decreasing SAR and
Ippolito et al. (2005) determined that an effective method of ESP.
lowering pH, SAR (ESP) and Na content, while raising Ca and Mg In light of the consistent apparent successes achieved with gypsum
concentrations was to apply acidic gypsum and wood waste. The and sewage sludge applications, contrary evidence from field studies in
ameliorating effect of the acidified gypsum was due to its greater Jamaica are noteworthy (Harris, 2009). The author reports studies
solubility, while the effects from wood chips are not entirely clear, but conducted by Alcan on bauxite residues deposited at the BRDA of the
they did not appear to improve permeability. Kirkvine alumina refinery, in which gypsum and poultry sewage sludge
did not succeed in establishing and sustaining a viable/self-supporting
2.2.2. Field scale work plant cover. It resulted in a 15-cm deep, brick-hard layer at the surface
Wong and Ho (1991) conducted field experiments on the Kwinana with little or no porosity and no permeability (K= 0 cm/h). Part of the
BRDA F lake using tall wheat grass (Agropyron elongatum) to failure was attributed to a so-called “un-activated” sewage sludge,
investigate the effects of gypsum and/or sewage sludge on the which did not permit resident microbes to decompose and make
physical qualities of bauxite residue, viz. bulk and particle densities, available nutrients to plants. Harris (2009) studied these gypsum-
total porosity and hydraulic conductivity. The amendments were hardened residues further and determined that mechanical break-up of
worked into the residue using a roto-tiller. Sewage sludge decreased the surface alone did not improve permeability in contrast to phyto-
bulk density and improved hydraulic conductivity, whereas gypsum organic amendments, which increased HC from 0 to 10 cm/h and also
was most instrumental in reducing the ESP and thus contributing to a increased water-stable aggregation of the residue particles. The main
25-fold increase in hydraulic conductivity (from ~ 0.001 to mechanism behind the improved permeability and aggregate stability
0.025 mm h− 1). The water field capacity of residue was positively was ascribed to the solubilization of Ca bearing compounds including
correlated to the organic matter content, which increased with the the phyto-organic amendment and CaCO35 dissolution due to the
rate of sewage sludge application. The long term efficacy (achieve and presence of organic acids.
sustain) of the applied sewage sludge and gypsum on the survival of
A. elongatum was unfortunately not determined. No information 2.2.3. Microbial studies
concerning the actual ESP (SAR), pH and RSC were made available in Williams and Hamdy (1982) determined that in bauxite residue
the study. metabolically injured bacteria exist, which, if provided nutrients
In an application of seawater to red sand (Gove, NT) Menzies et al. through either standard laboratory agars or hay, will repair their
(2004) showed that via a 0.8 m column leach study, breakthrough of injuries and begin to become metabolically active. The consequences
the major cations occurred in an order typical for the lyotrophic soil of the metabolic activity are (i) a multiplication of the number of
cation exchange series. K appeared after 1 m of sea water, Mg after bacteria, (ii) their respiration, and (iii) their exudation of organic
1.7 m and Ca after 2.6 m. The authors suggested that Na+ was acids. Within a two week period, the respiratory activity (effectively
replaced via cation exchange, whereby the more abundant Mg carbonation) and the exudation of organic acids dropped the pH of the
initially replaced Na, until Ca began to replace Mg from the solutions from N10 to circa 6.5.
exchange complexes consistent with the lyotropic series of Helfferich In later work by Hamdy and Williams (2001), scanning electron
(Helfferich, 1962). The exchange reactions occurred progressively micrographs showed that microbial colonies effectively dispersed
from the surface implying the formation of a saturation front slowly otherwise clumped particles. Hay-treated residues supported the
moving through the red sand profile. With divalent Ca and Mg being growth of several plants and pine trees, and earthworms for a period
strongly retained by the red sand, Na retained in the Bayer process between 6 and 12 months. Hay treatments effectively improved water
liquor was leached quickly and Na concentrations fell to that of the filtration and helped to remove soluble salts. Activation of such
input seawater. alkaliphilic microbes by sustained nutrient additions may therefore be
Courtney and Timpson (2004) determined that nutrient levels in the first step in mitigating pH and changing residue from a sodic–
sewage and gypsum amended bauxite residues (Aughinish) must be alkaline to a sodic–saline state.
actively managed in order to adequately supply ryegrass (Lolium
perenne) and fog grass (Holcus lanatus) with nutrients. Their two-year
field study showed deficiencies to be particularly apparent for N, Ca, 2.3. Other in situ remediation techniques
Mn, Mg, P and K. The nutrient deficiencies were further expressed by
significant reductions in biomass production in aboveground tissues. 2.3.1. Soil capping
Courtney and Timpson (2005) also investigated the effects of gypsum Wehr et al. (2006) have reported on the 30-year old and ongoing
and red sand additions on the ability to reclaim the fine fraction of a revegetation program of sections of Gove (NT, Australia) alumina
bauxite residue (Aughinish) with red clover (Trifolium pratense), and refinery's BRDA using a soil cap. The bauxite residues were originally
observed that the addition of 25 wt.% red sand improved permeability deposited as a wet slurry with an east-to-west gradient of increasing
of the bauxite residue/gypsum/sand mixture. Woodard et al. (2008) particle size and increasing seawater neutralization. The pH in the
arrived at a similar conclusion that a combination of gypsum and finer (eastern) fraction was 10.5, whereas the western, sandier,
improved drainage enhanced the removal of soluble Na+, Al(OH)− residue fraction had a pH of 9.7. The cap consisted of a 75–150 cm
4
and other toxic species, which was critical for their plant species clayey subsoil overlain by a 15 cm sandy topsoil. The total soil cap pH
(bermudagrass (C. dactylon), oldman saltbush (Atriplex nummalaria) was less than 7.6 and the EC was less than 0.1 mS cm− 1 and it was
and fourwing saltbush (Atriplex canescens)) to survive on bauxite fertilized with 1200 kg ha− 1 NPK (12/5/15) and an additional
residues (Alcoa Point Comfort, Texas, USA). Later work by Courtney application of 300 kg ha− 1 superphosphate fertilizer. A plethora of
et al. (2009) investigated the effects of spent mushroom compost naturally occurring vegetation was sown or transplanted, which was
(SMC, a material high in Ca due to gypsum amendments) and complemented by natural invasion of additional plants. Within
additional gypsum applications on bauxite residue (Aughinish) 5 years of the revegetation program, the pH in the residue had
physical properties. The authors determined that SMC additions
5
improved the organic C content of the residues while decreasing bulk The formation of CaCO3 in the cemented layer is presumably the consequence of
the gypsum application: CaSO4 + Na2CO3 → CaCO3 (s) + Na2SO4. CaCO3 is a well-
and particle densities and increasing porosity. SMC and gypsum in known cementing agent of clay-sized particles and is customarily removed with NH4-
combination improved porosity due to improved micro-aggregation, acetate (pH 5.5) to isolate the clay fraction in soils (Jackson (1956) Soil chemical
which, under mechanical disturbance did not result in the dispersion analysis — Advanced course, Madison, WI, University of Wisconsin).
54 M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59

decreased from 10.5 to 9.5 and roots had penetrated some 60 cm into 23–27 wt.% (dry weight basis) salt in their shoots (Zhao, 1991). Once
the residue. By 1990 aerial surveillance showed that the finer eastern in the leaf, research on Atriplex and Suaeda species suggests that Na+
side of the revegetated area was dominated by grasses and shrubs, is not remobilized or exuded (unlike K+) thus suggesting a near
whereas the sandier western end was dominated by trees. Where the irreversible compartmentalization in the leaves (Flowers et al., 1977).
surface cover became increasingly sparse (grasses, east and western For a more complete description of the salt tolerance mechanism in
ends), soil testing revealed that the soil had become sodic and alkaline halophytes see Flowers et al. (1977), Jennings (1968) and/or Ungar
(pH N 8.5, EC N 1.0 mS cm− 1). These areas had thin soil caps (0.6 ± (1991).
0.3 m), while thicker soil caps (1.4 ± 0.4) supported dense vegetation Halophytes provide great potential to accomplish some of the
including trees, and maintained a pH between 5.5 and 8.8 and an EC of rehabilitation goals stated herein. Reducing the Na content in solution
less than 1.0 mS cm− 1. Completely bare areas showed signs of salt (SAR) and on the bauxite residue solids (ESP) by farming residue
crusting at the surface. In 1994, the barren areas where recapped and profiles for Na using salt resistant halophytes may be an effective
replanted and in some areas, drainage lines were installed. In the means of removing Na+ from bauxite residues. Amshot grass
drained areas, soil testing in 1996 revealed that the pH remained (Echinochloa stagninum) reduced the ESP of a salt-affected soil (0–
circum-neutral and had an EC of b 0.1 mS cm− 1. In the bare areas, the 15 cm) from 30 to 20.2 and 10.1 after one and two years, respectively
pH had risen to 10 and the EC exceeded 0.6 mS cm− 1. By 2003, the (Helalia et al., 1992). In the same study, corresponding SAR and EC
drained areas were well populated with plant species including trees, values in the soil solution of the upper 15 cm were reduced from an
while the bare areas occurred in poorly drained and waterlogged initial 30.9 and 27.6 mS cm− 1 to 12.9 and 4.3 mS cm− 1 after two
areas during the annual wet period. years of cultivating with Amshot grass. Similar results were achieved
Analyses of plant root propagation showed that roots were most with other members of the Chenopodiaceae family (A. indicum,
prominent in the sandy topsoil cap and only few roots were present in S. fruticosa) and with Sesuvium portulacastrum (Rabhi et al., 2009).
the clayey subsoil cap. The main difference between these two cap In addition to the reclamation of salt-affected agricultural land,
zones being the Na content, which was up to 15 times higher in the halophytes have been evaluated to lower salt contents in oilfield brine
clayey subsoil than in the sandy topsoil. Some roots had penetrated contaminated soils. Atriplex removed up to 17% of Na+ from its
beyond the soil cap and were present in cracks that had developed in rhizosphere and accumulated around 600 meq 100 g− 1 Na in its leaf
the residue due to shrinkage; however, no penetration of bauxite and stem tissues (Howes Keiffer and Ungar, 2002).
residue peds was observed, indicating that no intimate association to The use of halophytes on bauxite residue surfaces offers a number
bauxite residues actually occurred. of interesting possibilities, advantages and similarities to their use on
The observations made by Wehr et al. (2006) are consistent with saline–sodic agricultural soils:
the behavior of uncapped bauxite residues ameliorated with sewage
sludge and or gypsum in that drainage, soil fertility and the 1. Na+ removal is less dependent of drainage and fresh water, a major
maintenance of plant suitable pH and EC (i.e., low Na levels) are hindrance factor for sustaining plant species on BRDAs.
critical for plant survival. 2. Gypsum is applied in order to displace Na+ off the exchange
complex and make it available to halophytes.
2.3.2. Bioremediation of saline–sodic soils in arid and semi-arid climates: 3. Gypsum and any other divalent cation applied to bauxite residues
farming for sodium controls the pH within the tolerance limits of halophytes (see
Analogous to achieving and sustaining plants on bauxite residues further discussion below).
are the challenges faced by farmers in arid climates irrigating crops 4. The halophyte exude organic acids and promote microbial
with saline ground water causing their soils to become saline–sodic populations thus providing H+ and increasing the partial pressure
(Qadir et al., 2006a,b, 2007; Shekhawat et al., 2006). Because chemical of CO2 in the rooting zones. Some halophytes also have the capacity
amendments and drainage with low salt content water is usually to take up heavy metals such as Cd and As.
prohibitively expensive, many subsistent farmers resort to cropping
sodic–saline soils with halophytes to remove excess Na+ (Qadir et al., Increasingly, research is conducted on alkaline stresses on the
2006a). Halophytes (in contrast to glycophytes, e.g., Bermuda grass) physiological performance (e.g., relative growth rates, photosynthe-
are salt resistant plants (as opposed to tolerant species), which thrive sis, Na uptake) of halophytes. Yang et al. (2009) evaluated the effects
in salt-affected soils, and take up a significant amount of salt (wt.% of of alkaline buffering capacity on the performance (relative growth
dry matter yield), in order to complete their lifecycle (Jennings, 1968; rates, photosynthesis, and Na uptake) of Chloris virgata in solutions of
Flowers et al., 1977). The limits of survival for Atriplex species, for pH of 9.5–9.7 and ANC between 0 and 316 mmol H+ L− 1. The authors
example, appear to lie between 300 and 700 mM NaCl (17 to 40 g showed that relative growth rate and photosynthetic activity declined
NaCl L− 1) with optimal growth conditions between 20 and 500 mM with increasing buffering capacity, while Na+ accumulation in tissues
NaCl (Flowers et al., 1977). The growth response of halophytes is was highest (4.6 wt.%) from solutions buffered at 316 mmol H+ L− 1
positive to NaCl, whereas KCl, CaCl2 and MgCl2 trigger various acid neutralizing capacity. The study showed that pH does not reflect
reactions depending on halophyte species from no effect at all, to a the stress that is induced by the acid neutralizing capacity of the
synergistic effect to an outright toxic effect. For example, Suaeda surrounding medium. The ability of the halophyte to function and
maritime grows slowly in MgSO4, while A. halimus benefits from the survive at a pH of ~9.6 and low ANC suggests that some direct or
presence of KCl and NaCl (ibid. and references therein). indirect Na+/H+ exchange at the root counteracts the buffering
The major difference between a halophyte (e.g., Atriplex nummu- capacity of the alkaline solutions. Several authors have reported that
laria) and a glycophyte (e.g., Cynodon dactylon (Bermuda grass)) is the under alkaline stress and combined saline and alkaline stress, the
way in which each responds to high salinity. Glycophytes tolerate physiological performance of otherwise alkali-resistant halophytes
high salinity by excluding Na+ from their leaves (restriction to stem diminishes (among others, see for example Zhang and Chun-Seng
and roots or no entry of Na+ into the plant at all), whereas a halophyte (2009), Guo et al. (2010) and Li et al. (2010)). A common effect
is resistant to high salinity by accumulating high concentrations Na+ measured is the increase in organic acid accumulation (e.g., citric,
in the vacuoles of their leaves. In contrast to an uncontrolled inflow of oxalic and succinic acids) in the shoot and roots of Puccinellia
Na+ into a plant, Na+ uptake has positive ramifications for the tenuiflora, Spartina alterniflora, and Lathyrus quinquenervius. Despite
halophyte. For example, Suaeda salsa members of the Chenopodiaceae the measureable stress levels in these and other halophytes, Na
family are halophytes native to coastlines of China and accumulate accumulation in above-ground tissues is usually maximized at high
between 10 and 12 wt.% (dry weight basis) of salt in their roots and levels of alkalinity. Fig. 2 shows a schematic representation of this
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 55

type of bio-remediation approach and some of the residue chemistry (Mg, and Ca) and or other (structural) amendments such as red
changes. sand that lower bulk density, improve aggregation and aggregate
There are numerous additional research studies investigating saline strength (avoids cementation and dispersion), and increase
and alkaline stresses on halophytes, however, they are outside the scope porosity, permeability, and hydraulic conductivity (Table 1).
of this review. For bauxite residue rehabilitation goals and remediation 3. The application of divalent cations such as Ca and Mg from sources
pathways, employing halophytes specifically for optimal removal of Na+ such as gypsum or seawater enhances the removal of Na
from residue profiles provides a challenging yet exciting new pathway for particularly under improved drainage conditions by ion exchange
bauxite residue remediation. Of the remediation strategies discussed processes consistent with the lyotropic series and improves the
above, those using Atriplex species can generally be considered as saturation of the exchange complex with macro-nutrients
halophytes (see Table 5). Research in halophyte biochemistry and salt (Table 1).
and alkali tolerance mechanisms indicate that a critical first step in 4. It is essential to supply adequate amounts of nutrients (macro- and
choosing a halophyte species is to identify its optimal growth parameters micronutrients) and available water to plants and microbes
(including climatic adaptability) with respect to salt, alkalinity and establishing seedlings/populations and to guarantee their survival
buffering tolerances and their effects on nutrient uptake and/or demand in irrespective of saline and or alkaline tolerance levels.
order to achieve more optimal growth conditions. 5. Microbes are effective pH suppressants and in combination with
hay additions achieve similar effects as gypsum and seawater with
2.4. Key physical and chemical parameters relevant to remediation respect to pH, ESP and permeability. To mitigate against the effects
strategies described under 1., alkaliphilic microbe activation could be one
way to initiate the remediation process of converting sodic–
In summary, laboratory/greenhouse, microbial and field studies alkaline residues to sodic–saline ones. This may be dependent on
come to the conclusion that: the inherent concentrations of Ca and Mg in the residue and the
solid phases in which they are locked up in.
1. Na+, Al(OH)− 4 , EC, pH, SAR and ESP levels must be reduced to plant
tolerable levels. Research on halophyte tolerances also point to the In order to lower SAR/ESP values, residue solution conditions need to
necessity of reducing alkali buffering capacity (Table 1). be amended such that either Ca or Mg bearing minerals become soluble
2. Drainage of irrigation waters must occur in order to remove Na+. and/or such that Ca and Mg additions to the residues do not precipitate.
This may be accomplished with sewage sludge, divalent cations With respect to the stated rehabilitation goal of an SAR value 7 or less

Fig. 2. Schematic representation of the idea of “farming for sodium” as a bio-remediation strategy. With the appropriate choice of halophytes it is possible to both remove sodium
from surface residue and reduce the residue alkalinity.
56 M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59

Table 5
Plant species used in revegetation programs or greenhouse trials of bauxite residues classified into glycophytes (G), halophytes (H) or unknown tolerance (U) (Flowers et al., 1977).

Species (common name, where known) G/H/U Reference

Chloris gayana (Rhodes grass) G Meecham and Bell (1977b)


Distichlis spicata var. stricta (Desert saltgrass) H Fuller et al. (1982), Fuller and Richardson (1986)
Hardenbergia comptoniana U Thiyagarajan et al. (2009)
Acacia cyclops (Western Coastal Wattle) G Thiyagarajan et al. (2009)
Grevillea crithmifolia U Thiyagarajan et al. (2009)
Eucalyptus gomphocephala U Thiyagarajan et al. (2009)
Agropyron elongatum (tall wheatgrass) G Wong and Ho (1992), Wong and Ho (1993), Wong and Ho (1994a,b)
Cynodon dactylon (Bermuda grass) G Woodard et al. (2008)
Tamarix sp. (salt cedar) H Xenidis et al. (2005)
Pittosporum chinense (Chinese cheesewood) U Xenidis et al. (2005)
Pistacia lentiscus (mastic tree) U Xenidis et al. (2005)
Atriplex halimus (Sea Orach) H (Xenidis et al., 2005)
Centaurea spinosa (Mediterranean saltbush) U Xenidis et al. (2005)
Quercus coccifera (Kermes Oak) U Xenidis et al. (2005)
Lolium perenne (ryegrass) G Courtney and Timpson (2004)
Holcus lanatus (fog grass) G Courtney and Timpson (2004)
Trifolium pratense (red clover) U Courtney and Timpson (2005)
Atriplex nummalari (oldman saltbush) H Woodard et al. (2008)
Atriplex canescens (fourwing saltbush) H Woodard et al. (2008)

(ESP≤ 9.5), a key research component must entail a means to achieve the literature yet, although several studies have employed Atriplex
and sustain the target SAR value. Ion exchange reactions are at the heart species to vegetate bauxite residue surfaces (see section above).
of lowering SAR and ESP to acceptable values and are thus fundamental
reaction mechanisms that require thorough understanding. While 3. Research recommendations
gypsum and bitterns applications are capable of lowering pH, RSC,
SAR and ESP, the choice of plant must consider the effect of such The knowledge gaps apply primarily to the remediation method-
amendments on EC and tolerance by the plant. For example, certain ology required to achieve the rehabilitation goals, i.e., based on what
halophytes and glycophytes have reduced physiological functioning in is known, the rehabilitation goals in themselves do not require any
high SO4, Ca and or Mg environments. Provided that drainage is in good further research. The knowledge gaps with respect to the remediation
operation (sufficient permeability) and that water sources have a high pathway can be separated into two distinct groups, abiotic and biotic.
water potential (low ion content → low EC), excess salts (including Ca For simplicity these are summarized in Tables 6 and 7, with abiotic
and Mg) will be flushed away. A salt resistant halophyte may provide knowledge gaps A1 through A6 and biotic knowledge gaps B1 though
assistance in achieving target SAR and ESP levels by removing Na+ from B3, along with expected outcomes. The abiotic knowledge gaps cover
solution, provided that it can survive the substantial pH buffering solution composition, understanding dissolution mechanisms, ion
capacity. An amendment with Ca and or Mg to suppress pH in the exchange processes, chemical speciation, the presence and form of
presence of a halophyte would appear to be necessary. Farming for Na+ macro- and micronutrients and a model for salt transportation and
on bauxite residues using halophytes has as such not been reported in deposition. The biotic knowledge gaps concern the development of a

Table 6
Abiotic knowledge gaps, research requirements, and research outcomes.

Knowledge gap/research requirement Research outcome

A1. Solution compositions of entrained liquors in bauxite residue deposited at the BRDA Defines the limits of stress and tolerance for plants and microbes (see B2 below).
particularly with respect to plant and microbe limiting species such as OH, CO2− 2−
3 , SO4 ,
B(OH)− − − −
4 , AlOH)4 , Cl , NO3 , AsO4, VO4, CrO4, PO4, Mg
2+
, Ca2+, Na+, NH3/NH+ 4 , etc.
A2. Understanding the dissolution mechanisms of sodalite and cancrinite over the target For a particular pH, the rate of Na, OH, Al, and CO3 replenishment into solution can be
pH range (8.9–5.6) is critical, because these minerals are the primary solid buffering predicted based on the kinetics of the dissolution reactions and secondary reaction
agents for Na, OH, Al, and CO2− 3 , all of which tend to be toxic to plants and microbes. products.
A3. Ion exchange is a key reaction that supplies plants and microbes with nutrients The thermodynamics of Ca:Na-, Mg:Na, and Ca, Mg:Na-exchange define upper limits
stored in soils/residues and affects micro-aggregation, bulk density, porosity, and for the saturation of the residues with Ca and Mg, which can be evaluated further in
permeability of bauxite residues. Binary and ternary ion exchange reactions in bauxite terms of their, when studied in situ (e.g., lysimeter studies) or in column experiments
residues and desilication products (e.g., sodalite, cancrinite) need to be evaluated as a in the laboratory.
function of pH (8.9–5.6) and counterions (e.g., SO4 vs. Cl vs NO3).
A4. Chemical speciation and mineralogical partitioning of trace metals, metalloids, heavy Research in this area will supply the data necessary to predict bioavailability of
metals and other potentially toxic elements contained in the last-washer underflow contaminants to plants and microbes and therefore will help to understand their
liquor and in bauxite residues. These investigations must entail a laboratory-scale type impact (if any) on the biological remediation agents. Understanding the chemical
experiments whereby the partitioning of soluble metals/metalloids is evaluated as a dynamics of potentially toxic trace metals in bauxite residues provides validation
function of pH and ionic strength, and a molecular/atomistic-scale spectroscopic whether the quality of the rehabilitated bauxite residue is truly improved.
experiments (e.g., X-ray absorption spectroscopy, X-ray photoelectron spectroscopy)
that determine the chemical states of the contaminants.
A5. Evaluation of the presence and form of macro- and micronutrients including organic This data, in conjunction with B1 (see below), will help establish fertilization rates
carbon: N, P, K, Ca, Mg, Cu, Zn, Fe, B, Mn, among others, in amended bauxite residues. that will be required to keep plants and microbes alive.
This research cannot rely simply on determining totals, but must in addition define
plant available levels through basic agriculture tests (e.g., Mehlich 3 test for P).
A6. Generic salt transport and deposition model for predicting bauxite residue salts This would assist the time-line prediction of remediation progress; especially for
profile behaviour during the remediation process. varying BRDA designs (e.g. drainage, residue depth, climatic impact).
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 57

Table 7
Biotic knowledge gaps, research requirements, and research outcomes.

Knowledge gap/research requirement Research outcome

B1. A detailed literature review of the tolerance and resistance levels and mechanisms of This literature review will identify the most promising species for remediating
glycophytes and halophytes. bauxite residues.
B2. Detailed tolerance and resistance studies of the species indentified in B1 with This data is of paramount importance in order to define proper residue amendments
respect, but not limited, to salinity, alkalinity, and tolerance to divalent cations and and to maintain microbes and plants in optimal conditions during the first months
anions such as Mg, Ca, and SO4, and soluble trace metals (e.g., Cu, Zn, Al), metalloids and years of establishment.
(e.g., CrO4, AsO4, VO4), and heavy metals (e.g., Pb).
B3. A detailed literature review of alkaliphilic microbes and fungi. Microbes and fungi, in Will identify suitable microbial species and fungi capable of surviving the harsh
particular obligate aerobes, are potentially the first level of biological agents to be conditions of bauxite residues and in addition identify chemical and physical
introduced to bauxite residues in order to suppress pH and create pore space. Knowing conditions conducive to their survival.
the most promising species and their minimum nutritional and moisture/oxygen
requirements is an important first step to establish such populations on bauxite
residue surfaces.

thorough understanding of the stress and tolerance levels of Goldstein, G.L., Reimers, R.S., 1999. Trace element partitioning and bioavailability in red
mud synthetic freshwater sentiment. In: Eckert, C.E. (Ed.), Light Metals. TMS, San
halophytes, glycophytes and microbes (including resident, injured
Diego.
microbes, alkaliphilic microbes and fungi) to salinity and alkalinity, Gräfe, M., Pang, D., Power, G., Klauber, C., 2009. BRaDD: Bauxite, Residue and Disposal
such that the amendments can be dosed and applied in a maximally Database. CSIRO-Minerals.
Griffin, R.A., Jurinak, J.J., 1973. Estiimation of acidity coefficients from the electrical
beneficial way for the plants and microbe populations to be
conuctivity of natural aquatic systems and soil extracts. Soil Sci. 116, 26–30.
established. Guo, L.Q., Shi, D.C., Wang, D.L., 2010. The key physiological response to alkali stress by the
alkali-resistant halophyte Puccinellia tenuiflora is the accumulation of large quantities of
organic acids and into the rhyzosphere. J. Agric. Crop Sci. 196, 123–135.
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Metals National Research Flagship and the Parker CRC for Integrated Hanawa, T., Kon, M., Doi, H., Ukai, H., Murakami, K., Hamanaka, H., Asaoka, K., 1998.
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Hydrometallurgy Solutions (established and supported under the
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Woodard, H., Hossner, L., Bush, J., 2008. Ameliorating caustic properties of aluminum residue particle and water and capillary forces at the air–water interface. The
extraction residue to establish a vegetative cover. J. Environ. Sci. Health A Tox./ matric potential is equal but opposite in sign to these combined forces.
Hazard. Subst. Environ. Eng. 43, 1157–1166. Osmotic Pontential: exists at the root membrane/residue interface that acts as a semi-
Xenidis, A., Harokopou, A., Mylona, E., Brofas, G., 2005. Modifying alumina red mud to permeable membrane. The osmotic potential will be more negative in solutions of
support a revegetation cover. J. Met. 57, 42–46. increasing salt content, which decreases the overall or total soil water potential.
Yang, C.-W., Zhang, M.-L., Liu, J., Shi, D.C., Wang, D.-L., 2009. Effects of buffer capacity on The osmotic potential illustrates the importance of the solution composition as
growth, photosynthesis, and solute accumulation of a glycophyte (wheat) and a any liquid with a higher (more positive) water potential will infiltrate into the
halophyte (Chloris virgata). Photosynthetica 47, 55–60. residue and equilibrate as the precipitated salts dissolve into solution until the
Zhang, J.-T., Chun-Seng, M.U., 2009. Effects of saline and alkaline stresses on the osmotic potential is equal throughout the wetted profile.
germination, growth, photosynthesis, ionic balance and anti-oxidant system in an Unconfined compressive strength: special case test of the deformability of soil for those
alkali-tolerant leguminous forage Lathyrus quinquenervius. Soil Sci. Plant Nutr. 55, soils that possess the cohesion to be tested unconfined (ASTM D2166).
685–697. Void Ratio (e): is the ratio of the volume of pores (Vv) to the volume of solids (Vs) for a
Zhao, K.-F., 1991. Desalination of saline soils by Suaeda salsa. Plant Soil 135, 303–305. given sample volume (V).
M. Gräfe, C. Klauber / Hydrometallurgy 108 (2011) 46–59 59

Volumetric water content (Θw, m3 m− 3): the volume of water relative to the total circa − 5000 ft moisture potential (− 1524 m = − 15,117 kPa), whereas in bauxite
volume of the residue sample (V). The maximally achievable volumetric water residues, the wilting point will be significantly affected by the presence of
content is equal to the porosity of the sample (Jarrett, 1995). dissolved salts that lower the free energy of water. As water flows from high to
Wilting point (Wp): describes the moisture content of the residues at which plant low energy, water will not be available to plants although the moisture content in
growth is not possible due to a lack of water (Jarrett, 1995). In soils it occurs at the residues might suggest otherwise (McBride, 1994).

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