Stepwise Recycling of Red Mud Through Electrochemical Activation for Enhanced Cementitious Performance and Magnetically Separable Iron Recovery

Red mud, a major solid waste from the alumina industry, suffers from an extremely low utilization rate due to its high alkalinity, complex chemistry, and particularly low cementitious activity, which drives the need for novel activation strategies. This study presents a new method for red mud activation through electrochemical treatment, which simultaneously enables iron recovery as a valuable by-product. The electrochemical activation was systematically investigated by performing experiments in alkaline, neutral, and acidic electrolytes. The alkaline system showed a pronounced enhancing effect on the electrochemical process. Under alkaline conditions, the average Faradaic efficiency exceeded 80%. The electrochemical treatment modified the microstructure of red mud particles and transformed iron oxides into magnetic species, which could be effectively separated via magnetic separation. More importantly, this activation process significantly enhanced the cementitious activity of the treated red mud by removing iron oxide that encapsulates reactive aluminosilicate phases and increasing surface reactivity. When used as a supplementary cementitious material with ordinary Portland cement and gypsum, the electrochemically activated red mud demonstrated remarkably improved mechanical properties, with 28-day compressive strength reaching up to 69 MPa. Characterization analysis revealed that the electrochemical activation promoted the formation of key hydration products, including C-S-H gel (formed through both OPC hydration and pozzolanic reactions between activated red mud and portlandite), ettringite, and portlandite. This work provides a green and low-carbon pathway for the stepwise utilization of red mud through activation and resource recovery.