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New Technique from Rice University Quickly Eliminates Harmful Elements and Reuses Aluminum Present in Industrial Waste.
A team from Rice University has developed a method that removes 96% of the toxic metals present in red mud, a dangerous byproduct of aluminum production. The technique transforms the waste into aluminum-rich materials that can re-enter the industrial cycle or be used to make durable ceramics.
Red mud poses a significant environmental challenge for the industry. Millions of tons of this waste accumulate annually, threatening nearby rivers and communities.
So far, traditional methods for treating this material involved prolonged heating and the use of corrosive chemicals, which are costly and harmful to the environment.
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Instant Heating and Chlorine Gas Eliminate Toxic Metals
The new process relies on instant heating by Joule effect (FJH). For less than a minute, a high-power electrical pulse passes through the red mud.
A small dose of chlorine gas acts alongside the pulse to vaporize the toxic metals, leaving a safe and aluminum-rich residue.
James Tour, professor of chemistry and materials science at Rice, celebrated the results. According to him, the technique transforms a toxic liability into a valuable asset in less than a minute. He described the achievement as a milestone for the aluminum industry and sustainable waste management.
The researchers confirmed that the purified aluminum can return to the production process.
It is also possible to transform the treated waste into high-strength bricks and tiles, providing new uses for the material previously considered hazardous.
Speed, Efficiency, and Less Environmental Impact
Postdoctoral researcher Qiming Liu highlighted the speed and simplicity of the process.
In just 60 seconds, the team removed 96% of the iron and almost all toxic elements, preserving nearly all the aluminum present in the red mud. The technique also removed sodium salts, another important advantage.
Additionally, the process avoids the use of water and solvents, making the solution more sustainable. The resulting material loses the caustic nature of untreated red mud, reducing risks to the environment and communities near industrial waste deposits.
Pathway to Broad Industrial Applications
Scientists believe that the technique could benefit other industries that generate hazardous waste, such as steelmaking, mining, and rare earth processing.
According to researcher Shichen Xu, the method transforms an environmental problem into useful materials, such as super-hard ceramics and reusable aluminum.
James Tour reported that the project is moving toward industrial implementation through the company Flash Metals USA, a subsidiary of Rice under Metallium Ltd.
The company is negotiating with aluminum producers to scale the process globally, bringing the technology to different regions of the world.
The study was published on September 15 in the journal ACS Applied Materials and Interfaces, with support from the Air Force Office of Scientific Research and the U.S. Army Corps of Engineers.
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